TM-5-6115-545-34
TM-5-6115-545-34
ARMY
AIR FORCE TO-35C2-3-444-2
NAVY
NAVFAC P-8-626-34
MARINE CORPS TM-0O038G-35
TECHNICAL MANUAL
INTERMEDIATE (FIELD) (DIRECT AND GENERAL SUPPORT
AND DEPOT MAINTENANCE MANUAL
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL
SKID MTD., 60 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS
DOD MODELS
HERTZ
50/60
50/60
400
CLASS
UTILITY
PRECISE
PRECISE
MEPOO6A
MEP006A
MEP115A
FSN
6115-118-1243
6115-118-1252
6115-118-1253
INCLUDING OPTIONAL KITS
NOMENCLATURE
DOD MODELS
MEP006AWF
MEPO06AWE
MEP006ALM
MEPO06AWM
WINTERIZATION KIT, FUEL BURNING
WINTERIZATION KIT, ELECTRIC
LOAD BANK KIT
WHEEL MOUNTING KIT
FSN
6115-407-8314
6115455-7693
6115407-8322
6115463-9092
This copy Is a reprint which includes current
pages from Changes 1 through 11.
,
Published under authority of the
Departments of the Air Force, the Army, and the Navy
(Including U. S. Marine Corps)
10 JUNE 1973
WARNING
All specific cautions and warnings contained in this manual shall be strictly
adhered to. Otherwise, severe injury,
death and/or damage to the equipment
may result.
HIGH VOLTAGE
is produced when this generator set is
in operation.
DEATH
or severe burns may result if personnel
fail to observe safety precautions. Do
not operate this generator set until the
ground terminal stud has been connected
to a suitable ground. Disconnect the
battery ground cable before removing
and installing components on the engine
or in the electrical control panel system.
Do not attempt to service or otherwise
make any adjust ments, connections or
reconnection of wires or cables until
generator set is shut-down and completely
de-energized.
DANGEROUS GASES (Cont)
When filling fuel tank, maintain metal to
metal contact between filler nozzle and fuel
tank. Do not smoke or use an open flame in
the vicinity.
Use extreme care, should a selenium rectifier malfunction, to avoid inhalation of
poisonous fumes.
LIQUIDS UNDER PRESSURE
are generated as a result of operation of the
generator set. Do not expose any part of the
body to a high pressure leak in the fuel or
hydraulic system of the generator set.
Relieve pressure from radiator before removing radiator cap.
NOISE
operating level of this generator can cause
hearing damage. Ear protectors, as recommended by the medical or safety officer, must
be worn when working near this set.
CAUTION
DANGEROUS GASES
DAMAGE
Batteries generate explosive gas during
charging; therefore, utilize extreme caution,
do not smoke, or use open flame in vicinity
when servicing batteries.
to the equipment may result if personnel fail
to observe the cautions contained in this
manual.
Exhaust discharge contains noxious and
deadly fumes. Do not operate generator
sets in inclosed areas unless exhaust discharge is properly vented to the outside.
If generator set is shut -down by the operation
of a safety device, do not attempt to operate
the unit until the cause has been determined
and eliminated.
ARMY
AIR FORCE
NAVY
MARINE CORPS
TM 5-6115-545-34
TO 35C2-3-444-2
NAVFAC P-8-626-34
TM 00038G-35
C 12
HEADQUARTERS
DEPARTMENTS OF THE ARMY, AIR FORCE, NAVY
AND U.S. MARINE CORPS
WASHINGTON, D.C., 30 SEPTEMBER 1994
CHANGE
NO. 12
Intermediate (Field) (Direct and General Support)
and Depot Maintenance Manual
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL
SKID MTD., 60 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS
DOD MODELS
CLASS
HERTZ
FSN
MEP006A
MEP105A
MEP115A
UTILITY
PRECISE
PRECISE
50/60
50/60
400
6115-118-1243
6115-118-1252
6115-118-1253
INCLUDING OPTIONAL KITS
MEP006AWF
MEP006AWE
MEP006ALM
MEP006AWM
FSN
NOMENCLATURE
DOD MODELS
WINTERIZATION KIT, FUEL BURNING
WINTERIZATION KIT, ELECTRIC
LOAD BANK KIT
WHEEL MOUNTING KIT
DISTRIBUTION STATEMENT A:
6115-407-8314
6115-455-7693
6115-407-8322
6115-463-9092
Approved for public release; distribution is unlimited.
TM 5-6115-545-34/TO 35C2-3-444-2, NAVFAC P-8-626-34/TM 00038G-35, 10
is changed as follows:
1.
Remove and insert pages as indicated below.
indicated by a vertical bar in the margin.
by a miniature pointing hand.
2.
June 1973
New or changed text material is
An illustration change is indicated
Remove pages
Insert pages
1-47 and 1-48
14-81 and 14-82
14-87 through 14-92
1-47 and 1-48
14-81 and 14-82
14-87 through 14-92
Retain this sheet in front of manual for reference purposes.
ARMY
AIR FORCE
NAVY
MARINE CORPS
TM 5-6115-545-34
TO 35C2-3-444-2
NAVFAC P-8-626-34
TM 00038G-35
c 12
By Order of the Secretary of the Army:
GORDON R. SULLIVAN
General, United States Army
Chief of Stafl
Official:
Administrative Assistant to the
Secretary of the Army
07552
DISTRIBUTION:
To be distributed in accordance with DA Form 12–25-E, block no.
ments for TM 5-6115-545-35.
0861,
require-
TM 5-6115-545-34
TO 35C2-3-444-2
NAVFAC P-8-626-34
TM-00038G-35
C11
HEADQUARTERS,
DEPARTMENTS OF THE ARMY, NAVY AND AIR FORCE
AND HEADQUARTERS U.S. MARINE CORPS
WASHINGTON, D.C., 28 November 1990
CHANGE
NO. 11
Intermediate (Field) (Direct Support and General Support)
and Depot Maintenance Manual
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD.,
60 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS
DOD MODELS
CLASS
MEP006A
MEP105A
MEP115A
UTILITY
PRECISE
PRECISE
HERTZ
FSN
50/60
50/60
400
6115-118-1243
6115-118-1252
6115–118-1253
Including Optional Kits
DOD MODELS
MEP006AWF
MEP006AWE
MEP006ALM
MEP006AWM
FSN
NOMENCLATURE
6115-407-8314
6115-455-7693
6115-407-8322
6115-463-9092
WINTERIZATION KIT, FUEL BURNING
WINTERIZATION KIT, ELECTRIC
LOAD BANK KIT
WHEEL MOUNTING KIT
Approved for public release; distribution is unlimited
TM 5-6115-545-34/TO 35C2-3-444-2/NAVFAC P-8-626-34/TM-00038G-35, 10 June 1973, is changed
as follows:
1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in
the margin. An illustration change is indicated by a miniature pointing hand.
Remove pages
Insert pages
14-3 and 14-4
14-9 and 14-10
14-3 and 14-4
14-9 and 14-10
2. Retain this sheet in front of manual for reference purposes.
TMS-6115-545-34
T035C2-3444-2
NAVFAC P-8-626-34
TM-00038G-35
C 11
By Order of the Secretaries of the Army, Air Force, and Navy (Including the Marine Corps):
CARL E. VUONO
General, United States Army
Chief of Staff
Official:
THOMAS F. SIKORA
Brigadier General, United States Army
The Adjutant General
MERRILL A. McPEAK
General USAF
Chief of Staff
Official:
CHARLES C. MCDONALD
General, USAF
Commander, Air Force Logistics Command
DAVID E. BUTTORFF
Rear Admiral, CEC, US Navy
Commander
Navy Facilities Engineering Command
H.E. REESE
Executive Director
Marine Corps Research, Development and
Acquisition Command
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25E, (qty rqr block no. 0861)
TM 5-6115-545-34
TO-35C2-3-444-2
NAVFAC P-8-626-34
TM-00038G-35
C 10
HEADQUARTERS, DEPARTMENTS OF THE ARMY, THE AIR FORCE
AND THE NAVY (INCLUDING U.S. MARINE CORPS)
Washington, D.C., 30 August 1989
CHANGE
No. 10
Intermediate (Field) (Direct and General Support)
and Depot Maintenance Manual
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD.,
60 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS
DOD MODELS
CLASS
HERTZ
FSN
MEPO06A
MEP105A
MEP115A
UTILITY
PRECISE
PRECISE
50/60
50/60
400
6115-118-1243
6115-118-1252
6115-118-1253
INCLUDING OPTIONAL KITS
MEPO06AWF
MEPO06AWE
MEPO06ALM
MEPO06AWM
FSN
NOMENCLATURE
DOD MODELS
WINTERIZATION KIT, FUEL BURNING
WINTERIZATION KIT, ELECTRIC
LOAD BANK KIT
WHEEL MOUNTING KIT
6115-407-8314
6115-455-7693
6115-407-8322
6115-463-9092
TM 5-6115-545-34, TO 35C-2-444-2, NAVFAC P-8-626-34 and TM 00038G-35, 10 June
1973, is changed as follows:
1.
Remove and insert pages as indicated below. New or changed text material
An illustration change is indicated
is indicated by a vertical bar in the margin.
by a miniature pointing hand.
2.
Remove pages
Insert pages
iii and iv
1-1 and 1-2
7-21 and 7-22
8-18A and 8-18B
14-13 and 14-14
I-1 and I-2
iii and iv
1-1 and 1-2
7-21 and 7-22
8-18A and 8-186
14-13
I-1 and I-2
Retain this sheet in front of manual for reference purposes.
TM 5-6115-545-34
TO 35C-3-444-2
NAVFAC P-8-626-34
TM-00038G-35
C 10
By Order of the Secretaries of the Amy, the Navy, and the Air Force:
Official:
CARL E. VUONO
General. United States Army
Chief of Staff
WILLIAM J. MEEHAN, II
Brigadier General, United States Army
The Adjutant General
B. F. MONTOYA,
Rear Admiral, CEC, US Navy
Commander
Naval Facilities Engineering Command
Official:
LARRY D. WELCH, General USAF
Chief of Staff
ALFRED G. HANSEN
General, USAF, Commander, Air Force
Logistics Command
H. E. REESE
Executive Director
Marine Corps Research, Development and
Acquisition Command
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25A, Direct Support and General
Support Maintenance requirements for Generator Set, Diesel Driven, Tactical, Skid
Mounted, 120/208V, 204/416V, 3PH, 4 Wire (50/60HZ: MEP-006A, MEP-105A; 400HZ:
MEP-115A).
TM 5-6115-545-34
TO-35C2-3-444-2
NAVFAC P-8-626-34
TM-00038G-35
C 9
ARMY
AIR FORCE
NAVY
MARINE CORPS
CHANGE
DEPARTMENT OF THE ARMY,
THE AIR FORCE, AND THE NAVY
(INCLUDING U.S. MARINE CORPS)
WASHINGTON, D.C., 12 January 1987
NO. 9
Intermediate (Field) (Direct and General Support)
and Depot Maintenance Manual
GENERATOR SFT, DIESEL ENGINE DRIVEN, TACTICAL
SKID MTD., 60 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS
DOD MODELS
MEPO06A
MEP105A
MEP115A
CLASS
HERTZ
FSN
UTILITY
PRECISE
PRECISE
50/60
50/60
400
6115-118-1243
6115-118-1252
6115-118-1253
INCLUDING OPTIONAL KITS
DOD MODELS
MEPO06AWF
MEPO06AWE
MEPO06ALM
MEPO06AWM
FSN
NOMENCLATURE
WINTERIZATION KIT, FUEL BURNING
WINTERIZATION KIT, ELECTRIC
LOAD BANK KIT
WHEEL MOUNTING KIT
6115-407-8314
6115-455-7693
6115-407-8322
6115-463-9092
TM 5-6115-545-34, TO 35C-2-444-2, NAVFAC P-8-626-34 and TM 00038G-35, 10
June 1973, is changed as follows:
1. Remove and insert pages as indicated below. New or changed text material
is indicated by a vertical bar in the margin. An illustration change is indicated
by a miniature pointing hand.
2.
Remove pages
Insert pages
i through iv
1-3 and 1-4
2-1 and 2-2
---------
i through iv
1-3 and 1-4
2-1 and 2-2
2-2.1 and 2-2.2
7-19 through 7-26
Retain this sheet in front of manual for reference purposes.
TM 5-6115-545-34
TO 35C-3-444-2
NAVFAC P-8-626-34
TM-00038G-35
ARMY
AIR FORCE
NAVY
MARINE CORPS
By Order of the Secretretaries of the Army, the Navy, and the Air Force:
Official:
JOHN A.WICKHAM, JR.
General, United States Army
Chief of Staff
R.L.DILWORTH
Brigadier General, United States Army
The Adjutant Genend
J.P. JONES, JR.
Rear Admiral, CEC, US Navy
Commander
Naval Facilities Engineering Command
Official:
CHARLES A. GABRIEL, General USAF
Chief of Staff
EARL T. O’LOUGHLIN
General, USAF, Commander, Air Force
Logistics Command
GEORGE B. CRIST
Lieutenant General, USMC
Deputy Chief of Staff for Inatallations and Logistics
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25A, Direct and General Support
Maintenance requirements for Generator Set, Diesel Driven, Tactical, Skid Mounted,
120/208V, 240/416V, 3 PH, 4 Wire (50/60 HZ: MEP-006A, MEP-105A; 400 HZ: MEP-115A)
(TM 5-6115-545 Series)
TM 5-6115-545-34
TO 35C2-3-444-2
NAVFAC P-8-626-34
TM-00038G-35
C8
ARMY
AIR FORCE
NAVY
MARINE CORPS
Department of the Army,
the Air Force, and the Navy
(Including U.S. Marine Corps)
WASHINGTON, D.C., 1 April 1986
CHANGE
No. 8
Intermediate (Field) (Direct and General Support)
and Depot Maintenance Manual
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL
SKID MTD., 60 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS
DOD MODELS
CLASS
HERTZ
FSN
MEPO06A
MEP105A
MEP115A
UTILITY
PRECISE
PRECISE
50/60
50/60
400
6115-118-1243
6115-118-1252
6115-118-1253
.
INCLUDING OPTIONAL KITS
DOD MODELS
NOMENCLATURE
FSN
MEPO06AWF
MEPO06AWE
MEPO06ALM
MEPO06AWM
WINTERIZATION KIT, FUEL BURNING
WINTERIZATION KIT, ELECTRIC
LOAD BANK KIT
WHEEL MOUNTING KIT
6115-407-8314
6115-455-7693
6115-407-8322
6115-463-9092
TM 5-6115-545-34, TO 35C2-2-444-2, NAVFAC P-8-626-34 and TM 00038G-35, 10
June 1973 are changed as follows:
1. Remove and insert pages as indicated below. New or changed text material
is indicated by a vertical bar n the margin. An illustration change s indicated
by a miniature pointing hand.
2.
Remove pages
Insert pages
3-3 through 3-6
5-51 and 5-52
5-57 and 5-58
8-27 and 8-28
8-31/8-32
3-3 through 3-6
5-51 and 5-52
5-57 and 5-58
8-27 and 8-28
8-31/8-32
Retain this sheet in front of manual for reference purposes.
TM 5-6115-545-34
TO 35C-3-444-2
NAVFAC P-8-626-34
TM-00038G-35
ARMY
AIR FORCE
NAVY
MARINE CORPS
By Order of the Secretaries of the Army, the Navy, and the Air Force:
Official:
JOHN A. WICKHAM, JR.
General, United Stutes Army
Chief of Staff
R.L.DILWORTH
Brigadier General, United States Army
The Adjutant General
J. P. JONES, JR.
Rear Admiral, CEC, US Navy
Commander
Naval Facilities Engineering Command
Official:
CHARLES A. GABRIEL, General USAF
Chief of Staff
EARL T. O’LOUGHLIN
General, USAF, Commander, Air Force
Logistics Command
GEORGE B. CRIST
Lieutenant General, USMC
Deputy Chief of Staff for Installations and Logistics
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25A, Direct and General Support
Maintenance requirements for Generator Set, Diesel Driven, Tactical, Skid Mounted,
120/208V, 240/416V, 3PH, 4 Wire (50/60HZ: MEP-006A, MEP-105A; 400HZ: MEP-115A)
(TM 5-6115-545 Series).
ARMY
AIR FORCE
NAVY
MARINE CORPS
CHANGE
TM 5-6115-545-34
TO 35 C2-3-444-2
NAVFAC P-8-626-34
TM-00038G-35
C-7
Department of the Air Force,
the Army, and the Navy
(Including U.S. Marine Corps)
WASHINGTON, D.C., 20 October 1983
No. 7
INTERMEDIATE (FIELD) (DIRECT AND GENERAL SUPPORT)
AND DEPOT MAINTENANCE MANUAL
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL
SKID MTD., 60 KW, 3 PHASE, 4 WIRE, 120/208 and 240/416 VOLTS
TM 5-6115-545-34, TO-35C2-3-444-2, NAVFAC P-8-626-34, TM-00038G-35, 10 June 1973,
are changed as follows:
1.
Remove and insert pages as indicated below.
Chapter 3
Chapter 8
Chapter 11
Chapter 14
Chapter 15
Index
2.
margin.
3.
Remove pages
Insert pages
3-1 thru 3-4
8-1 thru 8-6
8-11 and 8-12
8-21 and 8-22
8-25 and 8-26
11-1 and 11-2
14-27 and 14-28
14-37 and 14-38
14-61 and 14-62
14-65 and 14-66
14-79 and 14-80
15-1 and 15-2
I-3 and I-4
3-1 thru 3-4
8-1 thru 8-6
8-11 and 8-12
8-21 and 8-22
8-25 and 8-26
11-1 and 11-2
14-27 and 14-28
4-37 and 14-38
4-61 and 14-62
4-65 and 14-66
4-79 and 14-80
5-1 and 15-2
I-3 and I-4
New or changed text material is indicated by a vertical bar in the
An illustration change is indicated by a miniature pointing hand.
Retain these sheets in front of manual for reference purposes.
By Order of the Secretaries of the Army, the Navy, and the Air Force:
Official:
JOHN A. WICKHAM, JR.
General, United States Army
Chief of Staff
ROBERT M. JOYCE
Major General, United States Army
The Adjutant General
W. M. ZOBEL
Rear Admiral, CEC, US Navy
Commander
Naval Facilities Engineering Command
Official:
LEW ALLEN, JR., General USAF
Chief of Staff
JAMES P. MULLINS, General, USAF
Air Force Logistics Command
H. A. HATCH
Lieutenant General, USMC
Deputy Chief of Staff for
Installations and Logistics
DISTRIBUTION:
Active Army:
To be distributed in accordance with DA Form 12-25D, Direct and General Support
Maintenance Requirements for Generator Sets, Engine Driven 60 KW 60 HZ Precise Power,
60 KW 400 HZ Precise Power and 60 HZ Utility.
Marine Corps:
MARCORPS CODE: AGB
ARMY
AIR FORCE
NAVY
MARINE CORPS
TM 5-6115-545-34
TO 35C2-3-444-2
NAVFAC P-8-626-34
TM-00038G-35
C 6
Department of the Air Force,
the Army, and the Navy
(Including U.S. Marine Corps)
WASHINGTON, D.C., 20 May 1982
CHANGE
No. 6
INTERMEDIATE (FIELD) (DIRECT AND GENERAL SUPPORT)
AND DEPOT MAINTENANCE MANUAL
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL
SKID MTD., 60 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS
TM 5-6115-545-34, TO-35C2-3-444-2, NAVFAC P-8-626,34,TM-000-38G-35, 10
June 1973, are changed as follows:
1.
Chapter
Chapter
Chapter
Chapter
Chapter
Chapter
Remove and insert pages as indicated below.
1
2
5
8
9
14
Chapter 17
Remove pages
Insert pages
1-27/1-28
2-1 and 2-2
5-83 and 5-84
8-23 and 8-24
9-3 and 9-4
14-1 and 14-2
14-55 and 14-56
14-65 and 14-66
14-69 thru 14-76
14-87 and 14-88
17-19 and 17-20
1-27/1-28
2-1 and 2-2
5-83 and 5-84
8-23 and 8-24
9-3 and 9-4
14-1 and 14-2
14-55 and 14-56
14-65 and 14-66
14-69 thru 14-76
14-87 and 14-88
17-19 and 17-20
2. New or changed text material is indicated by a vertical bar
in the margin. An illustration change is indicated by a miniature
pointing hand
3.
Retain these sheets in front of manual for reference purposes.
By Order of the Secretaries of the Army, the Navy, and the Air Force:
E. C. MEYER
General, United Stated Army
Chief of Staff
Official:
ROBERT M. JOYCE
Brigadier General, United States Army
The Adjutant General
W. M. ZOBEL
RearAdmiral, CEC, U.S Navy
Commander
Naval Facilities Engineering Command
LEW ALLEN, JR., General, USAF
Chief of Staff
Official:
JAMES L. WYATT, JR., Colonel, USAF
Director of Administration
H. A. HATCH
Lieutenant General, USMC
Deputy Chief of Staff for Installation
and Logistics
DISTRIBUTION :
Active Army:
To be distributed in accordance with DA Form 12-25D, Direct and
General Support Maintenance Requirements for Generator Sets, Engine
Driven 60 KW 60 HZ Precise Power, 60 KW 400 HZ Precise Power and 60
HZ Utility.
Marine Corps:
MARCORPS CODE:
AGB
ARMY
AIR FORCE
NAVY
MARINE CORPS
TM 5-6115-545-34
TO 35C2-3-444-2
NAVFAC P-8-626-34
TM-00038G-35
C 5
Department of the Air Force,
the Army, and the Navy
(Including U.S. Marine Corps)
WASHINGTON, D.C., 2
CHANGE
No. 5
INTERMEDIATE (FIELD) (DIRECT AND; GENERAL SUPPORT)
AND DEPOT MAINTENANCE MANUAL
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL
SKID MTD., 60 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS
TM 5-6115-545-34, TO-35C2-3-444-2, NAVFAc P-8-626-34, TM-OO038G-35, 10
June 1973, are changed as follows:
1.
Remove and insert pages as indicated below.
Chapter 2
Chapter 7
Chapter 8
Chapter 14
Remove pages
Insert pages
2-11 and 2-12
2-15 thru 2-20
7-7 thru 7-10
8-27 and 8-28
14-75 and 14-76
2-11 and 2-12
2-15 thru 2-20
7-7 thru 7-10
8-27 and 8-28
14-75 and 14-76
14-76A/14-76B
14-85 thru 14-88
14-85 thru 14-88
2. New or changed text material is indicated by a vertical bar in the margin.
An illustration change is indicated by a miniature pointing hand.
3.
Retain these sheets in front of manual for reference purposes.
By Order of the Secretaries of the Army, the Navy, and the Air Force:
Official:
E. C. MEYER
General, United States Army
Chief of Staff
J. C. PENNINGTON
Major, General, United States Army
The Adjutant General
E, G. ISELIN
Rear Admiral, CEC, US Navy
Commander
Naval Facilities Engineering Command
Official:
VAN L. CRAWFORD, JR., Colonel, USAF
Director of Administration
LEW ALLEN, JR., General USAF
Chief of Staff
V.J. WALLS
Acting Deputy Chief of Staff for
Installations and Logistics
DISTRIBUTION:
Active Army:
To be distributed in accordance with DA Form 12-25D, Direct and General Support
Maintenance Requirements for Generator Sets, Engine Driven 60 KW 60 HZ Precise Power,
60 KW 400 HZ Precise Power and 60 KW 60 HZ Utility.
Marine Corps:
MARCORPS CODE: AGB
ARMY
AIR FORCE
NAVY
MARINE CORPS
TM 5-6115-545-34
TO 35C2-3-444-2
NAVFAC P-8-626-34
TM-00038G-35
C4
TECHNICAL MANUAL
Departments of the Air Force,
the Army, and the Navy
(Including. S. Marine Corps)
Washington, DC, 31 August 1977
Change
No. 4
INTERMEDIATE (FIELD) (DIRECT AND GENERAL SUPPORT)
AND DEPOT MAINTENANCE MANUAL
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL
SKID MTD. , 60 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS
TM-5-6115-545-34, TO-35C2-444-2, NAVFAC P-8-626-34, TM-00038G-35, 10 June 1973 are changed as
follows:
1. The attached new pages, as listed below, are to be inserted in the manual and the old pages removed.
New or changed material in the change pages is indicated by a vertical line in the margin of the page. Added or
completely revised sections, paragraphs, tables, etc. , are indicated by a vertical line by the title only. Added
or revised illustrations are indicated by the addition of the applicable change number at the end of the illustration number.
2.
Old pages
New pages
1-1, 1-2
5-39, 5-40
5-75/(5-76 blank)
5-77, 5-78
9-5, 9-6
9-7/(9-8 blank)
9-13/(9-14 blank)
9-1 5/(9-1 6 blank)
9-17, 9-18
9-19/(9-20 blank)
9-21/(9-22 blank)
9-23/(9-24 blank)
9-25/(9-26 blank)
14-13, 14-14
14-15, 14-16
14-81, 14-82
14-83, 14-84
16-1, 16-2
1-1, 1-2
5-39, 5-40
5-75/(5-76 blank)
5-77, 5-78
9-5, 9-6
9-7/(9-8 blank)
9-13/(9-14 blank)
9-15/(9-16 blank)
9-17, 9-18
9-19/(9-20 blank)
9-21/(9-22 blank)
9-23/(9-24 blank)
9-25/(9-26 blank)
14-13, 14-14
14-15, 14-16
14-81, 14-82
14-83, 14-84
16-1, 16-2
This transmittal sheet should be filed in the front of the publication for reference purposes.
a
By Order of the Secretaries of the Army, the Navy, and the Air Force:
BERNARD W. ROGERS
General, United States Army
Chief of Staff
Official:
J. C. PENNINGTON
Brigadier General, United States Army
The Adjutant General
D. G. ISELIN
Rear Admiral, CEC, U. S. Navy
Commander,
Naval Facilities Engineering Command
Official:
DAVID C. JONES, General, USAF
Chief of Staff
JAMES J. SHEPARD, Colonel, USAF
Director of Administration
J. R. JONES
Major General, U. S. Marine Corps
Deputy Chief of Staff for Installations and Logistics
Distribution:
Active Army:
To be distributed in accordance with DA Form 12-25D, Direct and General Support maintenance requirements for Generator Sets: 60 KW 60 HZ Precise Power, 60 KW 400 HZ Precise Power, 60 KW 60 HZ Utility.
Marine Corps:
MARCORPS CODE: AJH
ARMY
AIR FORCE
NAVY
MARINE CORPS
TECHNICAL MANUAL
TM-5-6115-545-34
TO-35C2-3-444-2
NAVFAC P-8-626-34
TM-00038G-35
C3
Change
Departments of the Air Force,
the Army, and the Navy
(Including. S. Marine Carps)
No. 3
WASHINGTON, D.C. 1 July 1975
INTERMEDIATE (FIELD) (DIRECT AND GENERAL SUPPORT)
AND DEPOT MAINTENANCE MANUAL
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL
SKID MTD. , 60 KW, 3 PHASE, WIRE, 120/208 AND 240/416 VOLTS
TM-5-6115-545-34, TO-35C2-3-444-2, NAVFAC P-8-626-34, TM-00038 G-35, 10 June 1973 are changed as
follows:
1. The attached new pages, as listed below, are to be inserted in the manual and the old pages removed.
New or changed material in the change pages is indicated by a vertical line in the margin of the page. Added or
completely revised sections, paragraphs, tables, etc. , are indicated by a vertical line by the title only. Added
or revised illustrations are indicated by the addition of the applicable change number at the end of the illustration number.
Old pages
v/(vi blank)
1-3, 1-4
1-9, l-l0
2-1 thru 2-14
2-19, 2-20
3-3, 3-4
6-1, 6-2
6-4 C/(6-4D blank)
None
7-17, 7-18
14-1, 14-2
14-9. 14-10
None
14-11 14-12
14-55, 14-56
14-59, 14-60
14-75 thru 14-78
14-85 thru 14-88
14-91 thru 14-96
2.
New pages
iii, iv
v/(vi blank)
1-3, 1-4
1-9, l-l0
2-1 thru 2-14
2-19, 2-20
3-3, 3-4
6-1, 6-2
6-4C, 6-4D
6-4E. 6-4F
7-17, 7-18
14-1, 14-2
14-9, 14-10
14-10 A/(14-10B blank)
14-11, 14-12
14-55, 14-56
14-59, 14-60
14-75 thru 14-78
14-85 thru 14-88
14-91 thru 14-96
This transmittal sheet should be filed in the front of the publication for reference purposes.
a
By Order of the Secretaries of thc Army, Navy, and the Air Force:
Official:
VERNE L. BOWERS
Major General, United States Army
The Adjutant General
FRED C. WEYAND
General, United States Army
Chief of Staff
A. R. MARSHALL
Rear Admiral, CEC, USN
Commander Naval Facilities
Engineering Command
Official:
JACK R. BENSON, Colonel, USAF
Director of Administration
DAVID C. ,JONES, General, USAF
Chief of Staff
F.W. VAUGHT
Major General, U.S. Marine Corps
Deputy Chief of Staff for Installations & Logistics
Distribution:
Army:
To be distributed in accordance with DA FOrm 12-25D, Direct/General Support requirements for
Generator Sets, 60 KW, 60 HZ Precise Power, 60 KW, 400 HZ Precise Power and 60 KW, 60 HZ
Utility
Marine Corps:
MARCORPS CODE AGC
DEPARTMENT OF THE ARMY TECHNICAL MANUAL
TM-5-6115-545-34
DEPARTMENT OF THE AIR FORCE TECHNICAL ORDER
TO-35C2-3-444-2
DEPARTMENT OF THE NAVY PUBLICATION
NAVFAC P-8-626-34
MARINE CORPS TECHNICAL MANUAL
TM-00038G-35
HEADQUARTERS
TECHNICAL MANUAL
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 10 JUNE 1973
INTERMEDIATE (FIELD) (DIRECT AND GENERAL SUPPORT)
AND DEPOT MAINTENANCE MANUAL
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL
SKID MTD., 60 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS
DOD MODELS
MEP006A
MEP105A
MEP115A
HERTZ
50/60
50/60
400
CLASS
UTILITY
PRECISE
PRECISE
FSN
6115-118-1243
6115-118-1252
6115-118-1253
INCLUDING OPTIONAL KITS
DOD MODELS
NOMENCLATURE
MEF006AWF
MEF006AWE
MEF006ALM
MEFOO6AWM
WINTERIZATION KIT, FUEL BURNING
WINTERIZATION KIT, ELECTRIC
LOAD BANK KIT
WHEEL MOUNTING KIT
FSN
6115-407-8314
6115-455-7693
6115-407-8322
6115-463-9092
TABLE OF CONTENTS
i
Page
Chapter
LIST OF ILLUSTRATIONS . . . . . . . . . . . . . . iii
LIST OF TABLES . . . . . . . . . . . . . . . . . .v
INTRODUCTION . . . . . . . . . . . . . . . .1-1
1
GENERAL MAINTENANCE
INSTRUCTIONS . . . . . . . . . . . . . .2-1
II
Hydraulic Sump and Filter
(Class 1, Precise Sets Only) . . . .13-6
Repair Parts Special Tools and
Equipment . . . . . . . . . . . . . . . .2-1
Troubleshooting . . . . . . . . . . . . . . 2-1
Radio Interference Suppression . . . 2-1
Removal and Installation of
Major Components . . . . . . . . . .2-20
I
II
III
IV
HOUSING GROUP REPAIR
INSTRUCTIONS . . . . . . . . . . . . . . 4-1
5
WIRING HARNESS REPAIR
INSTRUCTIONS . . . . . . . . . . . . . . 5-1
6
LOAD CONNECTION GROUP REPAIR
INSTRUCTIONS . . . . . . . . . . . . . .6-1
I
II
III
VII
VIII
IX
X
XI
XII
XIII
XIV
XV
Introduction . . . . . . . . . . . . .6-1
Main Load Contactor . . . . . . . . . . . . . . .6-1
Current Transformer . . . . . . . . . .6-5
ELECTRO-HYDRAULIC GOVERNING
SYSTEM (CLASS 1, PRECISE
SETS ONLY) . . . . . . . . . . . . . . . .7-1
ELECTRONIC GOVERNOR. . . . . . . . . . . . 7-19
RELAY TABLE GROUP REPAIR
INSTRUCTIONS . . . . . . . . . . . . . . 8-1
I
II
III
IV
V
VI
Introduction . . . . . . . . . . . . . . . .3-1
Fault Indicator Panel . . . . . . . . . . 3-1
Control Cubicle . . . . . . . . . . . . . . 3-4
4
9
14 ENGINE ASSEMBLY AND COMPONENTS
REPAIR INSTRUCTIONS . . . . . . . .14-1
GENERATOR SET CONTROLS REPAIR
INSTRUCTIONS . . . . . . . . . . . . . .3-1
I
II
III
8
13 HYDRAULIC ACTUATOR SUMP, AND
FILTER REPAIR INSTRUCTIONS . . 13-1
Hydraulic Actuator (Class 1,
Precise Sets Only) . . . . . . . . . .13-1
II
III
IV
7
12 COOLING GROUP REPAIR
INSTRUCTIONS . . . . . . . . . . . . . . 12-1
I
I
3
Page
General . . . . . . . . . . . . . . . . . . . 1-1
Description and Data . . . . . . . . . . 1-1
I
II
2
Chapter
Introduction . . . . . . . . . . . . . . . . 8-1
Control Relay Assemblies . . . . . . . 8-1
Excitation System Assembly. . . . . .8-21
Load Measuring Unit . . . . . . . . . .8-28
GENERATOR ASSEMBLY REPAIR
INSTRUCTIONS . . . . . . . . . . . . . . 9-1
XVI
XVII
Engine Assembly . . . . . . . . . . . .14-1
Battery Charging Alternator . . . . . 14-2
Hydraulic Pump Assembly (Class
1, Precise Sets Only) . . . . . . . . 14-6
Speed Switch, Tachometer
Drive and Adapter . . . . . . . . . . 14-9
Electric Starter. . . . . . . . . . . . . . 14-13
Lube Oil Cooler and Filter
Bypass Valve . . . . . . . . . . . . .. 14-24
Nozzle Holder Assemblies. . . . . . . 14-27
Fuel Injection Pump and
Related Parts . . . . . . . . . . . . . .14-30
Turbocharger . . . . . . . . . . . . . . 14-57
Water Pump and Fan . . . . . . . . . . 14-61
Crankshaft Pulley and Vibration
Dampener, and Engine Front
Support . . . . . . . . . . . . . . . . . .14-62
Oil Pump and Oil Pan Assembly . . . 14-65
Flywheel and Housing . . . . . . . . . . 14-70
Timing System . . . . . . . . . . . . . .14-72
Cylinder Head and ValveOperating Mechanism . . . . . . . . 14-76
Piston and Rings . . . . . . . . . . . . 14-88
Crankshaft and Cylinder Block . . . . 14-92
15 BASE GROUP REPAIR INSTRUCTIONS . . 15-1
15A PAINT AND MARKING REQ. AFTER OVHL. . 15A-1
16 GENERATOR SET TESTS AFTER OVERHAUL REPAIR INSTRUCTIONS. . . . 16-1
I
II
17
Inspection . . . . . . . . . . . . . . . . . .16-1
Operating Tests . . . . . . . . . . . . . . . 16-1
KIT AND OPTIONAL EQUIPMENT
REPAIR INSTRUCTIONS . . . . . . . .17-1
I
II
III
IV
Fuel-Burning Winterization Kit. . . . 17-1
Electric Winterization Kit . . . . . . . 17-7
Wheel Mounting Kit . . . . . . . . . . 17-13
Load Bank . . . . . . . . . . . . . . ..17-16
10 DAY TANK ASSEMBLY REPAIR
INSTRUCTIONS . . . . . . . . . . . . . . 10-1
APPENDIX
11
A REFERENCES . . . . . . . . . . . . . . . . .. A-1
ii
LIFTING FRAME REPAIR
INSTRUCTIONS . . . . . . . . . . . . . . 11-1
Change 9
LIST OF ILLUSTRATION
Number
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-11
1-12
1-13
1-14
1-15
Title
Page
Schematic Diagram, Control
Panel Relay, A4 . . . . . . . . . . . .1-8
Schematic Diagram, Fault
Indicator Panel . . . . . . . . . . . . . .1-9
Wiring Diagram, Fault
Indicator Panel . . . . . . . . . . . . . .1-10
Schematic Diagram, Electric
Governor Control Unit,
(Mode I, Class I) Sets. . . . . . . . . .1-11
Schematic Diagram, Electric
Governor Control Unit,
(Mode II, Class 1) Sets . . . . . . . .1-13
Wiring Schematic Diagram,
Tactical Relay Assembly. . . . . . . .1-15
Wiring Schematic Diagram, Precise
Relay Assembly, (Class 1,
Mode II) Sets . . . . . . . . . . . . . . . .1-17
Schematic Diagram, Excitation
System Assembly . . . . . . . . . . . .1-19
Wiring Diagram, Excitation
System Assembly . . . . . . . . . . . . 1-21
Wiring Schematic Diagram,
Voltage Regulator . . . . . . . . . . . . 1-23
Wiring Schematic Diagram,
Special Relay Assembly,
(Mode I) Sets . . . . . . . . . . . . . . . . l-25
Wiring Schematic Diagram,
Special Relay Assembly,
(Mode II) Sets . . . . . . . . . . . . . .1-27
Schematic Diagram, Fuel Burning
Winterization Kit . . . . . . . . . . . . 1-29
Wiring Diagram, Fuel Burning
Winterization Kit . . . . . . . . . . . . 1-31
Schematic Wiring Diagram
Electric Winterization Kit . . . . . . 1-33
Number
5-6
5-7
5-8
5-9
5-10
5-11
5-12
5-13
5-14
5-15
5-16
5-17
5-18
5-19
5-20
5-21
5-22
5-23
5-24
5-25
2-0
2-1
2-2
2-3
2-4
BREAKOUT CABLE . . . . . . . . . . . . . . . 2-1
Component Locations
(Right and Left Side) . . . . . . . . . . 2-21
Generator Removal . . . . . . . . . . . . 2-22
2-3 Engine Removal. . . . . . . . . . . . 2-24
Engine Generator Removal . . . . . . . 2-26
3-1
3-2
3-3
3-4
Fault Locating Indicator . . . . . . . . .3-2
Component Board Assembly . . . . . .3-3
Relay Assembly . . . . . . . . . . . . . . . 3-5
Control Cubicle Converter
Test Setup . . . . . . . . . . . . . . . . .3-6
5-1
AC Power Control 50/60 Hz
Wiring Harness . . . . . . . . . . . . . .5-2
AC Power Control 400 Hz
Wiring Harness (2 Sheets) . . . . . . .5-3
AC Power Control 5/60 Hz
Wiring Harness . . . . . . . . . . . . . .5-5
DC Power Cables Wiring
Harness (2 Sheets) . . . . . . . . . . . . 5-7
(Deleted) . . . . . . . . . . . . . . . . . . 5-9
5-2
5-3
5-4
5-5
5-26
5-27
5-28
5-29
5-30
5-31
5-32
5-33
5-34
5-35
5-36
5-37
5-38
Title
Page
Convenience and Paralleling
Wiring Harness (2 Sheets) . . . . . . . . .5-10
Fault Indicator Panel Wiring Harness . . 5-13
Fault Indicator Panel Interconnecting
Wiring Harness . . . . . . . . . . . . . . . 5-15
Control Cubicle Interconnecting
Wiring Harness (2 Sheets) . . . . . . . . . 5-16
Control Cubicle Wiring Harness
(3 Sheets) . . . . . . . . . . . . . . . . . . . . 5-19
Special AC Power Cables. . . . . . . . . . . 5-25
Current Transformer Assembly
Mode I Sets Wiring Harness . . . . . . . 5-27
Current Transformer Assembly
. . .5-29
Mode II Sets Wiring Harness
Electric Governor Control (Class i ,
Mode I) Sets Wiring Harness
. . .5-30
(2 Sheets) . . . . . . . . . . . . . .
Electric Governor Control (Class i ,
Mode II) Sets Wiring Harness. . . . . . . 5-32
Electric Governor Control to Actuator
Wiring Harness Class 1 Sets . . . . . 5-33
Electric Governor Control to Actuator
Class 1 Feedback Cable Sets . . . . . 5-34
Load Measuring Unit, Wiring Harness . . 5-35
Tactical Relay Assembly,
Wiring Harness . . . . . . . . . . . . . . .5-37
Tactical Relay Assembly Interconnecting Wiring Harness . . . . . . . 5-39
Load Bank Interconnect Tactical Relay .. 5-40
Precise Relay Assembly, Wiring
Harness . . . . . . . . . . . . . . . . . . . ..5-41
Precise Relay Assembly (Class 1,
Mode I) Sets Wiring Harness . . . . . . . 5-43
Excitation System Assembly,
Wiring Harness . . . . . . . . . . . . . . .5-45
Excitation System Assembly
Interconnecting Wiring Harness . . . . . 5-47
Voltage Regulator Wiring Harness . . . . 5-48
Set Special Relay Assembly (Class 1,
Mode I) Sets Wiring Harness
(5 Sheets) . . . . . . . . . . . . . . . . . . . .5-49
Set Special Relay Assembly (Class 1,
Mode 11) Sets Wiring Harness
(5 Sheets) . . . . . . . . . . . . . . . . . . .5-55
Load Measuring Unit Interconnecting
Wiring Harness . . . . . . . . . . . . . . .5-61
Engine Accessories Wiring
Harness (3 Sheets) . . . . . . . . . . . . .5-63
Paralleling Cable Assembly. . . . . . . . .5-67
Fuel Burning Winterization Kit,
Wiring Harness . . . . . . . . . . . . . . .5-68
Fuel Burning Winterization Control
Wiring Harness . . . . . . . . . . . . . . .5-69
Electric Winterization Kit,
Wiring Harness (2 Sheets) . . . . . . . . .5-70
Electric Heater Control Box,
Wiring Harness (2 Sheets) . . . . . . . . .5-72
Load Bank Wiring Harness
(3 Sheets) . . . . . . . . . . . . . . . . . . .5-75
Load Bank Capacitor (2 Sheets). . . . . . .5-79
Load Bank Control Panel,
Wiring Harness (2 Sheets) . . . . . . . . . 5-81
Change 9
iii
LIST OF ILLUSTRATIONS (Cont)
Title
Number
5-39
5-40
6-1A
6-lB
6-lC
6-1D
6-2
6-3
6-4
7-1
7-2
7-4
7-5
7-6
7-7
7-8
7-9
7-10
7-11
7-12
7-13
7-14
7-15
7-16
7-17
7-18
8-1
8-4
8-5
8-6
8-7
8-9
8-10
iv
Page
Special Purpose Cables Assembly. . . 5-83
RFI Capacitors Wiring Harness . . . . 5-84
Main Load Contactor (3 Sheets) . . . . 6-2
Operator Assembly-Main Contactor
Adjustment Procedure . . . . . . . . 6-4B
Actuator Assembly Adjustment
Procedure . . . . . . . . . . . . . . 6-4B
Contactor Adjustment . . . . . . . . 6-4C
Main Load Contactor (3 Sheets) . . . . 6-4D
Routing Main Generator Leads
Through Current Transformer . . . 6-5
Current Transformer Assembly
and Load Connecting Group
Mounting Brackets . . . . . . . . . . 6-6
Current Transformer Assembly . . . . 6-7
Electric Governor Control
Unit Removal. . . . . . . . . . . . .7-3
Electric Governor Control Unit . . . . 7-4
Electric Governor Control Unit,
Magnetic Amplifier Bias
Test (50/60 Hz) . . . . . . . . . . . . 7-5
Electric Governor Control Unit,
Frequency Sensing Check (High
and Low Frequent ) (50/60 Hz). . . . 7-6
Electric Governor Control Unit,
Rectifier Bridge and Feedback
Winding Test (50/60Hz) . . . . . . . .7-8
Electric Governor Control Unit,
Parallel Winding Test (50/60 Hz). . . 7-9
Electric Governor Control Unit,
Magnetic Amplifier Bias Test
(400 HZ) . . . . . . . . . . . . . . ..7-11
Electric Governor Control Unit,
Frequency Sensing Check Y400 Hz). . .7-12
Electric Governor Control Unit,
Rectifier Bridge and Feedback
Winding (Test 400) HZ . . . . . . . . . 7-13
Electric Governor Control Unit
Parallel Winding Test (400 Hz) . . . . 7-14
Electric Governor Control Unit,
Test Position for Unpotted Units . . . 7-14
Electric Governor Wiring Board
Assembly (2 Sheets). . . . . . . . . . 7-15
Electric Governor Control Unit,
Location of Adjustments and
controls. . . . . . . . . . . . . . . 7-18
Functional theory of Operation. 7-14
Governor Control Unit Removal
and Installation . . . . . . . . . . . . .7-15
Actuator Removal and lnstal lation . . . . . . . . . . . . . .. . . . . . . . .7-16
Magnetic Pickup Removal and
Installation . . . . . . . . . . . . . . . . .7-17
400Hz Electric Governor System Wiring Harness Assembly
Drawing No. 84-704 . . . . . . . . . . . 7-19
Relay Table and Related Parts. . .
Tactical Relay Box Assembly . . .
Tactical Relay Resistor Assembly.
Precise Relay Box Assembly. . . .
Resistor Assembly
Special Relay Box Assernbly
(sheets) . . . . . . . . . . . . . .
DC Relay Assembly. . . . . . . . .
Short Circuit Relay Test Set- Up. .
Overvoltage Relay Test Set-Up
Reverse Power Relay Test set-Up.
Change 10
.
.
.
.
.
.
.
.
8-4
8-5
8-6
8-7
8-8
. . 8-10
. . 8-13
. . 8-14
. 8-15
. . 8-16
Number
8-11
8-12
8-13
8-13A
8-14
8-15
8-16
8-17
8-18
8-19
8-20
8-21
8-22
9-2
9-3
9-4
9-5
9-6
9-7
9-8
Title
Overload Relay Test Set-Up . . . .
Underfrequency Relay Test Set-Up
Undervoltage Relay Test Set-Up. .
DC Relay Assembly
Test Set- Up. . . . . . . . . . . . .
Page
. . 8-17
. . 8-18
. . 8-18A
. . 8-18B
Permissive Parallel Relay
Test Set-Up . . . . . . . . . . . . . . . . 8-20
Exciter System Assembly . . . . . . 8-22
Voltage Regulator . . . . . . .
8-24
Voltage Regulator Printed Circuit
Board Assembly . . . . . . . 8-25
Electronic Component Assernbly. . . 8-26
Excitation Assembly System
Test Set-Up
8-27
Load Measuring Unit Disassembly 8-29
Load Measuring Unit Test.
Schematic Diagram . . . . . . . 8-30
Load Measuring Unit Test, Voltage
Relationship Graph. . . . . . . . 8-31
AC Generator Assembly c . . . . . 9-2
Rectifier Assembly . . . . . . . . 9-5
Stator Winding and Coil Connection
(50 60 Hz) (2 Sheets). . . . . . . 9-7
Rotor Winding and Coil Connection
(50/60 Hz) . . . . . . . . . . . . 9-13
Stator Winding and Coil Connection
(400 Hz) (2 Sheets). . . . . . . . 9-15
Rotor Winding and Coil Connection
(400 Hz
9-19
Exciter Stator Winding and Coil
Connection
9-21
Exciter Rotor Winding and Coil
Connection . . . . . . . . . . . 9-23
11-1
Lifting Frame Assembly . . . . . 11-2
12-1
12-2
Control Assembly . . . . . . . . . 12-2
Shutter Assembly . . . . . . . . . 12-3
13-1
Hydraulic Actuator and Related. . 13-2
Parts
Hydraulic Actuator
13-3
Hydraulic Actuator Tests,
Schematic Diagram . . . . . . . 13-5
13-2
13-3
14-1
14-2
14-3
14-4
14-5
14-6
14-7
14-7A
14-8
14-9
14-10
14-11
14-12
14-13
14-14
14-15
14-16
14-17
14-18
14-19
14-20
Voltage Regulator and Alternator
Test . . . . . . . . . . . . . . .
Alternator Assembly . . . . . . .
Regulator Excitation Test Circuit.
Two Terminal Brush Assembly . .
Hydraulic Pump and Related Parts
Speed Switch Sensitivity Tests . .
Speed Switch
Speed Switch
Tachometer Drive . . . . .
Deleted
Electrical Starter Brush and
Solenoid Assembly . . . . . . .
Electric Starter Assembly
Frame and Field Assembly . .
Solenoid Assembly . . . . . . . .
Solenoid Adjustments
Drive Assembly Pinion, Clear ance Adjustments
Electric Starter. Test Circuits
Lube Oil Cooler . . . . .
Lube Oil Bypass Valve . . . . .
Nozzle Holder Assembly . . . .
Injector Pumps and Related Parts
14-3
14-5
14-6
14-6
14-7
14-10
14-10A
14-11
14-12
14-15
14-16
14-17
14-18
14-21
14-22
14-23
14-25
14-26
14-28
14-38
LIST OF ILLUSTRATIONS (Cont)
Number
Title
Number
Page
14-21 Fuel Injection Pump Assembly
(7 Sheets) . . . . . . . . . . . . . . . . . . 14-41
14-22 Throttle Linkage Adjustment . . . . . . 14-51
14-23 Solenoid Armature Adjustments . . . . 14-52
14-24 Variable Speed Droop Adjustment . . . 14-53
14-25 Fuel Pump and Engine Timing . . . . . 14-55
14-26 Turbocharger Assembly . . . . . . . . . 14-58
14-27 Water Pump . . . . . . . . . . . . . . ...14-61
14-28 Crankshaft Pulley and Related Parts . 14-63
14-29 Engine Front Support . . . . . . . . . . 14-64
14-30 Oil Pan and Heater . . . . . . . . . . . . 14-66
14-31 Oil Pump and Related Parts . . . . . . . 14-67
14-32 Oil Pump Assembly . . . . . . . . . . . . 14-68
14-33 Flywheel and Housing . . . . . . . . . . 14-71
14-34 Timing Gear and Cover. . . . . . . . . . 14-73
14-35 Idler Gear Shaft Installation. . . . . . . 14-74
14-36 Cylinder Head and Valve -Oper sting Mechanism . . . . . . . . . . . . 14-79
14-37 Rocker Arm Shaft Assembly. . . . . . . 14-80
14-38 Cylinder Head Assembly . . . . . . . . 14-81
14-39 Valve Seat Insert Welding Details . . . 14-81
14-40 Installation of Wooden Dowels
in Valve Lifters . . . . . . . . . . . . . . 14-81
14-41 Piston, Crankshaft, and
Block (3 Sheets) . . . . . . . . . . . . . . 14-82
Title
Page
14-42 Cylinder Head Capscrew Locations
and Torquing Sequence . . . . . . . . . . .
14-43 Connecting Rod, Crankshaft End . . . . .
14-44 Cylinder Sleeve Hold-Down Bar . . . . . .
14-45 Main Bearing Caps . . . . . . . . . . . . . . .
15A-1 Noise Level Warning
15-1
Base Group . . . . . . . . . . . . . . . . . . .
14-87
14-89
14-94
14-95
15A-1
15-2
16-1
Overshoot and Undershoot
Chart Recording . . . . . . . . . . . . . . . 16-18
17-1
17-2
17-3
17-4
Fuel Burning Engine Coolant Heater .
Fuel Burning Heater Control Box . . .
Electric Winterization Pump . . . . . .
Electric Heater Control
Box Assembly . . . . . . . . . . . . . .
Electric Winterization Kit
Heater Control Box Test
Set-Up . . . . . . . . . . . . . . . . . . .
Wheel Mounting Kit . . . . . . . . . . . .
Load Bank . . . . . . . . . . . . . . . . . .
Load Reject Relay Test Circuit . . . .
Load Bank Fan and Motor
Assembly . . . . . . . . . . . . . . . . . .
17-5
17-6
17-7
17-8
17-9
. . 17-4
. . 17-5
. . 17-10
. . 17-11
.
.
.
.
.
.
.
.
17-12
17-15
17-18
17-19
. . 17-20
LIST OF TABLES
Number
.
1-1
1-2
1-3
1-4
1-5
1-6
2-1
2-2
7-1
7-2
7-3
8-1
8-2
9-1
9-2
9-3
9-4
9-5
9-6
14-1
14-2
16-1
17-1
17-2
17-3
17-4
17-5
Title
Page
Time Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Repair and Replacement Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Specific Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47
Engine Generator Set Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49
Electrical Performance Characteristic Parameters AC, Precise (Class 1) . . . . . . . . . . . . 1-50
Electrical Performance Characteristic Parameters AC, Utility (Class 2) . . . . . . . . . . . . . 1-52
Tools and Support Equipment (Test, Repair Calibration and Handling) . . . . . . . . . . . . . . . . 2-2
Generator Set Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Resistance Test (50/60 Hz)..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Electric Governor Control Unit Component Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Resistance Test (400 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Relay Table Group Equipment Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Excitation Assembly Resistor Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Stator Winding Data (50/60 Hz).... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Rotor Winding Data (50/60 Hz)... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Stator Winding Data (400 Hz).... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Rotor Winding Data (400 Hz).... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Exciter Stator Winding Data (50/60 and 400 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Exciter Rotor Winding Data (50/60 and 400 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Fuel Inject ion Pump Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-31
Fuel Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-54
Operating Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2
Fuel Burning Winterization Kit Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2
Fuel Burning Winterization Coolant Pump Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . 17-6
Electric Winterization Kit Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-9
Electric Winterization Coolant Pump Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-13
Electric Winterization Heater Control BOX Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-14
Change 8 v/(vi blank)
CHAPTER 1
INTRODUCTION
Section I. GENERAL
1-1. Scope.
a. This manual contains instructions for
immediate (field) (direct support, general support) and
depot maintenance personnel maintaining the engine
sets, 50/60 Hertz (Mode 1) Tactical Utility (Class 2) and
Tactical Precise (Class 1) and Engine Generator Sets, 400
Hertz (Mode 11) Tactical Precise (Class I) as authorized
by the maintenance allocation chart. It provides information on the maintenance of the equipment which is
beyond the scope of the tools, equipment, personnel, or
supplies normally available to the operator and organizational levels.
b. Demolition of material to prevent enemy use
will be in accordance with the requirement of TM
750-244-3. (Procedures for Destruction of Equipment to
Prevent Enemy Use for U.S. Army). Preparation for
shipment and storage for U.S. Air Force will be in accordance with T.O. 35-1-4. Shipment and storage for U.S.
Army will be in accordance with TB-740-97-2.
1-2. Forms and Records.
THIS TECHNICAL MANUAL IS USED BY THE
ARMY, AIR FORCE, NAVY AND MARINE CORPS.
THE USE OF FORMS IN COMPLIANCE WITH
DIRECTIVES AS STATED HEREIN WILL BE
ACCOMPLISHED ONLY BY THE PERSONNEL
OF THE SERVICE TO WHICH THEY APPLY.
a . Forms and Records used by the Army
will be only those prescribed by DA Pam
738-750. Those used by the Marine Corps
will be those prescribed by TM4700-15/l.
Other service users should refer to ap propriate specifications/publications
for equipment maintenance forms and
records.
b. Report of errors, omissions, and recommendations for improvement of this publication by the individual users should be submitted as follows:
(1) Air Force–AFTO Form 22. Direct to: Commander, Sacramento Air Logistics Center, ATTN: SMALC-MMETDA, McClellan Air Force Base, California
95652-5609, in accordance with TO-00-5-1.
(2) Army–DA Form 2028. Direct to: Commander, U.S. Army Troop Support Command. ATTN:
AMSTR-MCTS, 4300 Goodfellow Blvd., St. Louis, MO
63120-1798.
(3) Marine Corps-NAVMC Form 10772. Direct
to: Commanding General U.S. Marine Corps Logistics
Base, (Code 850), Albany, GA 31704-5000.
(4) Navy–by letter. Direct to: Commanding Officer, Naval Construction Battalion Center, ATTN: Code
15741, Port Hueneme, CA 93043-5000.
Section II. DESCRIPTION AND DATA
1-3. Description
A general description of the diesel engine generator sets
and information pertaining to the identification plates
are contained in the Operator and Organizational
Maintenance Manual. Detailed descriptions of the components of the diesel engine generator sets are provided
in the applicable maintenance paragraphs of this
manual.
1-4. Time Standards.
Table 1-1 lists the number of man-hours required under
normal conditions to perform the indicated-maintenance
and repair for the generator set. Components are listed
under the appropriate group number.-The times listed
are not intended to be rigid standards. Under adverse
conditions, the operations will take longer, but under
ideal conditions with highly skilled mechanics, most of
the operations can be accomplished in less time.
1-5. Tabulated Data.
a. General. This paragraph contains all
maintenance data pertinent to intermediate (field)
(direct, general support) and depot maintenance
personnel.
b. Engine Generator Set. Refer to Operator
and Organizational Maintenance Manual.
c. Main Generator. (50/60 Hz) Exciter field voltage
and current versus load, see the following:
Change 10 1-1
Exciter Field Voltage and Current Versus Load
Percent of Rated Load
Frequency
0
Exciter
volts Amps
50 HZ
,23 2.35
60 HZ 4.2
1.35
25
Exciter
Volts Amps
2.95
12.4
3.55
5.74 1.85
7.3
2.35
10.3
75
Exciter
volts Amps
50
Exciter
Amps
volts
14.5
4.15
8.84 2.85
100
Exciter
volts Amps
125
Exciter
Volts Amps
16.6 4.75
19.3 5.5
10.4 3.35
11.94 3.85
125
Exciter
Volts Amps
d. Main Generator. (400 Hz) Exciter field
voltage and current versus load. see the following:
Exciter Field Voltage and Current Versus Load
Percent of Rated Load
Frequency
0
Exciter
Volts Amps
400 HZ 11.1 3.35
25
Exciter
volts Amps
12.2
3.70
50
Exciter
Volts Amps
75
Exciter
Volts Amps
100
Exciter
Volts Amps
13.04
14.2
15.3
e. Engine. Refer to Operator and Organizational
Maintenance Manual.
f. Excitation Assembly.
DOD drawing No. 70-1367 . . . . . . . . 50/60 Hz
DOD drawing No. 70-1368 . . . . . . . .400 Hz,
Type . . . . . . . . . . . . . solid state, with capability
to automatically flash field of
generator.
Voltage regulation:
Precise sets. . . . . . . 1 percent of rated voltage.
Utility sets. . . . . . . . 3 percent of rated voltage.
Voltage stability:
Short term (30 seconds)
Precise sets. . . . . . within bandwidth equal to 1
percent of rated voltage,
Utility sets. . . . . . . . within bandwidth equal to 2
percent of rated voltage.
Long term (4 hours)
Precise sets. . . . . . within bandwidth equal to 2
percent of rated voltage.
Utility sets. . . . . . . within bandwidth equal to 4
percent of rated voltage.
Voltage Drift (8 hours). . ..1 percent with a change
ambient temperature up to 60° F
(33. 3°C).
3.95
4.30
4.65
13.3 4.95
g. Engine Accessories.
(1) Fuel injection pump.
Manufacturer. . . . . . . Roosa Master
Model. . . . . . . . . . . . . . DCMFC 629-2LQ
Type. . . . . . . . . . . . . . . Fuel metering distributor,
twin cylinders
Drive type. . . . . . . . . . gear
Governor type. . . . . . . flyweight (centrifugal)
Rotation . . . . . . . . . . . . Clockwise (viewed from driven
end),
Cylinders (output) . . .6
Mounting, . . . . . . . . . . . Flange
Plunger diameter. . . 0.290 inches
Operational Data
Line pressure (maximum permissible) 8000 psi
Maximum permissible transister pump pressure
130 psi
Transfer pump lift at 200 pump rpm (minimum)
18 in. high
Pump speed (maximum permissible)
3000 rpm
(2) Fuel transfer pumps. Refer to Operator and
Organizational Maintenance Manual.
(3) Governor hydraulic actuator.
Transient performance (application or rejection of
rated load).
Resumption of steady state condition:
Precise sets. . . . . . . within 0.5 second.
Utility sets. . . . . . . . within 3 seconds.
Overshoot and Undershoot:
Precise sets (50/60 Hz). . . .15 percent of rated
voltage,
Precise sets (400 Hz). . . . . .12 percent of rated
voltage.
Utility sets. . . . . . . . . . . . . . .20 percent of rated
voltage.
1-2
69-790-2.
variable reluctance type.
320 psi.
differential pressure
operated.
Gem . . . . . . . . . . . . . . . . . . 2.
DOD drawing no. . . . . . .
Position transducer. . . .
Input pressure. . . . . . . . .
Type . . . . . . . . . . . . . . . . . .
(4) Hydraulic pump.
Manufacturer. . . . . . . . . . . John S. Barnes.
Manufacturer’s model no. . . . GC-5183-A-DA.
Capacity . . . . . . . . . .2.6 gpm at 3600 rpm at 320 psi.
Rotation . . . . . . . . . . . clockwise.
Type . . . . . . . . . . . . . .gear driven.
Relief valve type. . . adjustable.
Relief valve setting. . . . 310/330 psi.
Model . . . . . . . . . . . . . . . . LEH
Type . . . . . . . . . . . . . . . . . . . . . . solid state
volts input . . . . . . . . . . . . . . . . . 24Vdc and 120 Vac
from generator.
Control frequency.. . . . . . . . . 50/60 Hz.
(5) Turbocharger. Refer to Operator and
Organizational Maintenance Manual.
Power dissipation. . . . . . . . . . . .115 watts max. at
60 Hz.
Frequency regulation. . . . . . . . .0.25 percent.
(6) Electric starter. Refer to Operator and
Organizational Maintenance Manual.
(7) Battery charging alternator. Refer to
Operator and Organizational Maintenance Manual
(8) Fuel solenoid valve.
DOD drawing No . . . . . . . . . . 69-787-2
Volts . . . . . . . . . . . . . . . . . . ..
Watts . . . . . . . . . . . . . . . . . . . . 10.
Input pressure . . . . . . . . . . . 25 psi
Orifice size . . . . . . . . . . . . . 1/4 in.
(9) Oil pump.
Type . . . . . . . . . . . . . . . . . . . gear driven.
(10) Oil cooler. Refer to Operator and
Organizational Maintenance Manual.
(11) Water pump. Refer to Operator and
Organizational Maintenance Manual.
h. Radiator: Refer to Operator and Organizational
Maintenance Manual.
i. Safety Devices:
(1) Coolant high temperature switch. Refer to
Operator and Organizational Maintenance Manual.
(2) Overspeed switch. Refer to Operator and
Organizational Maintenance Manual.
(3) Low oil pressure switch. Refer to Operator
and Organizational Maintenance Manual.
(4) Fuel Level Switch (day tank). Refer to
Operator and Organizational Maintenance Manual.
j. Electric Governor Control Unit (400 Hz).
DOD drawing No . . . . . . . . . . . 69-784-1
Type . . . . . . . . . . . . . . . . solid state
Volts Input . . . . . . . . . . . . . . . .24 Vdc and 120 Vac
from generator.
Control frequency. . . . . . . . . .400 Hz
Power dissipation. . . . . . . . . .115 watts max. at
400 Hz.
Frequency regulation. . . . . . .0.25 percent.
j. Governor Control Kit Classification
and Rating
DOD Drawing Numbers :
Governor control unit. . . . . . . . . . .81.-4903
agnetic actuator . . . . . . . . . . . . . . . 81-705
Magnetic pickup . . . . . . . . . . . . . . . . .81-4904
Solid state
Type:
Input volts . . . . . . . . . . . . . . . . . . . . .ll-40vdc
Frequency regulation . . . . . . . . . . . . 0. 25%
Temperature range. . . . . . . . . . . . . . .-65° to 185° F
(-55° to 85°C)
k. Electric Governor Control Unit (50/60 Hz).
DOD drawing No. . . . . . . . . . . .69-784-2
1 . Relays,
(1) Overvoltage relay.
DOD drawing No . . . . . . . . . . . . . 70-1138
Nominal voltage . . . . . . . . . . . . . 120 volts, 50-450 Hz.
operates at 153 + 3
volts for frequencies
50 to 450 Hz.
Time delay . . . . . . . . . . . . . . . . . operates when over voltage condition is
sustained for a minimum of 200 miniseconds.
Trip time . . . . . . . . . . . . . . . . . . . less than 1.0 sec.
after voltage reaches
and stays at pull-in
value.
Contact rating . . . . . . . . . . . . . . . 10 amperes, 28.5
volts, resistive.
Temperature limits. . . . . . . . . . -65° F to + 170° F.
Temperature effect on
pull-in voltage. . . . . . . . . . . . +77° F to - 65°F
decreases min. 1
volt. + 77° F to + 170°
F changes min. + 1
volt .
(2) Undervoltage relav.
DOD drawing No . . . . . . . . . . . . . 70-1120.
Nominal voltage. . . . . . . . . . . . . .120 volts, 50/400 Hz.
Dropout voltage . . . . . . . . . . . . . .99 ±4 volts.
Pull in voltage . . . . . . . . . . . . . . .110 + 3 volts.
Time delay . . . . . . . . . . . . . . . . . .6+ 2 seconds at dropout. Instant at 48 volts
and lower.
Contact rating. . . . . . . . . . . . . . . 10 amperes, 28 volts,
resistive.
Contact arrangement. . . . . . . . .2 pole double throw.
Temperature . . . . . . . . . . . . . . . .- 65° to + 170° F.
Temperature effects on trip
voltage . . . . . . . . . . . . . . . . . . . +77° F to-65°F ±l%
max. + 77° F to
170° F + 1% max.
(3) Under frequency relays.
(a) 400 Hz sets.
—
DOD drawing No . . . . . . . . . . . . . 70-1141.
Input voltage . . . . . . . . . . . . . . . . 120 volts nominal
(400 Hz.)
Trip frequency . . . . . . . . . . . . . . 370 Hz ± 5.
Voltage input limits . . . . . . . . . + 10%.
Contact rating . . . . . . . . . . . . . . . 10 amperes, 28 volts
resistive.
Temperature range . . . . . . . . . . -65° F to ± 170° F.
Temperature effect on trip
point . . . . . . . . . . . . . . . . . . . . . - 65 °F to ± 77° F ±
1 Hz max change.
+ 77 F to+ 170° F.
Change
9
1-3
(b) 50/60 Hz sets
DOD drawing No. . . . . .70-1119.
Input voltage. . . . . . . .114 - 139 volts, 50/60
Hz.
Trip frequency. . . . . 46 ± 1 H z o r 5 5 H z
± 1 Hz:
Voltage input limits . . . . ± 10%.
Temperature range . . . . -65°F to + 170°F.
External power required . . none.
Contact rating . . . . . . . 10 amperes, 28 Vdc,
resistive.
(4) Short circuit relay.
DOD drawing No. . . . . .70-1137.
Trip voltage . . . . . . . .24 volts ± 1, any phase
to neutral.
Contact rating . . . . . . . 10 amperes, 28 Vdc.
Frequency. . . . . . . . . 50/400Hz.
Temperature range . . . . -65°F to + 170°F.
Temperature effect on trip
point . . . . . . . . . . -65°F to +77°F ± 2
percent max. change.
+77°F to + 170°F ± 3
percent max. change.
(5) Reverse power relay.
DOD drawing No. . . . . .70-1136.
DC input voltage . . . . . . 0/10 volts with ac
voltage superimposed
on dc input voltage up
to 20 volts.
External power . . . . . .24 volts dc.
Reverse polarity . . . . . . approx. 10 percent r e verse power.
Temperature limits . . . . -65°F to + 170°F.
Temperature effect on trip
point . . . . . . . . . .-650F + 3volts + 77° F
+ 2 volts. + 170°F +
1.5 volts.
Reverse trip voltage . . . . + 2 volts.
Contact rating . . . . . . . 10 amperes, 28 Vdc.
(6) Permissive paralleling relay.
DOD drawing No. . . . . .70-1118.
External power required . .24 Vdc.
Operating level . . . . . . contacts close when
signal input voltage
falls below 8 volts ±
1, 50/400 Hz.
Temperature limit . . . . . -65°F to + 170°F.
Contact rating . . . . . . .28 volts, 10 amperes,
resistive.
1-4
m. Load measuring unit.
—
DOD drawing No. . . . . .69-785.
Use . . . . . . . . . . . . 50 to 400 Hz systems.
n. Contactor
DOD drawing No. . . . . . 69-680.
Construction . . . . . . . gasket sealed.
KVA rating (maximum) . . . 125 KVA 50/60 and
400 Hz.
Main contacts . . . . . . . 3 psi + (double break).
Voltage ac . . . . . . . . 120/208 and 240/416.
Frequency . . . . . . . . 50/60 and 400 Hz.
Continuous current . . . . 350 amperes, 208
volts. 50/60 and 400
Hz.
6 second current . . . . . 750 amperes at 50/60
and 400 Hz.
Interruption (maximum) . . . 5000 amperes, 50/60
and 400 Hz. 120/208
volts 2500 amperes
50/60 and 400 Hz
240/416 volts.
Mechanism . . . . . . . . electrically held.
Auxiliary contacts:
Voltage dc
28 volts.
Current
7.5 amperes.
Voltage ac
120 volts.
Lamp current
7.5 amperes.
Contact operation
auxiliary contacts
operate 0.001 to
0.003 second after
main contacts close
and 0.003 to 0.005
second after main
contact opens.
Temperature range . . . . 55° to 71°C.
Coil data
Operating voltage (without external resistance)
(maximum) . . . . . . . 32 volts.
(minimum) . . . . . . . 18 volts.
Operating time at voltage
close release . . . . 0.050/0.035 second
at 30/18 Vdc.
Close coil resistance. . . . 8 ohms.
—o. Thermal Watt Converter, 50/60 Hz.
DOD drawing No. .
volts . . . . . . .
Current. . . . . .
Elements . . . . .
Phase . . . . . .
Number of wires. .
Output . . . ..
. .
. .
. .
. .
. .
. .
o..
.
.
.
.
.
.
.
0
.
.
.
.
.
.
69-589-1.
100/130.
1 ampere.
3.
3.
4.
20 MV dc, open
circuit.
Output circuit resistance . . 4.97 ohms.
Watts per element . . . . . 96.26.
p. Thermal Wall Converter, 400 Hz.
DOD drawing No. . . . . . 69-589-2.
volts . . . . . . . . . . . 100/130.
Current . . . . . . . . . . 1 ampere.
Elements . . . . . . . . .3.
Phase . . . . . . . . . .3.
Wire . . . . . . . . . ..4.
Output . . . . . . . . . .20 MV dc. open circuit.
Output circuit resistance . .4.97 ohms.
Watts per element . . . . .96.3.
q. Alternator.
(1) Stator coils winding data 50/60 Hz.
Type . . . . . . . . . . . 3 phase.
No. of slots and COils . . . 84/84.
Turns per coil. . . . . . .4.
Coils per group . . . . . .7.
Conductor. . . . . . . . .6 of AWG 15.
Span . . . . . . . . . . . . . . .1-15 span.
(2) Rotor coils winding data 50/60 Hz.
Resistance . . .
Conductor . . .
Turns per coil. .
No. of poles and
. . .
. . .
. . .
coils .
.
.
.
.
.
.
.
.
0.390 ohm at 25°C.
9 of AWG #16 (0.0508).
103.
4.
(3) Stator coils winding data 400 Hz.
Type . . . . . . . . . ..3 phase.
No. of slots and coils . . . 108/108.
No. of coils per group . . .36 groups of 2,
36 groups of 1,
Turns per coil . . . . . . . . .5.
Span . . . . . . . . . . . l-4.
Conductor. . . . . . . . . AWG 16 and AWG 17.
(4) Exciter stator winding data.
Type of winding . . . .
No. of slots and coils .
No. of coils per group .
Turns per coil. . . . .
Span . . . . . . . . .
Conductor . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
salient pole dc.
10 slots, 10 coils.
1.
196.
1-2.
1 of AWG #21 (0.0285).
1 of AWG #22 (0.0253).
(5) Rotor coils winding data 400 Hz.
No. of poles and coils . . .24.
Turns per coil. . . . . . .30.
Conductor. . . . . . . . .4 of AWG 15.
(6) Exciter rotor winding data.
Type of winding . . . . . .3 phase.
No. of slots and coils . . .36 slots, 36 coils.
No. of coils per group . . .6 groups of 2, 24
groups of 1.
Turns per coil. . . . . . .3 for 60/50 Hz, 5 for
400 Hz.
Span . . . . . . . . . . . l-4.
Conductor. . . . . . . . . 5 of AWG #16 (0.0508)
60/50 Hz. 3 of AWG
#16 (0.0508) 400 Hz.
Insertion sequence . . . . . 211/112/111/121/111
and repeat.
r. Engine Repair and Replacement Standards.
Table 1-2 lists manufacturer’s sizes, tolerances,
and maximum allowable wear and clearances.
s. Schematic Wiring Diagrams. Figures 1-1
through 1-15 show the schematic wiring diagrams
for the 50/60 Hz and 400 Hz engine generator sets,
as well as schematic and wiring diagrams for elec trical assemblies, relay boxes and kits.
t. Torque Values.
(1) Table 1-3 lists specific torque values.
(2) All torque values are calculated for oil
lubricated threads. Increase this value by 10
percent when threads are not lubricated.
u. Unit Function Differences. The engine gener ator sets are provided in three configurations according to class and mode of operation. The class designation of a unit is determined by its frequency and
voltage performance and the mode designation is
dependent upon the output frequency. Table 1-4
provides a quick reference for determining engine
generator set classification and special component
complement required.
v. Performance Characteristics. The electrical
performance characteristics for Class 1 and Class 2
sets are provided in tables 1-5 and 1-6.
1-5
Table 1-1. Time Standards
MAC chart
group no.
Removal and replacement
10
Load connection group current transformer
assembly
11
Governor control unit
13
Relay table group
Tactical relay assembly
Precise relay assembly
Special relay assembly
Excitation assembly
Exciter
Voltage regulator
Load measuring unit
14
Generator assembly
Bearing
Rectifier rotating
Fan, generator
Rotor assembly
Stator, exciter assembly
Stator, generator assembly
16
Lifting frame assembly
Lifting frame
18
Hydraulic actuator
20
Engine assembly
Alternator/battery charging
Diodes
Brush assembly
Rotor
Field assembly
Voltage regulator (de)
Hydraulic pump and drive assembly
Speed switch and drive speed switch
Adapter
Tach drive
Electric starter and adapter
Starter assembly
Brushes
Solenoid, starter
Armature, starter
Drive, starter
Field j assembly
Lube oil cooler
Relief valve
Pump, fuel injection
Damper, vibration and crankshaft pulley
Engine front support
Oil pan assembly
Oil pump
Flywheel and housing
Flywheel assembly
Ring gear
Flywheel
Housing
1-6
Man hours
1.0
0.3
----0.6
0.6
0.6
0.6
0.6
0.6
0.6
----7.8
8.0
12.0
12.0
9.0
12.0
--2.0
0.4
----1.8
0.5
2.0
2.0
1.1
0.5
---
0.4
0.6
--1.0
0.5
1.0
1.0
1.0
1.0
--0.5
1.7
1.5
3.0
3.0
2.3
-----
11.8
10.0
10.8
Table 1-1. Time Standards (Cont)
MAC chart
group no.
Removal and replacement
Timing gear and cover
Cylinder head and valve operating mechanism
Rocker arm shaft assembly
Rocker arm assembly
Pushrod
Cylinder head assembly
Valves intake and exhaust
Springs valve
Seats intake and exhaust valves
Guides, valve
Head cylinder
Lifters, valve
Camshaft
Piston and rings
Piston pin
Connecting rod
Rod bearings
Piston rings
Piston
Crankshaft
21
25
Base group
Skid base
Winterization kit (fuel burning)
Control box assembly
Light assembly
Circuit breaker
Power switch
Heater assembly
Valve assembly, regulator
Terminal board
Switch, limit
Switch, flame
coolant pump and motor assembly
Relief valve
Motor assembly
Motor
Burner chamber
Heat exchanger
26
27
28
Man hours
5.9
----0.9
0.6
--5.9
5.4
6.1
6.1
4.0
14.8
14.6
--11.8
11.8
11.8
11.9
11.2
16.5
40.0
----0.5
0.5
0.5
0.7
0.6
0.3
0.4
0.4
0.9
0.5
0:2
1.4
1.6
1:6
2.0
1.6
Heater kit, winterization (electric)
Coolant pump and motor assembly
Pump
Relief valve
Mot or
Control box
Wiring harness
Transformers
Relay
Semi conductors
Circuit breaker
Power switch
Fuse holder
Light assembly
Wheel mounting kit
--0.5
0.2
0.5
--1.0
1.0
1.0
1.0
0.5
0.5
0.5
0.5
8.0
Load bank
Load reject relay
Terminal board
Diodes
1.0
--0.5
1-7
Figure 1-1.
1-8 Change 1
Schematic Diagram, Control Panel Relay, A4
Figure 1-2. Schematic Diagram, Fault Indicator Panel
Change 8 1-9
Figure 1-3.
1-10
Wiring Diagram, Fault Indicator Panel
Figure 1-10. Wiring Schematic Diagram, Voltage Regulator
1-23/(1-24 blank)
Figure 1-13. Schematic Diagram, Fuel Burning Winterization Kit
(1-29/1-30 blank)
1-31
Figure 1-14. Wiring Diagram, Fuel Burning Winterization Kit
Figure 1-15. Schematic Wiring Diagram Electric WInterization Kit.
Change 1 1-33/(1-34 blank)
Table 1-2. Repair and Replacement Standards
Manufacturer’s
dimensions and
tolerances in
inches
Maximum
allowable
wear and
clearance
Minimum
Maximum
Inside diameter at top of ring travel
4.2495
4.2510
0.005
Diameter of cylinder sleeve at machined area
just below flange
4.811
4.813
0.002
Diameter of cylinder sleeve at packing ring
location
4.749
4.751
0.002
Sleeve flange outside diameter
4.998
5.002
0.004
Cylinder block-to-sleeve clearance at sleeve
lower diameter
0.001
0.005
0.004
Cylinder block -to-sleeve clearance at machined
area just below flange
0.0005
0.0045
0.004
Cylinder block -to -sleeve clearance at
sleeve flange
0.004
0.013
0.009
Clearance of piston skirt with sleeve
0.0025
0.0050
0.003
Fire wall height cylinder sleeve flange
0.0445
0.0475
0.002
Top surface of cylinder flange above cvlinder
block with sleeve installed
0.002
0.005
----
Components
ENGINE
Cylinder sleeves:
Flange height adjusting shims available
0.005
0.010
0.015
0.020
Allowable taper
0.0015
Allowable out -of-round (When installed)
0.0015
Cylinder block:
Counterbore d. meter in cylinder block for
cylinder sleeve flame
5.006
5.011
0.005
Depth of counterbore for cylinder sleeve flange
0.3150
0.3165
0.0015
Bore in cylinder block for cylinder sleeve-top
4.8135
4.8155
0.002
Bore in cylinder block for cylinder sleeve - bottom
4.752
4.754
0.002
Bore in cylinder block for camshaft bearings
2.259
2.260
Bearing bore in cylinder block for main bearings
(without bearing), cap in place, and caps crews
tightened to specified torque
3.5607
3.5614
---
1-35
Table 1-2. Repair and Replacement Standards - (Cont)
Manufacturer’s
dimensions and
tolerances in
inches
Components
Maximum
allowable
wear and
clearance
Minimum
Maximum
Combustion chamber bore
2.998
3.002
0.004
Combustion chamber depth
0.592
0.596
0.004
Length
5.824
5.829
0.005
Diameter between top and second rim groove
4.225
4.229
0.004
Diameter at bottom of skirt measured at right
angle to piston pin
4.246
4.247
0.003
Bore for piston pin
1.5014
1.5016
0.001
Measurement from center of piston pin bore
to top of piston
3.142
3.146
0.004
Clearance of piston skirt with sleeve
0.0025
0.0050
0.003
Piston pin length
3.606
3.616
0.005
Diameter of pin
1,5011
1.5013
0.0002
Fit of pin in piston at room temperature
0.0001
0.0005 loose
0.0004
Bore of connecting rod bushing
1.5027
1.5032
0.001
Piston pin to connecting rod bushing clearance
0.0014
0.0021
0.002
Gap between ends - fitted, 1st ring
(chrome compression)
0.013
0.027
---
2nd and 3rd ring (compression)
0.013
0.024
---
4th ring (oil control)
0.013
0.024
---
1st ring (chrome compression)
0.0040
0.0060
0.005
2nd and 3rd ring (compression)
0. 0020
0.0040
0.002
4th ring (oil control)
0.0005
0.003
0.0025
Pistons
NOTE
Combustion chamber is in piston
Piston pins
Type full (floating)
Piston rings:
Clearance of rings in grooves
NOTE
Only standard Size ringss are available
1-96
Table 1-2. Repair and Replacement Standards -(Cont)
Manufacturer’s
dimensions and
tolerances in
inches
Maximum
allowable
wear and
clearance
Minimum
Maximum
Journal diameter for connecting rods
2.7470
2.7485
0.002
Journal diameter for main bearing
3.2465
3.248
0.002
Width between connecting rod journal checks
1.562
1.565
0.003
2.147
2.167
0.020
Intermediates
1.685
1. 689
0.004
Center
2.061
2.063
0.002
Rear
2.014
2.017
0.003
Crankshaft end clearance
0.007
0.013
0.008
Components
Crankshaft
Width of main bearing journals
Front
Separate type thrust flanges
Crankshaft journals may be ground
Fit of crankshaft gear on crankshaft
Available in standard
size and 0.005, 0.010,
0.015 oversize
----
0.002, 0.010, 0.020 or
0.040 undersize
----
0.001
0.003
interference
Main bearings:
Bore of front, intermediate, center, and rear
bearing (with capscrews tightened to specified
torque)
3.2499
3.2511
0.0038
Diameter of crankshaft main bearing journals
3.2465
3.248
0. 002
Bearing-to-journal clearance at front, inter mediate, center, and rear bearings (with capscrews tightened to specified torque)
0.0019
0.0046
0.0034
Front and Intermediate
1.432
1.442
0.010
Center
1.682
1.692
0.010
Rear
1.682
1.692
0.010
Undersize bearings available for service
0.002, 0.010, 0.020 and
0.040
Overall length of main bearings
1-37
Table 1-2. Repair and Replacement Standards -(Cont)
Manufacturer’s
dimensions and
tolerances in
inches
Components
Minimum
Maximum
allowable
wear and
clearance
Maximum
Main bearings
Separate type thrust flanges
Available in standard size
and 0.005, 0.010.0.015
oversize
Front, intermediate, center, and rear
bearing wall thickness (standard bearings)
0.1549
0.1554
0.0019
Bearing bore in cylinder block (without bearing,
cap in place, and capscrews tightened to
specified torque)
3.5607
3.5614
----
Bore of bearing (with caps crews tightened to
specified torque)
2.7495
2.7510
0.0035
Diameter of crankshaft connecting rod journals
2.7470
2.7485
0.002
Connecting rod bearing-to-journal clearance
(with capscrews tightened to specified torque)
0.001
0.0035
0.0045
Overall length of connecting rod bearings
1.195
1.205
0.010
Undersize bearings available for service
0.002
0.010
0.020
0.040
Connecting rod bearings:
----
0.10975
0.11025
0.00175
Connecting rod length (center-to-center)
8.498
8.502
----
Bore of connecting rod bushing (finished bore)
1.5027
1 5032
0.001
Bearing bore (wit bout bearing, cap in place,
and capscrews tightened to specified torque)
2.9700
2.9705
----
Connecting rod bearing-to-crankshaft journal
clearance (with capscrews tightened to
specified torque)
0.001
0.0035
0.0045
Connecting rod width at lower end
1.555
1.557
0.005
Side clearance -to-crankshaft journal
0.005
0.010
0.005
Bearing wall thickness (standard bearing)
Connecting rods:
1-38
Table 1-2. Repair and Replacement Standards - (Cont)
Manufacturer’s
dimensions and
tolerances in
inches
Minimum
Maximum
Maximum
Piston pin diameter
1.5011
1.5013
0.0002
Piston pin bushing length in connecting rod
1.490
1.510
0.010
Piston pin to connecting rod bushing clearance
0.0014
0.0021
0.001
Bore in connecting rod for piston pin bushing
1.6250
1.6255
0.0005
Valve lift (at valve) w/0.015 inch lash
0.4125
---
Valve lift (at cam)
0.285
---
Seat angle
30°
---
Valve seat contact width
3/32
1/64
Valve lash (cold)
0.018
----
Valve lash (engine coolant at normal operating
temperature)
0.015
----
1.656
0.010
6.017
0.010
0.3710
0.001
approx
----
Valve spring length (valve closed) (spring only
or spring w/damper)
2.237
----
Valve spring length
(valve open)
(spring only or spring w/damper)
1.780
Components
wear and
clearance
Connecting rods:
Exhaust valves:
Head diameter
1.646
Overall length
Stem diameter
0.3705
Valve must be recessed (in head)
0.053
Exhaust and intake valve springs:
Valve spring free length (spring only or spring
w/damper)
2-17/32
Spring load at 2.237 length spring w/damper
40 lbs
46 lbs
----
Spring load at 2.237 length
Spring only
38 lbs
42 lbs
----
108 lb
115 lbs
----
95 lbs
105 lbs
Spring load at 1.780 length
Spring w/damper
Spring load at 1.780 length
Spring only
NOTE
Install new spring when old spring is 5% below
the low limit or 5% above the high limit.
1-39
Table 1-2. Repair and Replacement Standards -(Cont)
Manufacturer’s
dimensions and
tolerances in
inches
Components
Minimum
Maximum
allowable
wear and
clearance
Maximum
Intake valveS
Valve lift (at valve) w/0.015 inch lash
0.462
Valve lift (at cam)
0.318
-----
Seat angle
30°
-----
Valve seat contact width
3/32
1/64
Valve lash (cold)
0.018
-----
Valve lash (engine coolant at normal operating
temperatures
0.015
----
1.844
0.010
6.016
0.010
0.3720
0.001
Seat angle
30°
-----
Seat contact width
3/32
1/64
Seat run-out
0.002
-----
Head diameter
1.834
Overall length
Stem diameter
0.3715
Valve must be recessed in head
0.054
Exhaust valve seat inserts:
Insert press fit
0.001
0.003
-----
Insert outer diameter not installed
1.667
1.668
-----
Bore in cylinder head for insert
1.665
1.666
-----
Depth of counterbore in cylinder head for insert
(from bottom deck of head)
0.4735
0.4755
0.002
Oversize insert
0.005
over
standard
Intake valve seat:
1-40
Seat angle
30°
Seat width
3/32
1/64
Seat run-out
0.002
-----
Insert press fit
0.001
0.003
-----
Insert outer diameter not installed
1.811
1.812
-----
Table l-2. Repair and Replacement Standards - (Cont)
Maximum
allowable
wear and
clearance
Manufacturer’s
dimensions and
tolerances in
inches
Minimum
Maximum
Bore in cylinder head for insert
1.809
1.810
-----
Depth of counterbore in head for insert
(from bottom deck of head)
0.4585
0.4605
0.002
Oversize insert
0.005
over
standard
--
2-7/8
0.010
--
0.3725
-----
Exhaust
0.0015
0.002
0.0035
Intake
0.0005
0.001
0.0025
Exhaust
1-3/32
+ 0.010
—
Intake
25/32
+ 0.010
—
Components
Intake valve seat inserts
Exhaust and intake valve guides
Length
Inside diameter ream after assembly
Stem-to-guide clearance
Guide stand-out from bottom of counterbore
in cylinder head
Rocker arms - with non-replaceable bushings:
Bore of rocker arm bushing (finish bore)
1.001
L 002
0.001
Outside diameter of rocker arm shaft
0.999
1.000
0.001
Rocker arm shaft -to-rocker arm bushing clearance
0.001
0.003
0.002
1.51
-----
Rocker arm ratio
Camshaft:
Bore of camshaft bearing (when installed)
2.133
2.136
0.003
Outside diameter of camshaft journals
2.130
2.131
0.001
Camshaft bearing-to-jourml running clearance
0.002
0.006
0.002
Outside diameter of camshaft bearings
2.263
2.265
0.002
Bore in cylinder block for bearing
2.259
2.260
0.001
Fit of camshaft bearings in bore of cylinder
block
0.003
0.006
interference
0.005
interference
1-41
Table 1-2. Repair and Replacement Standards - (Cont)
Manufacturer’s
dimensions and
tolerances in
inches
Components
Maximum
allowable
wear and
clearance
Minimum
Maximum
Overall width of camshaft bearings
front
intermediates
rear
------
1-3/8
1
1
-------------
Camshaft end play
0.0027
0.0083
0.0067
Fit of camshaft gear on camshaft
0.0015
0.003
inter ference
0.0025
inter
ference
Specified thickness of thrust collar
0.204
0.206
0.006
Bore in cylinder block for valve lifter
0.7495
0.7505
0.001
Outside diameter of valve lifter stem
0.7480
0.7485
0.0005
Valve lifter to bore of cylinder block clearance
0.001
0.0025
0.001
Crankshaft gear to camshaft gear
0.0015
0.009
0.0075
Crankshaft gear to idler gear
0.0015
0.0085
0.0065
Fuel pump drive gear to fuel pump driven gear
0.002
0.0095
0.0075
Camshaft gear to hydraulic pump gear
0.003
0.011
0.008
Bearing outside diameter
1.4995
1.5000
0.0005
Bore in water pump body (for bearing)
1.498
1.499
0.005
Fit - Bearing outside diameter to body
0.0005
0.002
interference
0.0015
interference
Bore in impeller for shaft
0.6225
0.6235
0.0005
Shaft diameter
0.6262
0.6267
0.0005
Fit - Shaft diameter to impeller bore
0.0027
0.0042
0.003
Camshaft:
Valve lifters:
Front gear train backlash:
Water pump:
Clearance - impeller to plate.
Set w/0. 15 feeler gauge
Bearing
Impeller
1-42
Table 1-2. Repair and Replacement Standards - Font)
Manufacturer’s
dimensions and
tolerances in
inches
Components
Maximum
allowable
wear and
clearance
Minimum
Maximum
Bore in hub for shaft
0.7435
0.7445
0.0005
Shaft diameter
0.7460
0.7465
0.0005
Fit - Shaft diameter to hub bore
0.0015
0.0030
interference
0.0025
interference
Bearing bore (bore for idler shaft)
1.000
1.0008
0.0008
Shaft diameter
0.9990
1.0000
0.001
Fit - shaft to bearing
0.0000
0.0018
clearance
0.0028
clearance
Bearing outside diameter
1.980
1.981
0.001
Bore in idler gear
1.9785
1.9795
0.0001
Fit - bearing outside diameter to idler gear
0.0005
0.0025
interference
0.002
inter ference
Bore in cylinder block for idler gear shaft
0.998
0.999
0.001
Idler shaft outside diameter
0.9990
1.000
0.001
Fit - idler shaft to bore in cylinder block
0.0000
0.002
interference
0.002
interference
Bearing bore (bore for hydraulic pump drive
shaft)
1.0000
1.0008
0.0005
Shaft diameter
1.0008
1.0013
0.0005
Fit - shaft to bearing
0.0000
0.0013
0.0007
Bearing outside diameter
1.980
1.981
0.0005
Bore in hydraulic pump drive housing for bearing
1.979
1.980
0.0005
Fit - Bearing outside diameter to hydraulic pump
drive housing
0.0000
0.002
interference
0.001
inter ference
Water pump:
Hub - for water pump pulley
Idler gear assembly:
Idler gear bearing
Hydraulic pump drive assembly
Hydraulic pump drive bearing
1-43
Table 1-2. Repair and Replacement Standards -(Cont)
Manufacturer’s
dimension and
tolerances in
inches
Components
,
Maximum
allowable
wear and
clearance
Minimum
Maximum
Bore in drive gear for shaft
1.0015
1.0025
0.0005
Fit - drive gear to shaft
0.0002
0.0017
interference
0.0012
interference
Outside diameter of bearing
1.0850
1.0855
0.0005
Bore in adapter for bearing
1.083
1.084
0.001
Fit - bearing-to-bore in adapter
0.001
0.0025
interference
0.0015
inter
ference
Bore in bearing after pressing into adapter
0.875
0.877
0.002
Shaft diameter
0.8735
0.8740
0.0005
Clearance - shaft -to-bearing
0.001
0.0035
0.0025
Lubricating oil pressure pump (crankshaft gear
driven) bore in cover and body for shafts
0.874
0.875
0.001
Shaft outside diameter
0.8715
0.8720
0.0005
Clearance - shaft to bore in cover and body
000020
0.0035
0.0015
Bore in drive gear - for shaft
0.8695
0.8705
0.005
Fit - shaft to drive gear
0.0010
0.0025
interference
0.0015
inter ference
End clearance (gear)
0.0025
0.0065
0.0015
Outside diameter of pressure gears
2.5694
2.5714
0.002
Bore in body for pressure gears
2.5754
2.5774
0.002
Radial clearance - gears to pump body
0.0020
0.004
0.002
Bore for bushing in housing
0.7495
0.7505
0.001
Outside diameter of bushing
0.752
0.753
0.001
Fit of bushing in housing
0.0015
0.0035
interference
0.0025
interference
Hydraulic pump drive assembly
Adapter assembly and fuel injection pump mounting:
Bearing adapter
Drive for tachometer, overspeed and/or cranking
limit switch
1-44
Table 1-2. Repair and Replacement Standards - (Cont )
Manufacturer’s
dimensions and
tolerances in
inches
Maximum
allowable
wear and
clearance
Minimum
Maximum
Bore bushing installed
0.5005
0.5013
0.001
Outside diameter of shaft
0.4990
0.4995
0.0005
Clearance - shaft to bushing
0.001
0.0023
0.002
Bore in gear
0.4975
0.4985
0.0005
Fit of shaft to gear
0.0005
0.002
interference
0.0015
inter
ference
End play installed
0.000
0.035
-----
Electric starter commutator diameter
1.6480
1.6800
0.002
Commutator minimum turned diameter
1.6470
1.6700
Brush length
0.3750
0.7500
0.3750
Armature shaft diameter
0.8700
0.8720
0.0140
Armature maximum end play
0.0300
0.0500
Fit of armature shaft in bearing
0.0020
0.0060
0.0020
Armature shaft drive end diameter
0.7450
0.7460
0.0030
Distance from end of armature shaft to face
of spline
4.8100
4.8400
0.0300
Clearance between thrust washer and pinion
0.020
0.050
Impeller shaft bearing bore
0.4000
0.4019
Impeller shaft bearing outer diameter
0.6182
0.6170
Components
Drive for tachometer, overspend and/or
cranking limit switch:
Turbocharged
Metallic seal ring bore
0.5015
Impeller wheel bore to shaft fit
0.0002
0.0004
Shaft radial movement
0.003
0.007
Shaft end play
0.001
0.0042
Bore, impeller shaft bearings
0.4019
Outer diameter impeller shaft bearings
0.6182
Thrust bearing collar bore
0.l7ll
Metallic seal ring bore
0.1720
0.5015
1-45
Table 1-2. Repair and Replacement Standards -(Cont)
Manufacturer’s
dimensions and
tolerances in
inches
Components
Minimum
Maximum
0.0002
0.0004
Maximum
allowable
wear and
clearance
Turbocharger
Impeller to shaft fit
Thrust bearing area width
0.1758
Thrust bearing ring groove
0.0665
Thrust collar to thrust bearing clearance measure 3 places
0.004
0.001
0.003
Journals, out of round
Journal diameter
0.3992
Sealing ring hub outer diameter
0.682
0.683
Sealing ring hub-ring groove
0.0645
0.0665
Clearance between thrust collar and thrust plate
0.001
0.004
Check at 3 place
Turbine wheel shaft journal diameter
0.3992
0.4020
0.003
Fuel injection pump:
Transfer pump blades
1.0930
Governor linkage
0.003
Roller to collar setting identical within 0.003
Clearance between throttle shut-off shaft and
linkage hook tab
0.190
0.220
Fuel injection nozzle opening ("popping") pressure
2825 psi
2975 psi
NOTE
New nozzles and rebuilt nozzles with
new springs are set at 3100 to 3150
psi to compensate for initial set of
new spindle springs.
Oil pump assembly
Oil gear, driven (heat in oil 350° F +— 25° F and
press on shaft)
0.848 in. from shaft end
Oil gear, driver (heat in oil 350° F + 25° F and
press on shaft)
1.812 in. from shaft end
Oil gear, drive (heat in oil, 350° F + 25° F and
press on shaft)
Shaft to protrude 0.057
to 0.062 in.
I
1-46
Table 1-3. Specified Torque Values
NOTE
Torque values listed are based on lubricated threads.
Type
Description
Caprscrew
Capscrew
Socket Head
Capscrew
12 Pt Head
Capscrew
Bearing, cap, main
Connecting rod cap
Capscrew
Cyl. head mtg. (long)
Cyl. head cover
Connecting rad cap
Cyl. head mtg. (short)
Capscrew
Nut
Nut
Fuel inj. pump shaft retaining
Nozzle retaining
Locknut
Nut
Nut
Size and Thread
5/8-11 x 4-1/4
(Hi-R-Thread)
7/16-20 x 2-5/32
(Hi-R-Thread)
7/16-20 x 2-5/32
9/16-12 x 5-1/16
Grade
9/16-12 x 8-1/8
1/4-20 x 5/8
9/16-18
Torque
(foot - pounds)
170-190
8
CS-8
80-85
CS-8
65-67.5
8
155-165
8
2
130-140
213
3-4
35-40
40-60
3/4-16
Spl.
Nozzle adjusting screw
Nozzle holder cap
Nozzle fuel line
7/8-14
7/8-20
Ermetto nut
Spl.
Spl.
--
60-75
Capscrew
Nozzle holder mounting
5/16-18 x 1-5/8
2
11-13
Plug
3/4-16
2
40
Nut
Rocker arm shaft - plug
Turbocharger to exhaust
manifold (mtg.)
3/8-16
Sst.
18-21
Nut
Turbocharger “V” band clamp
5
40-80
Capscrew
2
100-130 in. -lbs
Nut
Turbine housing to center
housing
Impeller
1/4-28
(self locking)
5/16-18 x 1/2
1/4-28
Spl.
18-20 in. -Ibs
Capscrew
Center housing to backplate
5
40-60 in. -lbs
Bolts
Generator mounting
1/4-20 x 5/8
(phosphate coated)
1-8 x 3-1/4
400-425
Bolts
Engine mounting
1/2-13 x 1-1/2
5
5
Capscrew
Hydraulic pump drive gear
1/2-20 x 2
8
95-105
Stop Screw
Fuel injection pump delivery
valve, retainer
Fuel injection pump headlocking
(straight)
Fuel injection pump
headlocating
5/16-32 x 7/32
3
85-90 in. -lbs
5/16-24 x 0.8
2
300 in. lbs
7/16-20 x 1-11/32
2
175-300 in. -lbs
2B
Screws
Screws
60-75
20-25
90-100
Capnut
Nuts
Pwct shaft, governor arm
Fuel solenoid, contact
8/32
8/32
2
35-40 in. -lbs
20-25 in. -Ibs
Capscrews
Water pump
3/8-16 x 3-1/4
3/8-16 x 2
5
5
28-33
28-33
Change 12
1-47
Table l-3. Specified Torque Values - (Cont)
Type
Description
Size and Thread
Grade
Torque
(foot - pounds)
Capscrews
Water pump inlet pipe
3/8-16 x 1
5
28-33
Capscrew
Fan pulley retainer
3/8-24 x 2 3/4
8
30-35
Capscrew
Idler gear
1/2-13 x 3 1/2
8
95-105
Capscrews
Oil pan - front
3/8-16 x 3/4
5
28-33
Capscrew
Crankshaft pulley
1-14 x 2
5
200-220
Capscrews
Oil pump mounting
1/2-13 x 1-1/2
1/2-13 x 3-1/2
5
5
68-73
68-73
Bolt capscrew
Oil pump cover
5/16-18 x 5/8
5/16-18 x 1
8
5
18-20
18-20
Capscrews
Camshaft retainer
7/16-14 x 4
8
18-20
Capscrews
Flywheel housing
1/2-13 x 1-1/4
5
73
Lockbolts
Capscrews
Flywheel, mounting
1/2-20 x l/7/8
100
95-105
Cap screws
Generator disc, mounting
1/2-13 x 1-1/2
5
950-1100 in. - lbs.
1 - 48 Change 1
1-49
Table 1-4. Engine Generator Set Classification
output
Frequency
Governing
System
Special
Component
Complement
Class
Mode
Common
Name
1
I
Tactical
Precise
50/60 Hz
Electro-Hydraulic,
With backup
manual governor
Electric governor control unit,
hydraulic actuator, hydraulic
pump and sump, precise
relay assembly, special
relay assembly, tactical
relay assembly
MEP105A
2
I
Tactical
Utility
50/60 Hz
Mechanical
(droop type)
Tactical relay assembly,
special relay assembly
MEP006A
1
II
Tactical
Precise
400 Hz
Electro-Hydraulic,
With backup
manual governor
Electric governor control unit,
hydraulic actuator, hydraulic
pump and sump, tactical
relay assembly, special
relay assembly
MEP115A
Model
Table 1-5. Electrical Performance Characteristic Parameters AC Precise (Class 1)
Characteristic parameter
a.
Value
Test method
MIL-STD-705
Voltage characteristics
1.
Regulation (%)
2.
Steady-state-stability (variation) (bandwidth %)
1
608.1
(a) Short term (30 seconds)
1
608.1
(b) Long term (4 hours)
2
608.2
3. Transient performance
(a) Application of rated load
(1) Dip (%)
—a.
60 Hz
15
619.2
b.
400 Hz
12
619.2
(2) Recovery (seconds)
0.5
619.2
(b) Rejection of rated load
(1) Rise (%)
a.
60 HZ
15
619.2
b.
400 Hz
12
619.2
(2) Recovery (seconds)
0.5
619.2
(c) Application of simulated motor load (twice rated current)
(1) Dip (%)
a.
60 Hz
30
619.1
b.
400 Hz
25
619.1
(2) Recovery to 95% of rated voltage (seconds) (Note 1)
0.7
619.1
(a) Maximum deviation factor (%)
5
601, 1
(b) Maximum individual harmonic (%)
2
601.4
5.
Voltage unbalance with unbalanced load (%) (Note 2)
5
620.2
6.
Phase balance voltage (%)
1
508.1
7.
Voltage adjustment range
4.
1-50
Waveform
(a) 50 Hz (120/208 volts)
50 Hz (240/416 volts)
190 to 213 volts
380 to 426 volts
511.1
(b) 60 Hz (120/208 volts)
60 Hz (240/416 volts)
197 to 240 volts
395 to 480 volts
511.1
Table 1-5. Electrical Performance Characteristic Parameters AC Precise (Class 1) (Cont)
Value
Test method
MIL-STD-705
197 to 229 volts
395 to 458 volts
511.1
0.25
608.1
(a) Sort term (30 seconds)
0.5
608.1
(b) Long term (4 hours)
1
608.2
(1) Undershoot (%)
1.5
608.1
(2) Recovery (seconds)
1
608.1
(1) Overshoot (%)
1.5
608.1
(2) Recovery (seconds)
1
608.1
(a) 50 Hz
±2
511.2
(b) 60 Hz
±2
511.2
(c) 400 Hz
+20
-10
511.2
Character parameter
(c) 400 Hz (120/208 volts)
400 Hz (240/416 volts)
b.
Frequency characteristics
1.
Regulation (%)
2.
Steady-state-stability (variation) (bandwidth %)
3. Transient performance
(a) Application of rated load
(b) Rejection of rated load
4.
Frequency adjustment range (Hz)
NOTE
1. The voltage shall stabilize at or above this voltage.
2. The generator set connected for three phase output and supplying a single phase,
unity power factor load connected line-to-linej with no other load on the set. The
load current to be 25 percent of the rated full load current of the set.
1-51
Table 1-6. Electrical Performance Characteristic Parameters AC Utility (Class 2)
Characteristic parameter
a.
Value
Test method
MIL-STD-705
Voltage characteristics
1.
Regulation (%)
2.
Steady-state-stability (variation)
3
608.1
(a) Short term (30 seconds)
2
608.1
(b) Long term (4 hours)
4
608.2
20
619.2
3
619.2
20
619.2
3
619.2
40
619.1
5
619.1
(a) Maximum deviation factor (%)
5
601.1
(b) Maximum individual harmonic (%)
2
601.4
5. Voltage unbalance with unbalanced load (%) (note 2)
5
620.2
6.
Phase balance voltage (%)
1
508.1
7.
Voltage adjustment range
3.
Transient performance
(a) Application of rated load
(1) DIP (%)
(2) Recovery (seconds)
(b) Rejection of rated load
(1) Rise (%)
(2) Recovery (seconds)
(c) Application of simulated motor load (twice rated current)
(1) Dip (%)
(2) Recovery to 95% of rated voltage (seconds) (Note 1)
4. Waveform
b.
(a) 50 Hz (120/208 volts)
50 Hz (240/416 volts)
190 to 213 volts
380 to 426 volts
511.1
(b) 60 Hz (120/208 volts)
60 Hz (240/416 volts)
197 to 240 volts
395 to 480 volts
511.1
Frequency characteristics
3
608.1
(a) Short term (30 seconds)
2
608.1
(b) Long term (4 hours)
3
608.2
1.
Regulation (%)
2.
Steady-state-stability (varition) (bandwidth %)
3. Transient performance
1-52
Table 1-6. Electrical Performance Characteristic Parameters AC Utility (Class 2) (Cont)
Value
Characteristic parameter
Test method
MIL-STD-705
(a) Application of rated load
(1) Undershoot (%)
3
608.1
(2) Recovery (seconds)
3
608.1
(1) Overshoot (%)
4
608.1
(2) Recovery (seconds)
3
608.1
(a) 50 Hz
±2
511.2
(b) 60 HZ
±2
511.2
(b) Rejection of rated load
4.
Frequency adjustment range (Hz)
NOTE
1. The voltage shall stabilize at or above this voltage.
2. The generator set connected for three phase output and supplying a single phase,
unity power load connected line-to-line with no other load on the set. The load
current to be 25 percent of the rated full load current of the set.
1-53/(1-54 blank)
CHAPTER 2
GENERAL MAINTENANCE INSTRUCTIONS
Section I. REPAIR PARTS, SPECIAL TOOLS AND EQUIPMENT
2-1. Tools and Repair Parts, Equipment
There are no special tools or equipment required to
perform intermediate (field) (direct and general
support) and depo t maintenance on generator sets
Models MEP006A, MEP105A and MEP115A. A
listing of recommended tools and support equipment
required to perform the maintenance operations
described in this manual are contained in Table 2-1.
2-2. Direct Support General Support and Depot
Maintenance Repair Parts.
Direct and general support and depot maintenance
repair parts are contained in the technical manual
listed in Appendix A of this manual.
2-3. Specially Designed (Fabricated) Tools and
Equipment.
A breakout cable is required to troubleshoot the electric governor system of MEP 114A. The breakout cable is used to gain
access to the governor Control Unit’s
MS3106R20-29 connector. Figure 2-0
gives fabrication instructions for the
breakout cable.
Section II. TROUBLESHOOTING
2-5. Troubleshooting Chart.
2-4. General.
This section provides information useful in
diagnosing and correcting unsatisfactory operation or failure of the engine generator set and
its components. Malfunctions which may occur
are listed in table 2-2. Each malfunction stated is
followed by a list of probable causes of the
trouble. The corrective action is described opposite the probable cause.
Table 2-2 lists generator set troubleshooting malfunctions, probable causes and corrective action.
2-6. Diagrams.
Wiring, schematic and trouble shooting diagrams for
the generator set are listed in the List of Illustrations
in the Table of Contents. Refer to the Operator and
Organizational Maintenance Manual for diagrams not
located in this manual.
Section III. RADIO INTERFERENCE SUPPRESSION
2-7. General Methods Used to Attain Proper
Suppression.
Essentially, suppression is attained by providing a
low resistance path to ground for the stray currents.
The methods used include grounding the frame
with bonding straps, grounding the engine-generator
set, and the use of capacitors.
2-8. Testing of Radio Interference Suppression
Components.
Test the capacitors for leaks and shorts on a
capacitor tester: replace defective capacitors. If
test equipment is not available and interference is
indicated, isolate the cause of interference by the
trial and error method of replacing each capacitor
in turn until the cause of interference is located
and eliminated.
2-9. Interference Suppression Components.
a. Primary Suppression Components.
components, RFI capacitors, whose primary purpose is interference suppression are the three
capacitors found on the generator side of CB2, main
line contarctor and the three on the input leads to the
engine-generator sets load bank. Their description,
location and removal are covered in the Operator and
Organizational Maintenance Manual.
Three suggested methods of grounding the enginegenerator set, instrumental in passing RFI induced
currents to ground are illustrated in the Operator
and Organizational Maintenance Manual.
b. Secondary Suppression Components. The
components, RFI capacitors whose secondary pur pose is interference suppression are the components
contained within the excitation system assembly.
Testing of the RFI filter A201 is described in paragraph 8-12 b (3), utilizing figure 1-8 schematic diagram, excitation system assembly. Refer to figure
8-1 for disassembly of the relay table which includes
the excitation system assembly, and figure 8-15 for
the excitation system assembly.
Change 9 2-1
Table 2-1.
TOOLS AND SUPPORT EQUIPMENT, TEST, REPAIR CALIBRATION AND HANDLING
Item
NSN or
Part No.
Reference
Fig
Para
Use
Stand, Radiator
Test and Repair
4910-00-505-4786
(or equivalent)
12-3
Test radiator for leaks
Tool, Test Set,
Diesel Injector
4910-00-317-8265
(or equivalent)
14-40
Test nozzle holder assemblies
Test, Stand,
Diesel Injector
4710-01-037-9417
(or equivalent)
14-48
Test fuel injection pump
Micrometers, Inside 5210-00-225-9763
and Outside
5210-00-221-1921
14-30
14-45
14-54
14-73
14-78
14-82
14-86
Measure dimension, clearance
thickness, and uniformity
Puller Kit,
Universal
5180-00-701-8046
(or equivalent)
14-61
14-69
14-72
14-85
Remove gears, flywheel and
Pulleys
Gage, Thickness
5210-00-222-1999
(or equivalent)
14-54
14-59
14-77
14-78
14-82
14-83
14-87
Measure clearance
14-20
14-21
Grinding machine,
valve face
4910-00-540-4679
(or equivalent)
14-78
Resurface valve face
Test Stand, Valve
Spring
5120-00-449-8028
(or equivalent)
14-78
Test valve springs
Grinding Kit,
Valve Seat
4910-00-473-643 14-39
(or equivalent)
Seal Installation tool
14-78
Resurface valve seats
14-70
Flywheel housing seal
installation
Allen Wrench
5/32
5120-00-198-5392
(or equivalent)
14-43
Fuel injection pump, transfer
pump delivery valve disassembly
TESTER CYLINDERI
COMPRESSION
4710-00-785-6437
(or equivalent)
14-77
Compression Test
Injection nozzle
Holding fixture
J-6999 (33287)
14-39
Disassembly of fuel injector
2-2
Change 6
Figure 2-0.
Breakout Cable (Sheet 1 of 2)
Change 9
2-2.1
Figure
2-2.2
Change 9
2-O.
Breakout Cable (Sheet
2 of 2)
Table 2-1. TOLLS AND SUPPORT EQUIPMENT, TEST, REPAIR CALIBRATION AND HANDLING
Item
NSN or
Part No
Reference
Fig
Para
Use
Pin Vise
J-4298-1 (33287)
(or equivalent)
14-39
Disassembly and cleaning fuel
injectors
Nozzle cleaning
Wire
J-8537-3 (33287)
(or equivalent)
14-39
Cleaning injector valve body
orifices
Injection Nozzle
bore cleaner
J-21609-7 (33287)
(or equivalent)
14-39
Cleaning nozzle bore with
cleaning solution
Snap ring pliers
13337 (84760)
(or equivalent)
14-43
Fuel injection pump governor
disassembly
Water pump coolant seal installer
5120-00-197-4920
(or equivalent)
14-59
Water pump coolant seal installation
Seal Installer
Handle
5120-00-677-2259
(or equivalent)
14-59
Water pump coolant seal installation
Soft Faced Hammer
5120-00-900-7882
(or equivalent)
14-34
14-72
14-87
Timing gear cover removal
Crankshaft end play test
Spring Compression Tool
5120-00-239-8686
(or equivalent)
14-38
14-77
Valve spring retainer removal
Valve Seat Installation Tool
5120-00-473-7393
(or equivalent)
14-78
Exhaust valve seat installation
Valve spring Testing Tool
5120-00-449-8028
(or equivalent)
14-78
Intake and exhaust valve spring
test
14-78
Exhaust valve seat insert installation
14-82
Connecting rod length and
twist test
Piston pin installation and removal
tool
14-83
Piston pin installation
Plastic head ham- 5120-00-900-7882
er
(or equivalent)
14-83
Connecting rod cap installation
Cylinder honing
001
5130-00-473-6236
(or equivalent)
14-85
Honing cylinder sleeves
Depth Micrometer 5120-00-619-4045
(or equivalent)
14-86
Cylinder sleeve protrusion
(standout) measurement.
Cold box
Connecting rod
checking fixture
4910-00-733-2487
(or equivalent)
Change 3
2-3
TABLE 2-1.
TOOLS AND SUPPORT EQUIPMENT, TEST, REPAIR CALIBRATION AND HANDLING (CONT)
Item
NSN or
Part No
REFERENCE
Fig
Para
Use
Cylinder sleeve
installation tool
14-87
Cylinder sleeve installation
Brass wire brush 16488 (84760)
(or equivalent)
14-39
Cleaning fuel injector nozzle
valve body
Holding fixture
5120-00-816-7030
(or equivalent)
14-21
14-45
Facilitates assembly of leaf
springs in hydraulic head and
rotor assembly.
Kit centrality
gage
16182 (84760)
(or equivalent)
14-21
14-45
Enables adjustment of rollers
in hydraulic head and rotor
assembly.
Delivery valve ex 13383 (84760)
(or equivalent)
tractor
14-21
14-45
Enables installation of delivery
valve in fuel injector pump
Piston ring
installation
tool
16199 (84760)
(or equivalent)
14-21
14-45
Enables adjustment of power
piston
Linkage gage
13389 (84760)
(or equivalent)
14-21
14-45
Enables adjustment of throttle
linkage on fuel injector pump.
Drive shaft seal
assembly tool
13369 (84760)
(or equivalent)
14-21
14-49
Enables installing drive shaft
in fuel injector pump
Multimeter
6625-00-553-0142
(or equivalent)
3-3
3-10
3-10 &
6-4
6-9
7-2
8-14
1-8
14-2
14-3
14-6
Test Set, Gen4910-00-092-9136
erator and voltage (or equivalent)
regulator automotive
2-4
Change 3
14-1
Check resistance
Control box relay testing
Control box relay assembly
Testing
Current transformer testing
Electro-hydraulic governing
system malfunction
7-6
Electro-hydraulic governing
system resistance test
Permissive parallel relay test
8-7
8-12
Excitation system assembly test
9-2, 9-3 Generator, removal disassembly
and test
14-10
Battery charging alternator
inspection and test.
14-12
14-19
Speed switch test
14-9
Battery charging alternator
TABLE 2-1.
TOOLS AND SUPPORT EQUIPMENT, TEST, REPAIR CALIBRATION AND HANDLING (CONT)
REFERENCE___
NSN or
Part No
Item
AC Power Supply
120/208 Vat, 3
Phase, 4 wire
60 HZ
17 BU-3 Superior
Electric (58474)
(or equivalent)
C Voltmeter
0-120 VAC
Para
Use
3-7
8-7
Thermal watt converter testing
Overload relay test
Model 904 Weston
8-8
(65092) (or equiva- 8-19
8-21
lent)
8-7
8-12
8-18
Short circuit relay test
Excitation system assembly test
Load measuring unit test
13-3
13-6
Hydraulic actuator test
Test stand Actua- 4940-00-152-2107
(or equivalent)
tor
AC Ammeter
Fig
Model 433
Weston (65092) or
equivalent
3-4
8-11
Overload relay test
8-11
8-7
Test Set, Gen & 4910-00-092-9136
(or equivalent)
Voltage Regulator
14-2
14-10
Battery charging alternator inspection and test
Test Set, armature
14-11
14-28
Electric starter inspection and
test
8-8
8-7
8-9
8-7
Short circuit (Bench Test) relay
test (400HZ)
Overvoltage relay test
8-12
8-7
8-12
8-13
8-14
7-3
8-7
8-7
8-7
7-6
7-4
7-6
7-5
7-6
7-5
7-6
7-7
7-6
7-8
7-6
7-9
7-6
7-10
7-6
Variable voltage
6625-00-828-5810
(or equivalent)
Model 1308
Variable frequency General Radio
power supply (0(24655)
160) VAC, 20-450
(or equivalent)
Hz
Underfrequency relay test (50/60
Hz)
Underfrequency relay test (400HZ
Undervoltage relay test (400 HZ)
Permissive parallel relay test
Electro-hydraulic governor
Magnetic amplifier bias test
50/60 HZ
Electro-hydraulic governor frequency sensing test (50/60 Hz)
Electro-hydraulic governor rectifier bridge and-feedback wind
ing test (50/60 Hz)
Electro-hydraulic governor parallel winding test (50/60 Hz)
Electro-hydraulic governor magnetic amplifier bias test (400 H
Electro-hydraulic governor frequency sensing test (400 Hz)
Electro-hydraulic governor rectifier bridge and feedback winding
test (400 Hz)
Electro-hydraulic governor parallel winding test (400 Hz)
Change 3
2-5
TABLE 2-1. TOOLS AND SUPPORT EQUIPMENT, TEST, REPAIR CALIBRATION AND HANDLING (CONT)
REFERENCE
Item
NSN or
Part No
Fig
Para
3-10
3-9
DC Power Supply
(24 vdc)
DC power supply
27 ± .5 Vdc
Model MP40
(98853) (or equivalent)
Model MP4-0
(98853) (or equivalent)
DC Power Supply
variable voltage(0-5 Vdc)
Model MP40 (98853)
(Or equivalent)
AC Power Supply
variable voltage
0-10 VAC)
Model 116B Superior
Electric (variac)
58474) (or equivalent)
Miliammeter dc,
0-1000 ma
6625-00-883-9734
(or equivalent)
2-6
Change 3
8-8
6-9
8-7
8-9
8-10
8-11
8-12
8-13
7-6
8-7
8-7
8-7
8-7
8-7
7-6
8-14
8-7
8-7
13-6
7-6
13-13
7-3
I
Use
Control box relay assembly test
ing
Frequency meter and transducer
test
Current transformer testing
Short circuit relay test (bench
test)
Overvoltage relay test
Reverse power relay test
Overload relay test
Underfrequency relay test
Undervoltage relay test
Electric governor control unit
parallel winding test
Permissive parallel relay
DC relay assembly test
Hydraulic actuator test
Electro-hydraulic governor magnetic amplifier bias test (50/
60 Hz) (Bench Test)
Electro-hydraulic governor
frequency sensing test (50/60
Hz)
Electro-hydraulic governor rectifier bridge and feedback
winding test (50/60 Hz)
Electro-hydraulic governor
parallel winding test (50/60 Hz
Electro-hydraulic governor
magnetic amplifier test (400Hz
Electro-hydraulic governor
frequency sensing test (400 Hz)
Electric-hydraulic governor
receptacle bridge and feedback
winding test (400 Hz)
Electro-hydraulic parallel wind
ing test (400 Hz)
7-4
7-6
7-5
7-6
7-6
7-6
7-7
7-6
7-8
7-6
7-9
7-6
7-10
7-6
8-10
8-7
Reverse power relay test (bench
test)
8-7
Reverse power relay test (bench
test)
8-10
7-3
7-6
Electro-hydraulic governor magnetic amplifier bias test (50/
60 Hz
TABLE 2-1. TOOLS AND SUPPORT EQUIPMENT, TEST, REPAIR CALIBRATION AND HANDLING (CONT)
REFERENCE
Item
NSN or
Part No.
Fig
Para
Use
7-4
7-6
Electro-hydraulic governor
frequency sensing test (50/60Hz)
7-5
7-6
Electro-hydraulic governor rectifier bridge and feedback
winding test (50/60 Hz)
7-6
7-6
Electro-hydraulic governor parallel winding test (50/60 Hz)
7-7
7-6
Electro-hydraulic governor magnetic amplifier bias test (400
Hz)
7-8
7-6
Electro-hydraulic governor frequency sensing test (400 Hz)
7-9
7-6
Electro-hydraulic governor rectifier bridge and feedback
winding test (400 Hz)
7-10
7-6
Electro-hydraulic governor
parallel winding test (400 Hz)
13-3
13-6
Hydraulic actuator test
Voltmeter O-5
Vdc
Model Weston (65092
(or equivalent)
8-10
8-7
Reverse power relay test (bench
test)
Frequency meter
set
6625-00-893-0021
(or equivalent)
8-12
8-7
Underfrequency relay test (400
Hz)
3-9
Control box relay assembly test
ing(frequency meter and transducer test)
8-7
Underfrequency relay test (50/
60 Hz)
8-12
AC Wattmeter
Three Phase
Model 329 (65092)
Voltmeter 0-10
Vac
Model 904 (65092)
3-6
8-21
8-18
AC Wattmeter testing
Load measuring unit test (bench
Test)
Change 3
2-7
TABLE 2-1.
TOOLS AND SUPPORT EQUIPMENT, TEST, REPAIR CALIBATION AND HANDLING (CONT)
REFERENCE
ITEM
NSN or
PART NO
Fig
Para
USE
Voltmeter 0-50
Vdc
Model 901 (65092)
8-21
8-18
Load measuring unit test (Bench
test)
Auto transf ormer
5625-00-124-7254
(or equivalent)
7-5
7-6
7-9
7-6
Electro-hydraulic governor rectifier bridge and feedback
winding test (50/60 Hz)
Electro-hydraulic governor rectifier bridge and feedback
winding test (400 Hz)
7-5
7-6
7-9
7-6
9-2
9-2
Generator removal, disassembly
and test
13-3
13-2
Hydraulic speed control actuator
14-14
Hydraulic pump assembly (class
1 precise sets)
Hydraulic pump reassembly, installation and adjustment
Miliammeter dc,
zero center -10,
0, +10 ma
Solder gun
6625-00-883-9734
3439-00-517-0603
(or equivalent)
Test Gage and Hose 4910-00-774-9343
Ay
(or equivalent)
Test Stand, Actu- 4940-00-152-2107
ator
(or equivalent)
Test Stand, Magnetic
1910-00-912-3690
(or equivalent)
Voltmeter 0-300
Vac
Model 904 (65092)
Power supply 208
Vat, 3 phase 47430 Hz
14-5
14-16
13-3
13-6
Hydraulic actuator test (bench
test)
14-19
Testing speed switch (bench
test)
8-21
8-18
Load measuring unit test (bench
test)
8-21
8-18
Load measuring unit test (Bench
test)
9-2
Generator, removal, disassemble
and test
Wheatstone bridge 3625-00-927-4451
(or equivalent)
Megger 500 Vdc
5625-00-581-2466
(or equivalent)
14-12
14-12
14-2
2-8 Change 3
Electro-hydraulic governor rectifier bridge and feedback
winding test (50/60 Hz)
Electro-hydraulic governor rectifier bridge and feedback
winding test (400 Hz)
14-29 Electric sater motor repair
14-28
Electric starter inspection
and test
14-10
Battery charging alternator
inspection and test
TABLE 2-10
TOOLS AND SUPPORT EQUIPMENT, TEST, REPAIR CALIBRATION AND HANDLING (CONT)
REFERENCE
Item
NSN or
Part No.
Fig
Para
9-2
9-2
Double Kelvin
Bridge
Use
Generator, removal, disassemble
and test
Generator, removal, disassemble
and test
Engine support
Stand
4910-00-808-3372
(or equivalent)
14-3
Support engine after removal
from skid base
Engine Stand Adapter plate
J22289-1 (33287)
(or equivalent)
14-3
Support engine after removal
from skid base
Engine stand ad- J22289-2 (33287)
apter plate spac- (or equivalent)
ers
14-3
Support engine after removal
from skid base
2-1
2-11
Support engine on skid base
hen removing generator
2-1
2-11
Support engine on skid base
hen removing generator
2-1
2-11
Support engine on skid base
hen removing generator
Generator lifting 70-1930-(12532)
eye bolt
2-1
2-11
Provide generator lifting point
Hoist chain, 3 ton 3950-00-292-9879
(or equivalent)
capacity
2-1
2-11
Lift generator or engine from
skid base
Dial indicator
0-.1.00
14-21
14-45
Fuel injection pump reassembly
14-83
14-79
installation of connecting rod
cap screws
Torquing cylinder head bolts
14-52
Turbocharger end play radial
earing retainer JD-274 (00713) (or
installation tool equivalent)
14-55
Turbocharger assembly
Magnifying glass
6650-00-252-6271
(or equivalent
14-39
Nozzle assembly valve
Voltage-freqnency
Recorder
6625-00-498-9984
(or equivalent
16-22
To evaluate set performance
Engine jacking stud
support angle
70-1419 (93742)
(or equivalent)
Engine jacking stud
5/8-11x 1-1/2
support angle bol ts cap screw (or
equivalent)
Engine Jacking
stud
70-1420 (93742)
(or equivalent)
5210-00-277-8840
(or equivalent)
Wrench, socket
5120-00-596-1199
(or equivalent)
Wrench, box
5120-00-930-6346
cylinder short head (or equivalent)
J-21886 (33287)
Dial Indicator
apdaptor
Kent-Moore (or
equivalent
14-42
16-1
Change 3
2-9
Table 2-2. Generator Set Troubleshooting
Probable cause
Malfunction
1.
Engine fails to crank when
START-STOP-RUN switch
is moved to START position
2. Engine cranks but fails to
start
Corrective action
a.
With START-STOP-RUN switch
(S2) in START position, check for
24 Vdc across relay K3 (two
small terminals) X1 and X2 in set
special box If voltage is present,
check for voltage across relay
contacts, two large terminals.
If voltage is present, relay K3 is
defective. Replace relay K3
(para 8-7).
b. Defective CR3 diode.
b.
Gain access to set special relay
assembly (para 8-6). Test diode
CR3 (para 14-10). Replace defective
diode.
c.
Defective ring gear.
—c.
Inspect ring gear. Replace defective
ring gear (para 14-69 and 14-70).
d.
Starter motor brushes
worn or not contacting properly.
d.
Replace starter motor brushes
(para 14-26, and fig. 14-10).
e.
Defective starter motor e.
solenoid.
Replace starter motor solenoid
(para 14-27 and fig. 14-10) and
adjust (para 14-30 and fig. 14-14).
f.
Defective starter
motor.
f.
Replace starter motor (para. 14-25,
and fig. 14-9).
a. Incorrect valve and
injector timing.
a.
Time as shown in figure 14-34.
b. Valves burned or
sticking.
b.
—
Check valves (para 14-77). Replace
valves (para 14-77 and 14-79),
c.
Valve clearance
incorrect.
C.
d.
Governor actuator
improperly positioned.
d. Check governor (para 7-2),
Adjust governor actuator
(para 7-8).
e.
Defective solenoid
on fuel injection
pump.
e.
a.
Defective crank relay
(K3).
Check clearance. Adjust fuel
injector (Operator and Organizational Maintenance Manual).
Replace defective solenoid
(para 14-46),
NOTE
Gain access to set special
relay assembly.
f.
2-10
Dc relay control
assembly (A5)
defective.
_.
f
With S2 in START position,
measure dc voltage between
A5 terminal 21 and ground stud
It should read 24 Vdc. Measure
dc voltage between A5 terminal
23 and ground stud. If no voltage
exists, replace dc relay control
circuit assembly (A5) (para 8-6).
Table 2-2. Generator Set Troubleshooting (Cont)
Probable cause
Malfunction
3.
4.
5.
6.
Engine runs when START STOP-RUN switch is held
in START position, but
stops when switch is put in
RUN
Engine runs rough
Engine runs erratically
or misfires
Engine runs but fails to
reach rated speed
a_. Defective stoprun relay (Kl).
Corrective action
a. Replace defective relay Kl in
generator control assembly
3-3 and 3-5).
(fig
b.
Defective overvoltage relay (K2).
b.
— Test overvoltage relay. Replace
defective relay (para 8-6).
c.
Defective fuel level
relay
c.
— Replace defective relay K8 in
the special relay assembly
(para 8-6).
—a.
Incorrect timing.
—a. Time engine as illustrated in
figure 14-25.
—b.
Defective fuel injection pump.
b. Check fuel injection pump
(para. 14-44). Repair or replace fuel injection pump
(para 14-44 and 14-45).
c.
Nozzle injector
assembly mal function.
—c. Repair or replace nozzle
injector assemblies (para
14-38 thru 14-41).
d.
Sticking valves.
d. Check valves and springs
(para. 14-77). Repair or replace
valves (para 14-77 thru 14-78).
e.
Blown cylinder head
gasket.
e. Replace cylinder head gasket
(para 14-79. )
f.
Defective cylinder
sleeve.
—f. Replace cylinder sleeve (para
14-85 thru 14-87).
g.
Defective piston.
—g. Replace piston assembly (para
14-81 thru 14-83).
h.
Broken or bent
push rod.
—h. Inspect valve operating mechanism. Replace defective push
rod (para 14-77).
a.
Improper fuel
timing.
a. Time fuel injection pump
(para 14-4 9).
b.
Improper governor
adjustment.
b. Adjust governor (para 7-8).
c.
Defective fuel injection pump.
c. Inspect fuel injection pump,
Replace or repair (para
14-49, 14-44 and 14-45).
d.
Deleted
e. Worn camshaft bear ings.
e. Replace camshaft bearing
(para 14-85 and 14-87).
a. Improper governor
adjustment.
a. Adjust governor (para 7-8).
Change 5
2-11
Table 2-2. Generator Set Troubleshooting (Cont)
Malfunction
6.
7.
Probable cause
Engine runs but fails to
reach rated speed.
(Continued)
b.
Lack of fuel.
b. Check fuel level. Replenish if
necessary. (Operator and organizational maintenance manual).
c.
Defective fuel injection pump.
—c. Inspect fuel injection pump. Repair or replace as required
(para 14-44 and 14-45).
a.
Defective oil pump.
a.
— Replace oil pump (para 14-65
thru 14-67).
b.
Worn main bearing.
—b. Replace main bearings (para
14-85 thru 14-87).
c.
Defective oil regulating valve (oil
pressure below 45
psi).
—c. Replace defective valve in
cylinder block (para 14-78
and 14-87).
Low oil pressure
8.
High oil pressure
Defective oil regulating
valve. (oil pressure
above 45 psi)
Replace defective valve in cylinder
block (para 14-78 and 14-87).
9.
Engine lubricating oil
consumption high
—a.
Pistons, sleeves or
rings worn or
defective.
—a. Replace pistons and rings (para.
14-81 thru 14-83). Replace
cylinder sleeve (para 14-85
thru 14-87).
b.
Main bearings worn.
b.
— Replace main bearings (para
14-85 thru 14-87).
c.
Oil leaks at crankshaft seals
—c. Replace seal (para 14-85 thru
14-87).
a.
Main bearings worn.
—a. Replace if required (para 14-85
thru 14-87).
b.
Connecting rod
bearings worn.
b.
— Replace if required (para 14-81
thru 14-83).
c.
Piston pins loose.
—c. Replace the piston or rings
(para 14-81 thru 14-83),
d.
Piston or rings
broken.
—d. Replace pistons or rings
(para 14-81 thru 14-83).
e.
Timing gears worn.
e. Inspect gear fit and replace
gears if required (para 14-72
thru 14-74).
f.
Crankshaft journals
eccentric or out of
round.
f. Inspect crankshaft and repair
or replace (para 14-85 thru 1487).
g.
Connecting rods
miss.lined.
g. Realine connecting rods (para
14-82).
10.
Engine noisy
h. Incorrect valve
adjustment,
2-12
Corrective action
h. Check valve adjustment.
Adjust valves (Operator and
Organizationl Maintenance
Manual).
Table 2-2. Generator Set Troubleshooting (Cont)
Probable cause
Malfunction
Corrective action
10.
Engine noisy
(Continued)
i.
Flywheel loose.
11.
Engine overheats
a.
Deleted
b.
Water pump defective.
b. Repair or replace water pump
(para 14-57 thru 14-50).
c.
Radiator leaks or
is clogged.
c. Repair or replace radiator
(para 12-2 thru 12-4).
d.
Defective shutter
or shutter
linkage.
d. Repair or replace shutter and
shutter linkage (para 12-2
thru 12-4).
a.
Defective actuator.
a. Isolate trouble (para 13-2).
Repair or replace actuator
(para 13-3).
b.
Valves burned or
sticking.
b.
— Isolate trouble (para 14-77).
Replace valves (para 14-77
thru 14-79).
c.
Piston rings worn
or defective.
c. Replace piston rings (para
14-81 thru 14-83).
d.
Defective nozzle
injector assembly.
d.
— Repair or replace nozzle
inject or assembly (para
14-38 thru 14-41).
—e.
Defective fuel injection pump.
e. Isolate trouble (para 14-43).
Repair or replace and test
fuel injection pump. (para 1443 thru 14-45 and 14-48).
f.
Improper engine
timing.
f. Time engine as shown in figure
14.25.
a.
Defective valves.
a. Isolate trouble (para 14-77),
Replace valves (para 14-77
thru 14-79).
b.
Fuel injector pump
b. Isolate trouble (para 14-43).
Clean, repair or replace
assembly malfunction.
injectors (fig. 14-21).
c.
Loose flywheel or
flywheel housing
mounting.
c. Tighten flywheel bolts or
housing bolts (para 14-69).
d.
Loose vibration
dampener.
—d. Inspect vibration dampener.
Tighten vibration dampener
(para 14-60, 14-61 and 14-63).
a.
Worn turbocharger
bearings
a. Inspect turbocharger. Repair
or rebuild turbocharger (para
14-52 thru 14-55).
12.
13.
14.
Engine lacks power
Excessive generator
set vibration
Noisy turbocharger
i. Inspect flywheel attaching bolts
and tighten if required (para
14-69 and 14-70).
Change 3 2-13
Table 2-2. Generator Set Troubleshooting (Cont)
Probable cause
Malfunction
14.
Noisy turbocharger (Continued)
15.
Turbocharger
leaks oil
16.
17.
18.
Excessive
gear noise
around front
of engine
Low engine
compression
Main generator
output voltage
too low
Corrective action
b.
Measure end play (para 14-52).
Disassemble and add correct
number of shims (para 14-52
and 14-55).
Worn or broken
turbocharger
shaft seal
ring.
a.
Inspect turbocharger. Replace
shaft seal ring (para. 14-53,
thru 14-55).
Worn or broken
turbocharger
oil pressure
and drain seal
rings.
b.
Inspect turbocharger. Replace
turbocharger oil pressure and
drain seal rings (para 14-53
thru 14-55).
Defective
vibration
dampener.
a.
Inspect vibration dampener.
Replace vibration dampener
(para 14-60,14-61 and 14-63).
Excessive timing gear
backlash.
b.
Inspect timing gears (para
14-73). Replace timing
gears (para 14-72 and 14-75).
a.
Defective
piston rings.
a.
Replace piston rings (para
14-81 thru 14-83).
b.
Defective
pistons and
cylinder
sleeves.
b.
Replace pistons (para 14-81 and
14-83) and cylinder sleeves
(para 14-85 thru 14-87).
c.
Leaking or
defective
valves.
c.
Isolate trouble (para 14-77).
Replace valves (para 14-77
thru 14-79).
a.
Exciterregulator
defective.
a.
Check exciter regulator (para 8-3).
Replace exciter voltage regulator
(para 8-10 thru 8-14).
b. Excessive turbocharger impeller
end play.
a.
Rotor assembly
defective.
c. Stator
defective.
2-14
d.
Exciter rotor
defective.
e.
Exciter stator
defective.
Check rotor resistance.
Check for shorts or
grounds. Replace, repair
or rebuild if required (para 9-2,
9-3,9 -4,9-6 and 9-7).
c.
Check stator resistance.
Check for grounds or shorts.
Replace, repair or rebuild
if required (para 9-2, 9-3, 9-4,
9-6 and 9-7).
Check exciter resistance.
Check for shorts or grounds
(para 9-2). Replace exciter
if defective. (para 9-5, 9-6
and 9-7).
e.
Check exciter stator
Check for shorts or
(para 9-2). Replace
stator (para 9-5,9-6
resistance.
grounds
exciter
and 9-7).
Table 2-2. Generator Set Troubleshooting (Cont)
Corrective action
Probable cause
Malfunction
Rotating diodes
defective.
f.
Check diodes (para 9-3). Replace diodes as required.
(Operator and Organizational
Maintenance Manual).
18.
Main generator output
voltage too low.
f.
19.
Main generator output
too high.
Exciter-regulator
defective.
20.
Main generator noisy.
a.
Defective
bearing.
a.
Replace bearing (para 9-2
and 9-6).
b.
—
Generator fan
loose or
defective.
b.
Inspect generator fan.
Tighten, repair or replace
fan (para 9-2, 9-3 and 9-6).
—a.
Governor system
defective.
a.
Adjust governor system (para
7-2). Repair or replace as
required (para 7-3 thru 7-6).
b.
Engine malfunctioning.
b.
See items 4, 5, and 6.
a.
Field flash
circuit defective.
a.
Check field flash relay (K5)
(fig.1-11). Disconnect
battery negative . Disconnect
J9 on regulator. Apply 24 Vdc
to terminals 13(+)and 15(-) on
A5 assembly. Check continuity
between terminals 1-14 and 2-15.
If circuit is open, replace K5
relay on A5. Check R219 and
CR207 in exciter regulator
(para 8-3). Replace defective
components as required (para
8-10 thru 8-14).
b.
Defective
exciter rotor.
b.
Check resistance of exciter rotor.
Check for short or ground. Replace as required. (para 9-2,
9-3,9 -5,9-6 and 9-7).
c.
Defective
exciter stator.
c.
Check resistance of exciter
stator. Check for short
or ground (para 9-2).
Replace as required. (para 9-2,
9-3, 9-5, 9-6 and 9-7).
d.
Defective
rotating diodes.
d.
Check rotating diodes (para
9-3). Replace any defective
diode (para 9-2 and 9-6).
e.
Defective
generator stator.
—e.
Check generator - stator resisCheck for short or ground
para 9-2).
Repair or rebuild as required.
(para 9-3,9 -4,9-6 and 9-7).
—f.
Defective
speed switch.
f.
Check S9-1, normally open, for
proper operation (para 14-19).
21.
22.
Main generator frequency
fluctuates or drifts.
Main generator fails to
flash.
g.
Defective
excitation
assembly.
Check exciter regulator
(para 8-3). Replace
exciter voltage regulator
(para 8-10 thru 8-14).
g.
Check R225 and R226
(para 8-12).
Change 5
2-15
Table 2-2. Generator Set Troubleshooting (Cont)
Malfunction
23.
240
Frequency meter fails
to register.
Percent power meter
fails to register.
Corrective action
Probable cause
—a.
Replace meter and transducer
(Refer to Operator and Organizational Maintenance Manual).
b. Frequency
transducer
defective.
b.
Replace frequency meter and
transducer (Refer to Operator
and Organizational Maintenance
Manual).
—c.
Engine speed
too low.
—c.
Raise engine speed to rated value.
(Refer to Operator and Organizational Maintenance Manual).
a.
Percent power
meter defective.
a.
—
Replace meter (Refer to Operator
and Organizational Maintenance
Manual).
b.
—
Thermal watt
converter
defective.
b.
—
Replace thermal watt converter
A1 (para 3-7).
—c.
Set operating
at no-load.
—c.
Adjust load bank or apply load.
(Refer to Operator and Organizational Maintenance Manual).
a.
Frequency
meter
defective.
25.
Units paralleling out of
phase (B2) (contactor
closing when paralleling lights are bright).
Permissive paralleling
relay (K16) defective.
Measure ac voltage between 1
and 2 on K16. When lights
are the brightest, 120 volts
should exist; voltage should
decrease toward zero, as
lights dim. If voltage is
OK, remove leads from
relay pins 7 and 8. Measure
continuity across pins 7
and 8 while observing volt meter connected at pins 1
and 2. Continuity should
exist at 9 volts and below.
There should be no continuity
at 9 volts and above. Replace
defective relay K16 (para
8-6 and 8-7).
26.
Remote sensing
inoperative.
a.
Local - Remote
voltage switch
(S5) on control
panel in local
position or
defective.
a.
Place switch in correct position.
Check switch for continuity in
all positions. (Refer to Operator
and Organizational Maintenance
Manual).
b.
Remote sensing
leads not
connected to
sensing point.
b.
Check connections. Make correct
connections,
c.
K6 relay defective.
c.
Check relay K6. Replace if
defective (para 3-5 and 3-10).
d.
Control panel
relay (A4)
components
(R10 and CR1)
defective.
d.
Replace R10 or CR1 if defective
(para 3-3 thru 3-5).
2-16
Change 5
Table 2-2. Generator Set Troubleshooting (Cont)
Probable cause
Malfunction
27.
Generator runs at 130
percent or more
rated current for
longer than 10 minutes,
CB2 does not open and
overload indicator does
not light.
Corrective action
a.
—
Defective overload
relay (K14).
a.
Replace K14 (para 8-6
and 8-7).
b.
Defective resisters R23, R24
or R25.
b.
Replace resistor R23, R24 or
R25, if ohmmeter test indicates defect (fig. 8-2 and 8-3).
c.
Defective current
transformer CT1,
CT2 or CT3.
c.
Replace defective current’
transformer CT1, CT2 or
CT3 (para 6-7 thru 6-8).
28.
Generator runs at
overvoltage (130
percent. Set does
not shut down and
overvoltage indicator does not light.
Defective overvoltage
relay K2.
Replace overvoltage relay (para 8-6
and 8-7).
29.
Generator runs
under voltage (85 percent
of rated voltage or less).
CB2 does not open and
undervoltage indicator
does not light
(Class I only)
Defective undervoltage
relay Kilo
Replace undervoltage relay K11
(para 8-6 and 8-7).
Percent power meter
reads down scale with
2 or more sets paralleled.
Reverse power relay
(K15) defective.
Measure dc voltage at K15 terminals
3 and 4. It should be 24 volts
(positive on terminal 3). Check
for Vdc at pins 1 and 2. If 2 or
more Vdc are present with 1 positive
replace reverse power relay (para
8-6 and 8-7).
Set starts but will not
run unless protection
bypass switch (S7)
is closed.
—a.
a.
30.
31.
System fault as
indicated by
fault indicator
panel.
Correct indicated fault.
b.
b. Replace any defective lamps.
If no lamp is illuminated, press
fault indicator
test switch to
ensure that all
lamps are working.
NOTE
If the corrective action in a and b above does not correct
the malfunction, proceed to determine if one of the following components are defective by placing jumpers
across their contacts as follows:
c. Overvoltage
c. Terminals 3 and 4 of K2.
relay K2.
d.
Low oil pressure
switch OP and high
coolant temperature
switch WT.
d.
Terminal 3 of K2 and 4 of AS.
Change 5
2-17
Table 2-2. Generator Set Troubleshooting (Cont)
Malfunction
Corrective action
Probable cause
e.
Fuel level
relay K8.
e.
Terminals 4 and 16 of A5.
NOTE
Start the generator set and open the protection
bypass switch S7. Remove the jumpers installed in
c, d, and e above. If the set stops when one of the
jumpers is removed, that component is defective and
must be replaced. If the set shuts down when the
jumper in step d is removed test OP and WT and
replace the defective component.
2-18
32.
Paralleling
lights, DS4
and/or DS5,
will not light
with S6 in
parallel
position
DC relay control
circuit assembly
(A5) defective.
With set stopped, check resistance
between A5 terminals 7 and 8 for
DS5, and terminals 19 and 20 for
DS4. Resistance should be 7500
Ohms ±5.0 percent. If no continuity,
replace dc relay board (A5) (para 8-6
and 8-7).
33.
Improper governor
operation (i. e.,
load sensing)
Current transformer
resistor board (A7)
defective.
Measure resistance of R23, R24,
and R25 on A7 (located in precise relay box on Class 1, Mode
1 sets - in set special box on
other sets). Replace any resistor
that does not read 7.5 ohms ±0.5
percent (fig. 8-2 and 8-3).
34.
Generator
set hunts
Governor resistor
board capacitor (Cl )
defective
(Class I only)
Check capacitor (C1) on A6, between
pins 5 and 6. Replace a defective
capacitor. (60 mfd non-polarized)
(fig. 8-4 and 8-5).
35.
Main AC contactor (CB2)
will not close
a.
Defective short
circuit relay
K13.
a.
Check relay K13. Replace if
defective (para 8-6 and 8-7).
b.
Defective overload
reload relay K14.
b.
Check relay K14. Replace if
defective.
c.
Defective reverse
power relay K15.
c“
Check relay K15. Replace if
defective (para 8-6 and 8-7).
d.
Defective undervoltage relay K11.
(Class I only)
d.
Check relay K11. Replace if
defective. (para 8-6 and
8-7).
e.
Defective underfrequency
relay K12.
e.
Check relay K12. Replace if
defective. (para 8-6 and
8-7).
f.
Defective permissive paralleling
relay K16.
f.
Check relay K16. Replace if
defective (para 8-6 and 8-7).
g.
Defective contactor
switch S3.
g.
Check switch S3. Replace if
defective. (para 6-2).
Table 2-2. Generator Set Troubleshooting (Cont)
36.
37.
38.
Corrective action
Probable cause
Malfunction
Electric governor not
controlling set.
(Class I only)
Generator sets will not
parallel and share
real (kw) load.
Generator sets wilI not
parallel and share reactive load.
a.
Isolate (para 7-2).
Adjust, repair or replace as
required (para 7-2 and 7-4).
Low hydraulic
pressure.
b.
Isolate (para 14-14 and correct
trouble. (para 14-15 and 14-16).
c.
Defective hydraulic
actuator.
c.
Isolate (para 13-2).
Repair or replace actuator
as required (para 13-3 thru 13-5).
a.
Governor is not
adjusted correctly.
a.
For a Class 1 set, Precise,
refer to paragraph 7-2.
b.
Fuel injection
pump is not
adjusted properly.
—b.
For a Class 11 set, Utility,
refer to paragraph 14-45.
—a.
Defective electric
governor control
unit .
b.
Exciter regulator system
including the reactive
load sharing potentiometer (R29) is not correctly adjusted.
–
Refer to paragraph 8-14 for correct
adjustment procedures.
NOTE
Additional troubleshooting procedures
are contained in Tables 8-1 and 14-1.
Change 5
2-19
Section IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
2-10. General.
(2) Insert generator lifting eye bolt in top of
generator housing and attach suitable lifting device.
This section contains instructions for removal and
installation of major components of the generator
set to facilitate repair and overhaul procedures.
Removal of assemblies and repair and overhaul instructions are covered in subsequent sections of
this manual.
(3) Remove two screws and two flat washers
and two lockwashers on each side of generator
housing near forward end and remove access cover
and screen.
2-11. Generator Removal.
See figure 2-1 for location of major components.
—a. Disconnect the ground cable from the battery.
b. To remove the following refer to the Operator
and Organizational Maintenance Manual.
(1) Receptacle panels (as required).
(2) Manual speed control.
(4) Remove 4 generator mounting screws, 8
washers and 4 nuts.
(5) Adjust jacking studs to support the weight
of the engine, approximately 1/2 turn beyond hand
tight.
(6) Reaching through inspection holes in generator housing, bend lockstrips away from heads of
eight fan-coupling screws securing generator coupling. Remove the screws to separate the engine and
generator at the coupling. Removal of these screws
also frees the fan. To facilitate access to the
screws, rotate the engine.
(3) Fault indicator.
(5) Rear grille.
(7) Reaching through inspection holes in forward end of generator, remove 12 rim coupling
screws and washers around perimeter of flange
mating engine to flywheel housing.
(6) Rear panels and doors.
2-12. Generator Installation.
(7) Rear roof and corner posts.
a. Using a suitable lifting device, position main
generator mounting pads in skid base and line up
generator mounting flange with flywheel housing.
(4) Control cubicle.
(8) Main load contactor.
(9) Load terminal board.
(10) Reconnection board.
(11) Air cleaner.
c. See figure 6-2 for removal of main generator
leads from current transformer assembly. Before
removing current transformer assembly, tag 18
harness wires from terminal strip and identify the
leads which are passed through the current transformers more than once.
b. Install 12 screws and washers through generator front flange into flywheel housing. Torque
screws to 35 foot-pounds.
c. Reach through generator inspection holes,
support fan to line up holes and install eight fan
coupling screws each with a lockstrip. Before
tightening make sure lockstrip extension is in small
hole adjacent to threaded screw hole. Torque bolts
to 110 foot-pounds. Bend lockstrip corners against
screw head flats.
d. See para 6-8 for removal of current transformer assembly.
d. Install four main generator mounting screws
and washers and secure with four nuts and 8 washers.
Do not torque screws at this time.
e. On Class I sets only, remove the governor
control unit and mounting bracket. (See para 7-3. )
e. Loosen and remove engine support brackets.
f. Remove the relay table group. (See para 8-5.)
g. Remove generator. See figure 2-2 and proceed
as fOllOWS:
(1) Position engine jacking supports on the
engine flywheel housing. Adjust engine jacking
studs by hand until firm contact is established with
skid base.
2-20
Change 3
f. Torque generator mounting screws to 440
foot-pounds.
g. Install screen and access cover on generator
and secure with two screws, two flat washers, and
two lockwashers on each side.
h. See figure 8-1 and install relay table group in
reverse order of removal.
Figure 2-1. Component Locations (Right and Left Side)
2-21
Figure 2-2. Generator Removal
i. On precise sets, install the governor control
unit and mounting bracket in reverse order of removal (fig. 7-1).
j. See figure 6-3 and install current transformer assembly in reverse order of removal.
k. See figure 6-2 and thread generator output
cables through current transformers in reverse
order of removal. Connect 18 tagged harness wires
to terminal strip on transformer assembly.
l. Refer to the Operator and Organizational
Maintenance Manual and install the following:
(1) Air cleaner.
(2) Reconnection board.
2-22 Change 1
(3) Load terminal board.
(4) Main load contactor.
(5) Rear roof and corner posts.
(6) Rear panels and doors.
(7) Rear grill.
(8) Control cubicle.
(9) Fault indicator.
(10) Manual speed control.
(11) Receptacle panels (as required).
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 contactor. 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 following tests.
(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:
g. 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 generator, 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 engagement 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.
(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).
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.
e. Remove all components of the relay table
group and load connection group as instructed in
paragraph 2-11.
(5) Interconnecting wiring harnesses.
f. Remove the top bracket from the lifting frame
assembly. (fig. 11-1)
(7) Housing and cooling groups.
(6) Manual speed control.
(8) Receptacle panels (as applicable).
Change 1 2-23
Figure 2-3. Engine Removal
2-24 Change l
(9) Rain cap exhaust system.
d. Remove the four screws securing the generator
to the skid base.
(10) Crankcase breather cover and tubing.
2-15. Engine Generator Assembly Removal.
e. Remove two screws securing the engine front
support to the skid base.
a. Follow all instructions for disassembly given
in paragraphs 2-11 a thru 2-11 f and 2-13 a thru 2-13 f.
f. Hoist assembly up and out of skid base. Place
on a flat surface with supporting block under engine
front support.
b. Insert the lifting eye in the socket on top of the
generator.
2-16. Engine Generator Assembly Installation.
c. Attach a suitable lifting device to the front
engine hoist bracket and the generator lifting eye.
(fig. 2-4.)
Install and reassemble in reverse order of removal.
Torque engine mount bolts to 90-100 foot-pounds
and generator mounting bolts to 440 foot-pounds.
2-25
Figure 2-4. Engine Generator Removal
2-26
CHAPTER 3
GENERATOR SET CONTROLS REPAIR INSTRUCTIONS
Section I. INTRODUCTION
3-1. General.
3-2. Generator Set Controls Description.
This chapter includes repair instructions for the
fault indicator panel and the control cubicle. Test
procedures for the control cubicle include individual
tests for the converter, control box, relay assembly, frequency meter and transducer, ac wattmeter
and ac ammeter.
The generator set controls are mounted at the rear
of the set, and provide all monitoring and control
devices required to operate the set. Controls consist of the fault indicator panel, the control cubicle,
and the manual throttle control. Refer to the Operator and Organizational Maintenance Manual for
manual throttle control repair instructions.
Section II. FAULT INDICATOR PANEL
3-3. Removal, Disassembly and Repair,
a. Removal. Refer to Operator and Organizational Maintenance Manual and remove the fault indicator panel.
b. Disassembly. See figures 3-1 and 3-2 and
disassemble the fault indicator panel.
—c. Repair. Proceed as follows
(1) Clean all components with low pressure
compressed air, or wipe clean with dry, lint free
cloth.
(2) Inspect for broken fuseholders, cracked or
broken lamp holders, damaged wire insulation, broden wires and bent or broken connector pins.
(3) Remove any components that show visual
damage, such as broken fuseholder, or broken lamp
holder (fig. 3-1).
(6) Unplug relay 17, (fig. 3-1) in fault indicator panel and check resistance of relay coils with
ohmmeter probes across pins 3 and 7. Reading
should be 300 ohms ±10 percent. Replace relay if
variation exceeds 10 percent. Plug relay into circuit board.
(7) Rebuild wiring harness if inspection reveals 30 percent or more defective wires. Wiring
harness rebuilding instructions are described in
Chapter 5. Otherwise replace damaged wires.
3-4. Reassembly, Testing and Installation.
a. Reassembly. See figures 3-1 and 3-2 and reassemble the fault indicator panel.
b. Testing. See figure 1-2. To test the fault indicator panel, proceed as follows:
(1) Connect 24Vdc, positive to pin A of terminal board.
(4) Replace circuit board if broken, cracked
or distorted.
(2) Connect 24Vdc negative to pin B and case.
(3) Operate reset switch. All lights should
(5) Resistors may be checked by breaking connection at one end to prevent feedback resistance
and touching both ends with ohmmeter probes. Resistors R1 through R10 (fig. 1-2) should read 2. 2K
ohms ±10 percent. Resistors R11 through R20
should read 1K ohms ±10 percent. Any variation
in excess of 10 percent indicates that the resistor
should be replaced. If any connections are opened
or bared for test purposes or if any defective components are replaced, the affected area must be
coated with polyurethane resin to prevent oxidation
or other corrosion. The coating must be of a minimum thickness of O. 007 inches and air bubble entry
into the applied polyurethane must be controlled so
that the legibility of component coding and identification is not impaired. The polyurethane resin to be
utilized will correspond to MIL-I-46058 grade S,
Type PUR.
light.
(4) Connect pin C to pin D. Low oil pressure
light should light.
(5) Open C to D connection. Low oil pressure
lights should remain on.
(6) Connect pin C to pin E. Low oil pressure
light should remain on.
(7) Operate reset switch. Low oil pressure
light should go out and overspeed switch should light.
3-1
1.
2.
3.
4.
5.
Screw
Fuseholder
Switch
Tiedown strap
Tiedown strap
6.
7.
8.
9.
10.
Capacitor
Lampholder
Cover
Screw
Cover
11.
12.
13.
14.
Screw
Plate assembly
Screw
Component board
assembly
15. Screw
16.
17.
18.
19.
20.
Washer
Relay
Screw
Wiring harness
Chassis
ME 6115-545-34/3-1 C7
Figure 3-1. Fault Locating Indicator
3-2 Change 7
1.
2.
3.
4.
5.
6.
7.
8.
Socket
Nut
Washer
Washer
Spacer
Resistor
Resistor
Rectifier
9.
10.
11.
12.
13.
14.
15.
Rectifier
Capacitor
Terminal
Board
Insulation
Wire
Wire
ME 6115-545-34/3-2 C7
Figure 3-2. Assembly, Fault Indicator
Change 7 3-3
TM 5-6115-545-34
(8) Repeat paragraphs (5), (6), and (7) above for other
lights, connecting pin C to pins F, G, H, I, K, L, M, and N.
c. Installation. Refer to Operator and Organizational
Maintenance Manual and install the fault indicator.
Section III. CONTROL CUBICLE
3-5. Removal, Disassembly and Repair.
WARNING
To avoid serious injury to personnel before doing any work in the control cubicle, be sure all
power circuits are disconnected. Never work in
the control cubicle while the engine is running.
Killing voltages are present.
a. Removal. Refer to Operator and Organizational Maintenance Manual and remove the control
cubicle.
b. Disassembly. Refer to Operator and Organizational
Maintenance Manual and disassemble the control cubicle,
See figure 3-3 and disassemble the relay assembly.
b. Start the generator set.
—
c. Vary load and compare the readings of the ac wattmeter on the set with readings of the master wattmeter.
d. The operating set wattmeter error must not exceed 10
percent of full scale value. If it does, replace the ac wattmeter. If it does not, proceed to para 3-7.
3-7. Transducer Testing.
To test the control cubicle watt transducer, proceed as
follows;
a. Connect the watt transducer to the test equipment
as illustrated in figure 3-4. Use a calibrated % of rating
meter.
b. Adjust all autotransformers T1, T2 and T3 to their
MIN positions.
c. Close switch S1 and open switches S2 and S3.
(1) Clean all components with low pressure compressed
air, or wipe clean with dry, lint free cloth.
d. Energize the power source.
—
e. Adjust T1 until 600 milliamperes is indicated on ammeter A1. The % of rating meter of known accuracy should
indicate approximately 33%.
(2) Inspect for broken fuseholders, cracked or broken
lamp holders, damaged meters, broken terminals on components, damaged wire insulation, broken wires and bent
or broken connector pins.
f. Close switch S2 and adjust T2 until 600 milliamperes
is indicated on ammeter A2. The % of rating meter should
indicate approximately 66%.
(3) Replace any components which show visual damage,
such as cracked or broken meters, broken lamp holders, or
cracked or broken switches and rheostats.
(4) Inspect control panel relay assembly for damage.
Replace component (fig. 3-3) if damage is evident. If any
connections are opened or bared for test purposes, or if any
defective components are replaced, the effected areas and
components must be coated with polyurethane resin to prevent oxidation or other corrosion. The coating must be a
minimum of 0.007 inches and air bubble entry into the applied polyurethane must be controlled so that the legibility
of component coding and identification is not impaired. The
polyurethane resin to be utilized will correspond to MILI-46058 grade S, Type PUR.
g. Close switch S3 and adjust T3 until 600 milliamperes is
indicated on ammeter A3. The % of rating meter of known
accuracy should indicate 100%.
h. Replace the thermal watt transducer if it does not
—
satisfy the above requirements.
i. If the transducer meets the above requirements,
replace the wattmeter.
3-8. AC Ammeter Testing.
To test the ac ammeter of the control cubicle, proceed as
follows:
a. Connect a suitable master ac current meter in series
—
with the set ac current meter.
b. Start the unit and connect a variable load to the output
—
terminals and compare the readings of the two meters.
3-6. AC Wattmeter Convertor Testing.
To test the ac wattmeter of the control cubicle proceed as
follows:
a. Connect a master 3-phase wattmeter of known
accuracy (1/2 of 1 percent) and a suitable variable load to
the output of terminal lugs of the generator set.
3-4
Change 8
c. The generator set ac ammeter error must not be
greater than 2 percent of full scale value. If it is, replace
the ac ammeter.
1.
2.
3.
4.
5.
6.
7.
8. Screw
9. Nut
10. Washer
11. Terminal board
12. Rectifier
13. Resistor
13A. Capacitor
14. Board
Screw
Relay
Socket
Nut
Washer
Washer
Spacer
ME 6115-545-34/3-3 Cl
Figure 3-3. Relay Assembly
Change 1 3-5
TM 5-6115-545-34
Figure 3-4. Control Cubicle Transducer, Test Setup
3-9. Frequency Meter and Transducer Test.
3-10. Control Box Relay Testing.
To test the frequency meter and transducer of the control
cubicle, proceed as follows:
To test the control box relay assembly of the control cubicle
(see figure l-l) and proceed as follows:
NOTE
The frequency meter and transducer are a
matched set and must be tested as a set.
a.
— Connect a variable frequency 120 Vac sinusoidal input
to the ac side of the frequency transducer,
b. Connect a master frequency meter across the input.
The master frequency meter shall have inaccuracy of a
minimum of 3/4% or greater of the set frequency meter and
transducer (l/20 of l percent).
c. Vary the frequency from lowest scale reading to full
scale reading.
d. The error at any point infrequency meter shall not be
greater than l percent.
e. If the above requirements are not satisfied, replace
both the frequency meter and transducer.
3-6
Change 8
CAUTION
When applying the 120 Vac to control box relay
assembly terminals, insure correct placement of
power supply leads. Damage to other components could result if leads are inadvertently
misplaced.
a. With no power applied, check continuity across following terminals of the control box relay assembly: terminals
10 and 11; 5 and 6; and 1 and 3 (fig. l-l).
b. Apply a dc voltage of 24 volts to terminals 2 and 8.
The normally open contacts between terminals 7 and 9, and
the normally closed contact between terminals 1 and 3
should transfer (fig. l-l).
c. Apply an ac voltage from 50 to 80 volts, 50/60 Hz or
400 Hz to terminals 4 and 12. The normally open contacts
between terminals 4 and 6, and terminals 10 and 12 and the
normally closed contacts between terminals 5 and 6, and
terminals 10 and 11 should transfer (fig. l-l).
( c ) Turn on the power supply and wait 3
d. Connect 120 Vac 60 Hz power supply to terminals 4 and 12 of the control box relay assembly.
Measure voltage at terminals 6 and 10. Voltage
should be 120 Vac (fig. 1-1).
( d ) After 3 minutes have elapsed, the oil
pressure gage should indicate 60 psi.
e. Measure dc voltage across relay K6. Voltage
should be above 18 Vdc (fig. 1-1).
( e ) Turn off the power supply and disconnect
the test circuit.
3-11. Control Cubicle Wiring Harness.
Rebuild wiring harness if inspection reveals 30 percent or more defective wires. Wiring harness rebuilding instructions are described in Chapter 5.
Otherwise replace damaged wires.
3-12. Control Cubicle Reassembly, Testing and
Installation.
a. Reassembly. Refer to Operator and Organizational Maintenance Manual and reassemble the
control cubicle.
minutes.
(4) Water Temperature gage test.
( a ) Connect the positive lead of a variable
voltage dc power supply, adjusted for 28.5 Vdc, to
pin small w of receptacle J1.
( b ) Connect the negative lead of the power
supply via a 0-2K ohm S watt potentiometer adjusted
for 917 ohms, to pin W of receptacle J1.
minutes.
( c ) Turn on the power supply and wait 3
( d ) After 3 minutes have elapsed, the water
temperatike gage should indicate 180 degrees F.
b. Testing. Refer to the Operator and Organizational Maintenance Manual (Control cubicle,
s thematic diagram) to test the assembled control
cubicle.
( e ) Turn off the power supply and disconnect
the test circuit.
(1) The following control cubicle component
tests are described in paragraphs 3-6 through 3-10
respectively :
( a ) Connect the positive lead of a variable
voltage dc power supply adjusted for 28.5 Vdc, to
pin small w of receptacle J1.
Ac Wattmeter
Converter
Ac Ammeter
Frequency meter and transducer
Control box relays
(2) Wiring test.
( a ) Using an ohmmeter, check the wiring
from each-pin of receptacle J1 to the last point of
its connection.
(5) Fuel Level gage test.
( b ) Connect the negative lead of the power
supply via a 0-50 ohm 100 watt potentiometer adjusted for 15 ohms to pin X of receptacle J1.
( c ) Turn on the prover supply and wait 3
minutes.
( d ) After 3 minutes have elapsed, the fuel
level indicator should indicate one-half tank
( e ) Turn off the power supply and disconnect
the test circuit.
(6) Total Time indicator test.
( b ) Where the wiring of two or more pins
of the receptacle can be tested by a switch closure,
close the switch and complete the teat. After completing the test, return the a switch to its normal
position.
(3) Oil pressure gage test.
(8) Connect the positve lead of a variable
voltage dc power supply adjusted for 28.5 Vdc , to
pin small w of receptacle Jl.
( b ) Connect the negative lead of the power
reapply to pin small r of receptacle J1.
( c ) Turn on the power supply.
( a ) Connect the positive lead of a variable
dc power supply, adjusted for 28.5 Vdc, to pin small
w of receptacle J1.
( b ) Connect the negative lead of the power
supply via a 0-50 ohm 100 watt potentiometer adjusted for 15 ohms to pin V or receptacle J1.
( d ) Observe the tenths column of the indicators digital read out.
( e ) The indicadicator shall display one-tenth
after six finutes of operation.
(f) Turn off the power supply and remove
the test leads.
3-7
(7) Panel light test.
( a ) Connect the positive lead of a variable
voltage dc power supply, adjusted for 24 Vdc, to pin
small v of receptacle J1.
( b ) Connect the negative lead of the power
supply to pin small r of receptacle Jl
( g ) Turn on the power supply.
( h ) The CKT. BRKR. light illuminates.
( i ) Turn off the power supply and disconnect the test leads.
(10) Battle short light test.
( c ) Place the PANEL LIGHT switch to the
ON position and observe the illumination of three
panel lights.
( a ) Connect the positive lead of a variable
voltage dc power suppy adjusted for 24 Vdc, to pin
small v of receptacle J1.
( d ) Place the PANEL LIGHT switch to the
OFF position.
( b ) Connect the negative lead of the power
supply to pin small r of receptacle J1.
( e ) Turn off the power supply and disconnect
the test leads.
(8) Air cleaner condition light test.
( a ) Connect the positive lead of a variable
voltage de–power supply, adjusted for 24 Vdc to pin
small c of receptacle J1.
( b ) Connect the negative lead of the power
supply to pin small r of receptacle J1.
( c ) Turn on the power supply.
( d ) The AIR CLEANER CONDITION light
does not illuminate.
( e ) Depress the AIR CLEANER CONDITION
light, the light illuminates.
( f ) Turn off the power supply and connect
the position lead to pin small u of receptacle J1.
( g ) Turn on the power supply.
( h ) The AIR CLEANER CONDITION light
illuminates.
( i ) Turn off the power supply and disconnect
the test leads.
(9) Circuit breaker light test.
( a ) Connect the positive lead of a variable
voltage dc power supply, adjusted for 24 Vdc, to
pin small v of receptacle Jl.
( b ) Connect the negative lead of the power
supply to Fin small r of receptacle Jl.
( c ) Turn on the power supply.
( d ) The CKT. BRKR. light does not illuminate.
(e) Depress the CKT. BRKR. light, the
light illuminates.
(f) Turn off the power supply and connect
the position lead to pin small a of receptacle J1.
3-8
( c ) Turn on the power supply.
( d ) The BATTLE SHORT light does not
illuminate.
( e ) Depress the BATTLE SHORT light, the
light illuminates.
( f ) Turn off the power supply and connect
the position lead to pin R of receptacle J1.
( g ) Place the BATTLE SHORT switch to
the ON position, the BATTLE SHORT light illuminates.
( h ) Place the BATTLE SHORT switch to
the OFF position.
( i ) Turn off the power supply and disconnect the test leads.
(11) Synchronizing lamp test
( a ) Connect one lead of a 120 Vac power
supply to pin J of receptacle J1.
( b ) Connect the remaining lead of the
power supply to pin G of receptacle J1.
( c ) Turn on the power supply.
( d ) Place the unit operation switch to the
PARALLEL position.
( e ) One of two synchronizing lamps (DS4)
shall illuminate.
( f ) Place the unit operation switch to the
single unit position.
( g ) Turn off the power supply and disconnect the test leads.
( h ) Repeat the procedure b (11) (a) through
(g) for the-second synchronizing lamp (DS5) utilizing pins K and H of receptacle J1.
(12) DC ammeter test
(a) Connect a Simpson 260 or equivalent
ohmmeter, with the R x 10,000 scale selected, to
pins Z and Y of receptacle J1.
( b ) With the positive lead connected to pin
Y and the negative lead to pin Z, the ammeter will
read approximately 6 amperes up scale.
( c ) Reverse the connections at receptacle
J1 so that the positive lead is connected to pin Z and
the negative lead is connected to pin Y.
( d ) The ammeter will read approximately
6 amperes down scale.
( e ) Disconnect the ohmmeter and test leads.
(13) Voltage adjusting rheostat test
( c ) Rotate the VOLTAGE ADJUST rheostat
from stop to stop, the resistance will vary from 0
to 250 + 10 percent ohms,
( d ) Rotate the VOLTAGE ADJUST rheostat
until 125 ohms are indicated on the ohmmeter and
disconnect the test leads.
(14) Frequency adjust rheostat test
( a ) Connect a Simpson 260 or equivalent
ohmmeter; with the R x 100 scale selected, across
pins N and T of receptacle Jl. The resistance indicated should be 500 ohms ± 10 percent.
( b ) Remove the test lead from pin T and
place it in pin M.
( a ) Connect a Simpson 260 or equivalent
ohmmeter; with the R x 100 scale selected, across
pins small z and large U of receptacle J1.
( c ) Rotate the FREQUENCY ADJUST rheostat from stop to stop, the resistance should vary
from 0 to 500 ± 10 percent ohms.
( b ) Place the VOLTAGE SENSING switch
to the LOCAL position.
c. Installation. Refer to Operator and Organizational Maintenance Manual and install the control
cubicle.
3-9/(3-10 blank)
CHAPTER 4
HOUSING GROUP REPAIR INSTRUCTIONS
4-1. General.
The engine generator set housing provides a protective enclosure during set operation or storage.
Doors permit sufficient access to all areas of the
engine generator set for operating and routine maintenance procedures.
d. Paint scratches that reveal bare metal or
paint that is removed during repair should be touched
up as follows:
(1) Smooth edges of remaining paint with fine
sandpaper.
4-2. Housing Removal and Cleaning.
(2) Clean area with Federal Specification PD-680 solvent and wipe dry with clean cloth.
Refer to Operator and Organizational Maintenance
Manual.
(3) Treat area and paint in accordance with
service requirements.
4-3. Housing Inspection, Servicing, and Repair.
e. Replace any cover, door, panel, or hardware
that is damaged beyond repair.
a. Refer to Operator and Organizational Maintenance Manual for inspection and servicing procedures.
4-4. Housing Installation.
b. Repair any minor sheet metal dents in doors,
covers, and panels.
Refer to Operator and Organizational Maintenance
Manual.
c. Sheet metal tears can be repaired by welding.
4-1/(4-2 blank)
CHAPTER 5
WIRING HARNESS REPAIR INSTRUCTIONS
5-1. General.
Electrical interconnection of control devices and
indicators is accomplished through wiring harnesses.
Wires in the harnesses are bundled and secured to
prevent unnecessary movement and chafing, and to
conserve space. Internal wiring harnesses for the
relay boxes, kits and other electrical assemblies
are also provided in this section.
(3) Refabricate anew wire harness using the
illustration for dimension and the wire run list for
proper wire connection.
(4) If a wiring harness cannot be identified,
compare it with the illustrations until proper identifications made. Check numbers stamped on wires
against those in the wire run list to insure proper
identification before proceeding with refabrication.
a. Refer to Operator and Organizational Maintenance Manual for harness removal procedures.
(5) Wiring shall be neatly laced through the
use of self-locking nylon straps, located at intervals
not to exceed three inches, and also at each wire
break out.
b. Refer cooperator and Organizational Maintenance Manual for inspection procedures.
(6) Soldering shall be in accordance with requirement 5 of MIL-STD-454 using SN60 solder.
5-3. Wiring Harness Repair and Rebuild.
(7) Wire numbering shall be in accordance
with MIL-W-5088, except that length between adjacent groups of numbers shall not exceed six
inches.
5-2. Wiring Harness Removal and Inspection.
a. Repair.
(1) Repair procedures for individual wires are
covered in the Operator and Organizational Maintenance Manual.
(2) If a wiring harness has sustained damage
to 30 percent or more of the wires in the harness,
the wiring harness must be completely rebuilt.
b.
— Rebuild.
(1) Figures 5-l through 5-40 are illustrations
of the wiring harnesses installed on the generator
set.
(8) Cut insulation tubing in one-half inch
pieces and install around wires at pins of connectors and receptacles.
(9) Install nylon filler plugs MS25251-16 in
unused openings of connectors.
5-4. Installation.
Refer to Operator and Organizational Maintenance
Manual for installation procedures.
(2) Each illustration includes a wire run list
providing wire origination, destination, identification number, wire length, and preparation requirements, and end preparation. Find numbers
(circled) related to specific components.
5-1
Figure 5-1. AC Power Control 50/60 Hz Wiring Harness
5-2 Change 1
Figure 5-2. AC Power Control 400 Hz, Wiring Harness (Sheet 1 of 2)
Change 1 5-3
Figure 5-2. AC Power Control 400 Hz, Wiring Harness (Sheet 2 of 2 )
5-4
ange 1 5-7
ME 6115-545-34/5-4(1) C1
Figure 5-4. DC Power Cables Wiring Harness (Sheet 1 of 2)
5-8 Change 1
ME 6115-545-34/5-4(2) Cl
Figure 5-4. DC Power Cables Wiring Harness (Sheet 2 of 2)
(DELETED)
Change 1 5-9
5-10
Figure 5-6. Convenience and Paralleling, Wiring Harness (Sheet 1 of 2)
Figure 5-8. Fault Indicator Panel, Interconnecting Wiring Harness
5-15
Figure 5-9. Control Cubicle, Interconnecting Wiring Harness (Sheet 1 of 2)
5-16
Figure 5-9. Control Cubicle, Interconnecting Wiring Harness (Sheet 2 of 2)
5-17/(5-18 blank)
Figure 5-11. Special AC Power Cables
Change 1 5-25/(5-26 blank)
ME 6115-545-34/5-13 Cl
Change 1 5-29
Figure 5-13.
Current Transformer Assembly Mode II Sets Wiring Harness
5-30
Figure 5-14. Electric Governor Control (Class 1 Mode I) Sets, Wiring Harness (Sheet 1 of 2)
Figure 5-14.
Electric Governor Control (Class 1 Mode I) Sets, Wiring Harness (Sheet 2 of 2)
5-31
Figure 5-15. Electric Governor Control (Class 1 Mode II) Sets, Wiring Harness
5-32
Figure 5-16.
Electric Governor Control To Actuator Wiring Harness, Class 1 Sets
5-33
5-34
Figure 5-17.
Electric Governor Control To Actuator Class 1 Sets Feedback Cable
Figure 5-20. Tactical Relay Assembly, Interconnecting Wiring Harness
5-39
Figure 5-21. Load Bank Interconnect, Tactical Relay
5-40 Change 4
Figure 5-23.
Precise Relay Assembly (Class 1 Mode I) Sets, Wiring Harness
5-43/(5-44 blank)
Figure 5-25. Excitation System Assembly Interconnecting Wiring Harness
5-47
5-48 Change 1
ME 6115-545-34/5-26 Cl
Figure 5-26.
Voltage Regulator Wiring Harness
TM 5-6115-545-34
Figure 5-27. Set Special Relay Assembly (Class 1, Mode I) Sets. Wiring Harness (Sheet 2 of 5)
ME 6115-545-34/5-27(2)
5-51
TM 5-6115-545-34
5-52
Change 8
Figure 5-27. Set Special Relay Assembly (Class 1, Mode I) Sets, Wiring Harness (Sheet 3 of 5)
Figure 5-27.
Set Special Relay Assembly (Class 1, Mode I) Sets, Wiring Harness (Sheet 4 of 5)
Change 1 5-53
ME 6115-545-34/5-27(5)
Figure 5-27. Set Special Relay Assembly (Class 1, Mode I) Sets, Wiring Harness (Sheet 5 of 5)
5-54
TM 5-6115-545-34
Figure 5-28. Set Special Relay Assembly (Class 1, Mode II) Sets, Wiring Harness (Sheet 2 of 5)
Change 8
5-57
TM 5-6115-545-34
5-58 Change 8
Figure 5-28. Set Special Relay Assembly (Class 1, Mode II) Sets, Wiring Harness (Sheet 3 of 5)
Figure 5-28. Set Special Relay Assembly (Class 1, Mode II) Sets, Wiring Harness (Sheet 4 of 5)
Change 1 5-59
Figure 5-28. Set Special Relay Assembly (Class 1, Mode II) Sets, Wiring Harness (Sheet 5 of 5)
5-60
Figure 5-29. Load Measuring Unit Interconnecting, Wiring Harness
5-61/(5-62 blank)
5-65
ME 6115-545-34/5-30(2)
Figure 5-30.
Engine Accessories, Wiring Harness (Sheet 2 of 3)
5-66
ME 6115-545-34/5-30(3)
Figure 5-30. Engine Accessories, Wiring Harness (Sheet 3 of 3)
Figure 5-31. Paralleling Cable Assembly
5-67
Figure 5-32. Fuel Burning Winterization Kit, Wiring Harness
5-68
ME
6115-545-34/5-33
Figure 5-33. Fuel Burning Winterization Control, Wiring Harness
5-69
5-70
ME 6115-545-34/5-34(1)
Figure 5-34.
Electric Winterization Kit, Wiring Harness (Sheet 1 of 2)
ME 6115 545-34/5-34(2)
5-71
Figure 5-34.
Electric Winterization Kit, Wiring Harness (Sheet 2 of 2)
ME 6115-545-34/5-35(1) Cl
Figure 5-35. Electric Heater Control Box, Wiring Harness (Sheet 1 of 2)
5-72 Change 1
ME 6115-545-34/5-35(2)
Figure 5-35. Electric Heater Control Box, Wiring Harness (Sheet 2 of 2)
5-73/(5-74 blank)
Figure 5-36. Load Bank, Wiring Harness (Sheet 2 of 3)
Change 4
5-77
Figure 5-36. Load Bank, Wiring Harness (Sheet 3 of 3)
5-78
Change 4
5-79
Figure 5-37.
Load Bank Capacitor (Sheet 1 of 2)
5-80
Figure 5-37.
Load Bank Capacitor (Sheet 2 of 2)
Figure 5-38. Load Bank Control Panel, Wiring Harness (Sheet 1 of 2)
5-81
Figure 5-38. Load Bank Control Panel, Wiring Harness (Sheet 2 of 2)
5-82
Figure 5-39. Special Purpose Cables Assembly - 70-1274 for Generator
Set to Load Bank Main Power Cable
Change 6
5-83
5-84
Figure 5-40. RFI Capacitors, Wiring Harness
CHAPTER 6
LOAD CONNECTION GROUP REPAIR INSTRUCTIONS
Section I. INTRODUCTION
6-1. Scope.
This chapter contains repair instructions for the
main load contactor and current transformer of the
load connection group.
6-2. Load Connection Group Description.
a. The load connection group consists of the main
load contactor, load terminal board assembly, current transformer assembly, and reconnection board.
b. The main load contactor connects the main
generator output to the load. The contactor closes
when the load contactor switch (S-3) (refer to Operatar and Organizational Maintenance Manual) is
placed in the on position momentarily.
c. The load terminal board provides a means of
connection to the generator set load. The contactor
connects the generator output to the load through the
load terminal board.
d. The output cables of the generator pass through
the cores of the current transformers. When the
generator is connected to a load, a proportional current is induced in the current transformer secondary.
This secondary current is used by the excitation system as a current boost during a short circuit and
cross current compensation during parallel operation
The current transformer secondary is also used to
operate the ammeter and wattmeter circuits in the
control panel and it is used in the load measuring unit
circuit.
e. The reconnection board permits reconnection
of the generator phase windings to give optional output voltages. Both ends of each coil of each phase
winding run from the generator to a stud on the reconnection board. A changeover board, with copper
bus bars, is mounted so that the studs contact the
bus bars. The bus bars are so designed that by moving the changeover board to one of two positions, the
generator phase coils may be connected in series or
parallel for 120/208 volt or 240/416 volt operation
f. Refer to the Operator and Organizational Maintenanance Manual for maintenance instruction procedures covering the load terminal board and reconnection board.
Section II. MAIN LOAD CONTACTOR
6-3. Removal and Disassembly.
6-5. Repair.
a. Removal. Refer to Operator and Organizational Maintenance Manual and remove the main load contactor.
—a. Replace contactor actuator coil if defective.
b. Replace contacts in contactor if badly pitted or
burned. When one contact is damaged, all contacts
must be replaced.
b. Disassembly. See figure 6-1 or figure 6-1 D
(used on Serial Numbers FZ-01639 on, for 50/60 Hz
and Serial Numbers FZ-06463 on, for 400 Hz) and
disassemble the main load contactor as illustrated.
6-4. Cleaning, Inspection, and Testing.
a. Cleaning. Clean all components with cloth
dampened in cleaning solvent, Federal Specification
P-D-680.
b. Inspection. Refer to Operator and Organizational Maintenance Manual.
c. Testing. Refer to Operator and Organizational
Maintenance Manual.
c. Repair damaged threads with a die or by filing
with a fine mill file.
6-6. Reassembly and Installation.
a. Reassembly. See figure 6-1 and reassemble
the-main load contactor observing the following:
(1) After assembly of the operator assembly
(23) refer to figure 6-1A and perform the
following adjustment procedures:
Change 3 6-1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Plate
Plate
Screw
Washer
Washer
Cover
Screw
Washer
Screw
Washer
Washer
Cover assy
Contactor assy
Gasket
Gasket
ME 6115-545-34/6-1(1) Cl
Figure 6-1. Main Load Contactor
(Sheet 1 of 3)
6-2 Change 1
16. Screw
17. Washer
18. Washer
19. Chamber
20. Gasket
21. Nut
22. Washer
23. Operator assy.
24. Ring, retaining
25. Bushing, locating
26. Spring
27. Shim
28. Shim
29. Shim
30. Bridge assy.
31. Operator
32. Bushing, adjusting
33. Nut
34. Washer
35. Washer
36. Screw
37. Washer
38. Base assy.
39. Nut
40. Washer
41. Washer
42. Contact assy.
43. Arc c h u t e
44. Grommet
45. Spacer
46. B a s e
ME 6115-545-34/6-1(2) Cl
Figure 6-1. Main Load Contactor
(Sheet 2 of 3)
Change 1 6-3
47.
48.
49.
50.
51.
52.
Screw
Screw
Washer
Washer
Clamp
Connector aux.
contact assy.
53. Connector and
wire assy.
54.
55.
56.
57.
58.
59.
60.
61.
Connector
62. Washer
Aux. contact assy 63. Bracket
Au. contact assy 64. Actuator assy
Screw
65. Nut
Washer
66. Washer
Switch
67. Terminal
Screw
68. Rod
Washer
69. Spring
70.
71.
72.
73.
74.
75.
76.
77.
Operator aSS y
Nut
Washer
Washer
Screw
Bracket
Nut
Washer
78.
79.
80.
81.
82.
83.
84.
85.
86.
Operator aux.
Core and rod
Screw
Washer
Washer
End Plate
Washer
Coil
Core and frame
ME 6115-545-34/6-1(3) C1
Figure 6-1. Main Load Contactor
(Sheet 3 of 3)
6-4 Change 1
(a) Check each individual contact at its
edge (insert A) with a force gauge. Preload should
be between 1-1/2 -2 1/2 lbs. This can be attained
by adding or removing shim (see chart, figure 6-1A).
(b) Preload is checked by the initial
breakaway of the E ring at point B, figure 6-1A.
Preload should be between 1-1/2 to 2-1/2 lbs. This
can be obtained by adding or removing shim (See
chart, figure 6-1A).
(2) After assembly of the actuator assembly
(64, figure 6-l), refer to figure 6-lB and perform the following adjustment procedures
(5) Secure by tightening nuts (l).
(6) Recheck continuity at 0.035. No
continuity at 0.040 readjust if necessary.
(b) Economizing switch. Refer to figure
6-lC and proceed as follows:
(1) Adjust switch bracket (3) to
transfer switch. Check that white button is fully
depressed and allow approximately 0.010 clearance
between white button and tap operator (point C).
Secure screws on bracket.
(2) Insert 0.010 gauge into movable core
(a) Leave four screws (1) loose.
(b) Clamp assembly at points A and B to
assure no-air gap at points C and D.
(c) With assembly clamped, tighten four
screws (1).
gap (A).
(3) Apply 24 VDC to coil.
(4) Adjust lower tap (D) by bending to
transfer switch.
(5) Recheck
(d) Remove clamp.
(e) Insert feeler gauge (0. 150 + 0.010 in.)
into movable core gap and adjust guide screws (2)
evenly until gauge is snug throughout the parimeter.
(f) Secure after adjustment by tightening
two nuts (3).
(3) Contactor adjustment.
(a) Contact overtravel. Refer to figure
6-lC and proceed as follows:
(1) Attach indicator lamp on ohmeter to
terminal A1-A2 & C1-C2.
(2) Insert 0.035 gauge into movable
core cap (A).
0.010 gauge transfer
0.018 gauge no transfer
Readjust if necessary
(c) Auxiliary contacts. Refer to figure 6-lC
and proceed as follows:
(1) Before adjustment, set lift comb item
(5) so that the deflector on the guide leaf springs
(6) are near equal in energized and de-energized
position. Secure by tightening nuts (4).
(2) Normally closed. Insert 0.018
guage between guide rod head and operator plate,
Adjust stationary contacts to
(point D 2 places).
just touch the movable contact (use indicator light) recheck with 0.025 gauge at point (D). No continuity.
Readjust if necessary.
(3) Apply 24 VDC to coil.
(4) Adjust carrier bushings at point (B)
until continuity is made on A1-A2 & C1-C2.
(3) Normally Open. Same as normally
closed except shims are inserted into movable core
gap (point A).
Change 1 6-4A
Figure 6-lA Operator Assembly- Main Contact Adjust Procedure
Figure 6-1B. Actuator Assembly Adjustment Procedure
6-4B Change 1
Figure 6-1C. Contactor Adjustment
Change 8 6-4C
1.
2.
3.
4.
5.
6.
7.
Identification plate
Wiring diagram plate
Screw
Lock washer
Flat washer
Shield
Contactor subassy
8.
9.
10.
11.
12.
13.
14.
Screw
Lock washer
Screw
Lock washer
Flat washer
Screw
Lock washer
15.
16.
17.
18.
19.
20.
Figure 6-lD. Main Load Contactor (Sheet l of 3)
6-4D Change 8
Cover
Switch-Connector assy
Aux switch
Aux switch
Connector
Gasket
21. Locking spacer
22. Lock washer
23. Flat washer
24. Chamber
25. Gasket
26. Nut
27. Lock washer
28. Flat washer
29. Base assy
30. Screw
31. Lock washer
32. Flat washer
33. Flat washer
34. Nut
35. Bus bar
36. Insert
37. Base
38. Gasket
39. Nut
40. Lock washer
41. Flat washer
42. Spacer
43. Bushing
44. Bushing
45. Bridge assy
46. Housing
47. Bridge
48. Spring
49. Bushing
50. Arc chute
51. Screw
52. Lock washer
53. Metallic washer
54. Insulation
55. Detent
Figure 6-lD. Main Load Contactor (Sheet 2 of 3)
Change 3 6-4E
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
Operator
Operator
Screw
Lock washer
Screw
Lock washer
Nut
Spring
Solenoid subassy
Moveable core-rod assy
Lock washer
Nut
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
Rod
Core assy
Stud
Operator
Frame-core assy
Frame assy
Screw
Flat washer
Frame
Screw
Lock washer
Flat washer
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
Figure 6-1D. Main Load Contactor (Sheet 3 of 3)
6-4F Change 8
Frame
Frame
Screw
Flat washer
Micro switch assy
Screw
Lock washer
Flat washer
Switch
Bracket
Plate
Coil
Section III. CURRENT TRANSFORMER
6-7. On Equipment Test.
a. The following resistance readings should be
precent for good current transformers. Use a Simpson 260 or equivalent meter, (properly zeroed) with
the R x 1 scale selected for making the measurements.
b . Current transformer secondary resistance
readng. (fig. 6-2)
Percent of
Rated Load
Meter
LMU
CT1 . . . 2.5 ohms
CT2 . . . same as CTl
CT3 . . . same as CTl
CT4 . . . 0.2 ohms pins 1 to 3, 0.1
ohm center pin to 1 and
center pin to 3
CT5 . . . same as CT4
CT6. . . same as CT4
6-8. Removal and Disassembly.
a . Removal
(1) Remove and tag the generator output leads
and pass them through the associated current transformers freeing the current transformer assembly
for removal. (fig. 6-2)
(2) Remove the generator harness wiring
from terminal block TB16, identifying each lead with
the terminal block post number from which it was
removed.
(3) Remove the current transformer assembly (7, fig. 6-3) by removing hardware items 3,
4 and 5.
b . Disassembly. See figure 6-4 and disassemble
the current transformer as illustrated.
Cross Current
Compensation CT7 . . . 0.5 ohms pins l and 2
Figure 6-2. Routing Main Generator Leads Through Current Transformers
Change 1 6-5
Figure 6-3. Current Transformer Assembly and Load Connecting Group Mounting Brackets
6-6 Change l
Figure 6-4. Current Transformer Assembly
Change 1 6-7
6-9. Cleaning, Inspection, and Testing.
(3) To test CT7 on Mode II sets, proceed a
follows:
a. Cleaning. Clean all components with a cloth
dampened in cleaning solvent, Federal Specification
P-D-680.
(a) Apply 15 volts (rms) 400 Hz across,
terminals 1 and 2.
b . Inspection. Refer to Operator and Organizational Maintenance Manual.
(b) The excitation current shall be less than
45 ma (rms).
—c. Testing.
(1) To test CTl, CT2, and CT3 on either Mode
I or Mode II sets, proceed as follows:
(a) Wrap 10 turns of a conductor around the
coils of cm.
(b) Apply an ac current of 10 amperes to
the conductor.
(c) The current measured at terminals Al
and A2 must be 360 ma.
(d) Repeat steps (a) through (c) on CT2 and
CT3. Measure CT2 at terminals B1 and B2; measure CT3 at terminals Cl and C2.
(c) Apply 50 amperes 400 Hz through 1
primary turn. Secondary current should be 250 ma
± 1%.
(4) To test CT7 on Mode I sets, proceed as
follows:
(a) Apply 15 volts (rms) 60 lb across terminals 1 and 2.
(b) Excitation current shall be less than
60 ma (rms).
(c) Apply 50 amperes 60 Hz through 1
primary turn. Secondary current should be 250 ma
± 1%.
6-10.
(2) To test CT4, CT5, and CT6 on either Mode
I or Mode II sets, proceed as follows
(a) Apply 20.7 volts (rms) 60 Hz across
terminals l and 3.
Repair.
a. Replace defective current transformers.
b.
Replace worn grommets.
c. Replace all gaskets with new ones.
(b) Voltage between terminals 1 and 2 shall
measure 16. 5 ± 1 percent Vac.
(c) Excitation current shall be less than
36 ma.
(d) Apply 50 amperes 60 Hz through 1
primary turn. Secondary current should be 180 ma
± 1% at terminals 1-3.
6-8 Change 1
6-11.
Reassembly and Installation.
a. Reassembly
See figure 6-4 and reassemble
the current transformer assembly.
b. Installation. See paragraph 6-8 and install the
current transformer assembly.
CHAPTER7
ELECTRO-HYDRAULIC GOVERNING SYSTEM
(CLASS I, PRECISE SETS ONLY)
7-1. General
a. The electro-hydraulic governing system is a
speed (frequency) sensing stem used to maintain
prime mover speed constant and therefore generator
output frequency, during periods of unchanging
load and when load additions or deletions occur.
b . The system consists of a control unit, load
measuring unit and hydraulic throttle actuating unit.
c. The control unit inputs are the generator output
voltage, and a dc voltage (0-9. 8 Vdc) proportional to
the generator load, supplied by the load measuring
unit. The generator voltage input is applied to a
frequency sensing network and reference voltage
network, The differ ential output of these two networks determines the control current of two magnetic amplifiers whose outputs drive separate coils
of the hydraulic actuators pilot valve. The actuator
pilot valve positions the actuator power piston which
is connected to the input arm of the fuel injection
pump. The actuators hydraulic system is comprised
of a reservoir, engine driven pump (300-320 psi, 2
gpm), cooler and filter.
d. Any deviation of engine speed, reflected as a
change in frequency at the input of the governor, produces a change in the magnitude and direction of magnetic amplifier control field current. This change in
ccntrol field current will increase the strength of one
coil of the pilot valve while decreasing the strength of
the other, The resultant difference repositions the
pilot valve in turn repositioning the power piston which
changes the output of the fuel injection pump, changing engine speed and consequently restoring generator
frequency to its nominal value.
e. The load measuring units (LMU) input to the
governor control provides for automatic load sharing
when two or more sets are operated in parallel.
Each set is equipped with an LMU.
f. If the load added to the system is not equally
divided, the LMU inputs to their respective governors will differ. The resulting difference acting
through additional windings of each sets governor
(which are all connected in parallel) will reposition
each sets actuator power piston such that fuel flow
in the more heavily loaded set is decreased while
that of the lightly loaded set is increased. Since the
power input of each prime mover has been readjusted,
equal division of true power (Kw) occurs with no
deviation in frequency of any set.
7-2. Malfunction.
The following procedures are to be performed in the
generator set unless otherwise specified.
a. If the FL - NL or NL - FL transient exceeds
1-1/2 percent of rated speed and/or does not re establish stable engine operating conditions within
one second, realign the control unit in accordance
with paragraph 7-8 . Also follow this procedure
if the engine speed hunts. If the set cannot be
stabilized, check sockets A and B of plug P-21
(refer to Operator and Organizational Maintenance
Manual) for 24 Vdc (A is positive).
b. If the engine speed increases to above nominal
operating speed, check sockets A and B of P-17 for
120 Vat. If it is missing, troubleshoot the generator
set wiring. (Refer to Operator and Organizational
Maintenance Manual). If it is present, check the
resistance of the frequency adjusting circuit consisting of R4 (250 ohms) rheostat R1 frequency adjust
(500 ohms) and R5 (250 ohms) fixed resistor.
Refer to Operator and Organizational Maintenance
Manual. Measure the total circuit resistance
across N and T of harness plug P17. The circuit
resistance should be 1000 ohms (5 percent tolerance).
After testing for correct total resistance, test the
operation of the frequency adjust rheostat by
connecting an ohmmeter across pins M and T and revolving the frequency adjust rheostat through
its entire travel. The resistance should vary from
750 ohms to 250 ohms. Repeat this procedure
using the ohmmeter across pins M and N of the
harness plug. If the problem persists, check sockets
A and B of plug P-21 for 24 Vdc (A is positive).
c, If the engine speed remains below the nominal
operating speed, adjust R1. If there is no improvement, check the resistance of the frequency adjust
circuit. Disconnect P-17 and check the resistance
of the frequency adjust circuit consisting
of R4 (250 ohms) fixed resistor, R1
frequency adjust rheostat (500 ohms) and R5
(250 ohms, 5 percent) fixed resistor. Refer to
Operator and Organizational Maintenance Manual.
Measure the total circuit resistance across N and T
of harness plug P17. The circuit resistance should
be 1000 ohms (5 percent tolerance). After testing
for correct total resistance, test the operation of the
frequency adjust potentiometer by connecting an
ohmmeter across pins M and T and revolving the
frequency adjust potentiometer through its entire
travel. The resistance should vary from 750 ohms
to 250 ohms. Repeat this procedure using the
ohmmeter across pins M and N of the harness plug.
Disconnect actuator electrical connector before
making this measurement. Push actuator piston all
the way down and adjust engine speed with manual
throttle. If this value resistance is measured, check
sockets A and B at plug P-21 for 24 Vdc (A is positive).
d. If the set is operating at a constant load and
voltage and during an eight-hour period the change
in ambient temperature does not exceed 60°F, the
set frequency should not drift beyond 1/2 of one
percent of rated frequency. The above requirement
assumes that the set temperatures were stabilized
7-1
at the initial and final ambient temperatures.
NOTE
If the drift in paragraph d is
excessive, realign the control
unit following the procedure outlined in paragraph 7-8.
e. At constant ambient temperature, constant load,
constant voltage and constant barometric pressure,
the set frequency should remain within a bandwidth
of 1 percent of rated frequency for a period of 4 hours.
If this bandwidth has been exceeded, realign the
control unit in accordance with paragraph 7-8.
f. If the preceding solutions to the specific
problem do not resolve the problems, replace and
repair the control unit, actuator (para 13-3 thru
13-8) or load measuring unit (para 8-15 thru
8-19) as required.
7-3. Removal.
Refer to figure 7-1 and remove in the order of
sequence numbers.
CAUTION
The melting temperature of the
potting compound is 165 F. The
flash point is 515°F. Do not unpot
by placing unit on a hot plate type
surface or by using an open flame.
e. Set the oven temperature at 180°F to 185°F
and allow the unit to soak until the potting compound
is melted. The normal soak period at this temperature is 11 to 12 hours.
WARNING
Use care when handling the hot potting
compound. It can cause severe injury to personnel.
f. Using heavy gloves and wearing safety
glasses, remove the printed circuit board from the
melted putting compound. Lift the board s1owly,
allowing the potting compound to drain off the components.
7-4. Disassembly and Repair
g. Set the printed circuit board with transformers
on the bottom on a drain board and allow it to cool
to room temperature.
a. Disassemble electric governor control unit,
if required, as illustrated in figure 7-2.
h. Remove screw (4) and lockwashers (5) which
attach connectors (P1, J3, P5, P2) to cover.
NOTE
Disassembly and repair of electric
governor control unit at the field
level is restricted to removal of
the cover, connectors, potentiometers and test jacks. further
disassembly requires unpotting and
the following disassembly can be
performed by depot maintenance
personnel only.
b. Remove cover and components installed on
cover in the order of sequence numbers (1 thru 15).
NOTE
Tag and unsolder wires for the
components on the cover.
(1) Replace defective test jacks, potentiometers
or connectors.
(2) Repair procedures for individual wires of a
wiring harness are covered in the Operator and
Organizational Maintenance Manual.
i. Tag wiring and remove harness (6).
j. Disassemble remaining components mounted
on cover in accordance with index numbers 7 through
27.
7-5. Cleaning and Inspection.
a. Clean all parts with a cloth dampened in
cleaning solvent Federal Specification P-D-680 and
dry thoroughly.
b. Inspect for cracks, breaks, damaged connectors,
damaged terminals, defective wiring, and defective
components. Check potentiometer for continuity,
resistance, and wiring for open insulation.
7 - 6 . Tests and Repair.
a. Perform test as outlined in figures 7-3 thru
7-10.
NOTE
Mount circuit card as shown in
figure 7-11 prior to test.
c. Remove six screws and lockwashers from cover
of control unit. Lift cover slightly and set at a
slight angle to keep the connectors and potentiometers
out of the potting compound.
b. Resistance Test (50/60 Hz) . Refer to Table
7-1 and perform resistance test.
d. Place the complete unit in a temperature controlled oven, large enough to allow air to circulate
completely around the unit.
7-2
d. See table 7-2 for values of individual components. When measuring individual components, disconnect at least one lead to prevent feedback readings.
c. See figure 1-4 and 1-5 for schematic diagrams.
Figure 7-1.
Electric Governor Control Unit Removal
Change l 7-3
Figure 7-2. Electric Governor Control Unit
7-4 Change 1
P1
Connection
Table 7-1. Resistance Test (50/60 Hz)
Nominal
Potentiometer
Resistance
Position
T-N (T +)
M-N (M +)
(M +)
R18CCW
F-N (F +)
Allowance resistance
range (ohms)
5100
3400-6800
2180
1950-2400
12180
11000-13000
6000
5000-7000
(F+)
R16CCW
31000
30000-32000
(F+)
Rl5CCW
6500
5500-7500
E-G (E +)
5500
4500-6500
R-G (R+)
120
100-140
F-G (F +)
650
550-750
LESS THAN 0.2 OHMS
J-H (J +)
T-P (T +)
(T+)
R14CCW
U-S (U+ )
2200
1400-3000
2600
1800-3400
525
450-600
USING M1, MEASURE RESISTANCE OF EACH PIN (ALL CONNECTORS) AND
EACH TEST POINT TO GOVERNOR CONTAINER. RESISTANCE SHOULD BE
INFINITY ON 100,000 OHM SCALE REPEAT FOR REVERSE POLARITY
RESISTANCE SHOULD BE INFINITY ON 100,000 OHM SCALE.
MAGNETIC AMPLIFIER BIAS TEST
TURN R1l, R12, R14, R15, R16, R18
FULL CW.
CONNECT GOVERNOR CONTROL UNIT TO
TEST EQUIPMENT AS SHOWN.
ALMOST R11 AND Rl2 FOR BALANCED
READING OF 450 MA ON M2 AND M3.
TURN R12 FULL CW. M2 AND M3 SHALL
READ 0-300 MA, AND BE BALANCED
WITHIN 50 MA.
TURN R12 FULL CCW. M2 AND M3 SHALL
READ 600-1000 MA, AND BE BALANCED
WITHIN 50 MA.
READJUST Rll AND Rl2 FOR BALANCED
READING OF 450 MA ON M2 AND M3.
LOCK Rll AND Rl2 FOR REMAINDER OF
TEST.
ME 6115-545-34/7-3
Figure 7-3.
Electric Governor Control Unit, Magnetic Amplifier
Bias Test (50/60 Hz)
Change 1 7-5
FREQUENCY SENSING CHECK (HIGH AND LOW
FREQUENCY)
CONNECT GOVERNOR CONTROL UNIT TO
TEST EQUIPMENT AS SHOWN
TURN Ra SO THE Resistance BETWEEN
P1-M AND Pl-T IS 250 OHMS.
REDUCE THE FREQUENCY OF THE APPLIED 120 ± 2 VOLT SUPPLY UNTIL M2
AND M3 BALANCE.
THE FREQUENCY SHALL BE 57-58 Hz.
TURN Ra SO THE RESISTANCE BETWEEN
P1-M AND P1-N IS 250 OHMS.
INCREASE THE FREQUENCY OF THE APPLIED 120 ± 2 VOLT SUPPLY UNTIL M2
AND M3 BALANCE.
THE FREQUENCY SHALL BE 64-65 Hz.
TEST EQUIPMENT
REF DES
QUANTITY
Ra
Rb, RC
M2., M3
Vl
1
2
2
DESCRIPTION
POTENTIOMETER, 10 TURN, 500 OHM, 5 WATT
RESISTOR, FIXED, 250 OHM, 5 WATT
MILLIAMMETER, DC, 0-1000 MA
DC POWER SOURCE
ME 6115-545-34/7-4 C1
AC POWER SOURCE
Figure 7-4. Electric Governor Control Unit, Frequency Sensing Check (High and
Low Frequency) (50/60 Hz)
e. Magnetic Amplifier Bias Test (50/60 Hz).
Refer to figure 7-3 and perform the magnetic amplifier bias test.
f. Frequency Sensing Check, High and Low
Frquency (50/60 Hz). Refer to figure 7-4 and
perform the frequency sensing check.
and perform the rectifier bridge and feedback
winding test.
m. Parallel Winding Test (400 Hz). Refer to
figure 7-10 and perform the parallel winding test.
n. Replace any component found to be defective
during tests.
g. Rectifier Bridge, CR7 thru CR30 and Feedback Winding Test (50/60 Hz). Refer to figure 7-5
and perform the rectifier bridge and feedback winding
test.
o. For wiring harness repairs, refer to Operator
and organizational Maintenance Manual.
h. Parallel Winding Test (50/60 Hz). Refer to
figure 7-6 and perform the parallel winding test.
p. If wiring harness has sustained extensive
damage, refer to Chapter 5 for wiring harness
rebuilding procedures.
i. Resistance Test (400 Hz). Refer to Table 7-3
and perform resistance test.
7-7. Assembly.
j. Magnetic Amplifier Bias Test (400 Hz). Refer
to figure 7-7 and perform the magnetic amplifier bias
test.
k. Frequency Sensing Check, High and Low
Frequency (400 Hz). Refer to figure 7-8 and perform the frequency sensing check.
L Rectifier Bridge, CR7 thru CRl0 and Feedback Winding Test (400 Hz). Refer to figure 7-9
7-6 Change 1
a. See figure 7-12 and assemble printed circuit
board. If any connections are opened or bared for
test purposes, or if any defective components are
replaced, the effected area and components must be
coated with polyurethane resin to prevent oxidation
or other corrosion . The coating must be of a minimum thickness of 0.007 inches and air bubble entry
into the applied polyurethane must be controlled so
that the legibility of component coding and identification is not impaired. The polyurethane resin to
be utilized will correspond to MIL-I-46058,
Table 7-2. Electric Governor Control Unit Component Values
50/60 Hz Unit
(ohms)
Component
400 Hz Unit
(ohms)
Remarks
3.0% tolerance
R1, R1A, R15
500
500
Rll
5000
5000
R4, R8, R22
5100
5100
R37
5100
3500
R2, R10
1250
750
3.0% tolerance
R12, R18
10,000
10,000
3.0% tolerance
R16
25,000
25,000
3.0% tolerance
R14, R20
3,000
3,000
3.0% tolerance
Parallel winding
Less than 1.0
(nominal )
Less than 1.0
(nominal)
Less than 1.0
(nominal)
Less than 1.0
(nominal)
Less than 1.0
(nominal)
Less than 1.0
(nominal)
Check for open
Less than 1.0
(nominal)
Less than 1.0
(nominal)
Check for open
Feedback winding
Frequency control
winding
Bias control winding
3.0% tolerance
Check for open
Check for open
Grade S, Type PUR.
h. When compound has cooled and is substantiality
solid, install top cover and hardware.
b. See figure 7-2 and reassemble control unit
components.
7-8. Adjustment.
c. Reconnect cover to printed circuit board with
wiring harness.
See figure 7-13 for location of adjustment and controls
and adjust electric governor according to the following
procedures
d. Place the container in a temperature controlled
oven. Set oven temperature at 180 to 185°F and allow
container to soak 11 to 12 hours or until potting compound is completely melted.
e. Prior to installing the printed circuit board,
remove the container from the oven and make sure
that insulation paper is positioned next to the
container shell.
f. Using heavy gloves, and safety glasses slowly
lower the printed circuit board into the potting compound,
WARNING
Use care not to splash hot potting
compound om operating personnel. It
can cause severe injury.
g. Position the printed circuit board and allow
compound to cool.
a.
Single Set Adjustment Procedures
(1) With engine not operating, set frequency
adjust control (on control panel), R11, R14, R16, and
R18 to midpoint by turning full each way and approximating center. Set RI 5 full counterclockwise and R12
approximately 1/4 clockwise.
(2) Start engine. Refer to Operator and Organizational Maintenance Manual for operating instructions. If engine hunts, perform following
adjustments to stabilize operation
(a) If hunt is of high frequency and small
amplitude; adjust R12 clockwise and/or R16 counterclockwise.
(b) If hunt is of low frequency and long
amplitude; adjust Rl8 countercloclwise. If operation
does not stabilize, turn R16 clockwise. It maybe
necessary to adjust R12 counterclockwise in conjunction
with R18 and R16 adjustments to stabilize operation.
Change 5
7-7
TEST EQUIPMENT
REF DES
Rd
Rf, Rg
Rh, Ri
Rj
M2, M3
M4
QUANTITY
1
2
2
1
2
1
1
1
1
1
DESCRIPTION
RESISTOR, FIXED, 5000 OHMS, 1 WATT
RESISTOR ] FIXED, B2 OHM, 10 WATT
RESISTOR FIXED, 15 OHMS, 5 WATT
RESISTOR, FIXED, 25 OHMS, 5 WATT
MILLIAMMETER, DC, 0-1000 MA
MILLIAMMETER, DC, ZERO CENTER,
10-0-10 MA
SWITCH, ROTARY, 3 POSITION, 1 POLE, 1 AMP
DC POWER SOURCE
AC POWER SOURCE
AUTOTRANSFORMER 2:1 RATIO
ME 6115-545-34/7-5
Figure 7-5. Electric Governor Control Unit, Rectifier Bridge and Feedback Winding Test
(50/60 Hz)
(3) Once the set has been stabilized, connect
a 0 - 10 volt range dc voltmeter (high impedance
type -2000 ohms per volt or more) across test
points 3 and 4 with the positive lead at test point 4.
Adjust FREQUENCY ADJUST control to obtain operating frequency (400 W, or 60 Hz), and then adjust
R14 until volt e across test points 3 and 4 is zero
volts, with no load on generator.
(4) Connect dc voltmeter across tests points 1
and 2 with positive lead at test point 1. Adjust R11
and the frequency adjust control until the dc voltmeter reads zero volts at nominal frequency. Repeat
the adjustment until the voltage across test points 3
and 4 and across 1 and 2 is zero volts, and the set
frequency is 50 Hz, 60 Hz or 400 Hz with no load
on the engine. If test points 1 and 2 cannot be
zeroed, they must be reduced to a minimum.
7-8 Change 1
(5) Adjust RI 2 until a reading of approximately
4.5 volts is obtained across test points A and B, with
no load on generator. If this voltage is too low,
response will be sluggish and if it is too high, a rapid
oscillation may occur. Normal range is 3 to 6 volts.
(6) Adjust R18 clockwise as far as possible,
and R16 counterclockwise as far as possible without
causing oscillation,
NOTE
Increasing the load measurement gain
R15 (turing in a clockwise direction)
will improve transient performance;
therefore it should be adjusted as high
as possible. Transient performance must
be checked using a frequency recorder.
PARALLEL WINDING TEST
CONNECT GOVERNOR CONTROL
UNIT TO TEST EQUIPMENT AS
SHOWN.
M2 SHALL READ 0-300 MA.
M3 SHALL READ 600-840 MA.
REVERSE POLARITY OF CONNECTIONS TO PINS J1-E AND J1-G.
M2 SHALL READ 600-840 MA.
M3 SHALL READ 0-300 MA.
TEST EQUIPMENT
REF DES
QUANTITY
Re
M2, M3
Vl
V2
1
2
1
1
1
DESCRIPTION
RESISTOR, FIXED, 50,000 OHMS, 10 WATT
MILLIAMMETER, DC, 0-1000 MA
DC POWER SOURCE
DC POWER SOURCE
ME 6115-545-34/7-6
AC POWER SOURCE
Figure 7-6. Electric Governor Control Unit Parallel Winding Test (50/60 Hz)
(7) The adjustment of R18 and R16 are
interdependent. For any position of R18 there is an
optimum position for R16. Therefore, to improve
transient performance, increase the frequent y gain
by turning R18 clokwise. If hunt develops, readjust
R16 for stability. If no hunt develops, apply and
reject load on the generator set to check for stability
under transient conditions. Assuming that no hunt
develops for an increase in frequency gain, (R18
turned clockwise) or that hunt can be removed by
readjustment of R16, again increase frequency gain.
by turning R18 clockwise and note the transient performance. Finally a position may be reached where
no readjustment of R16 can stabilize for the high
frequency gain of R18. Then reduce the frequency
gain to the stable region and optimize stability
and performance with R16. The frequency gain
should be reduced to a point where the system is
not on the edge of instability for long-term stable
operation.
(8) Transient performance improves as the
frequency gain R18 is increased and the feedback
gain R16 is a minimum for that particular position
of frequency gain adjustment. If R16 is adjusted
too far counterclockwise, there will be insufficient
feedback to stabilize the operation at steady state.
If a slow oscillation occurs, turn R16 clockwise until
stability is reached. This is the optimum setting for
the level of frequency gain.
(9) If R16 is turned far clockwise, a very fast
oscillation may occur. Turn R16 counterclockwise
to the optimum point of stability.
b. Parallel Operation (Class 1 sets)
(1) Adjust in accordance with paragraph 16-11.
(2) If the sets will not divide load, or if they
oscillate (successively interchange load) on the first
attempt to parallel, check the polarity across pin
A and B of the parallel receptacle on both sets and
verify, that the input circuits to pin C and D are
correct and that the voltages are as specified.
7-9. Equipment Test
If the electric governor control has been renewed or
repaired, refer to Chapter 16, Section II and conduct
the following tests.
a. Frequency and voltage regulation, stability and
transient response test, short term. (para 16-15)
b. Frequency adjustment range test (para 16-16)
Change 1 7-9
Table 7-3. Resistance Test (400 Hz)
P1
Connection
Potentiometer
Position
Nominal
Resistance
Allowable resistance
range (ohms)
T-N (T +)
2550
2300-3200
M-N (M +)
1400
1200-1700
11480
10000-12000
4160
3500-5500
(M +)
R18CCW
F-N (F + )
(F +)
R16CCW
29160
27000-31000
(F +)
R15CCW
4660
4000-5500
E-G (E +)
5500
4500-6500
R-G (R + )
120
100-140
F-G (F +)
650
550-750
J-H (J+)
LESS THAN 0.2 OHMS
T-P (T+)
(T +)
U-S (U +)
R14CCW
1950
1400-2500
2150
1500-2800
520
450-600
USING Ml, MEASURE RESISTANCE OF EACH PIN (ALL CONNECTORS) AND EACH
TEST POINT TO GOVERNOR CONTAINER. RESISTANCE SHOULD BE INFINITY ON
100,000 OHM SCALE. REPEAT FOR REVERSE POLARITY. RESISTANCE
SHOULD BE INFINITY ON 100,000 OHM SCALE
7-10
Change 5
MAGNETIC AMPLIFIER BIAS TEST.
TURN Rll, R12, R14, R15, R16,
R18 FULL CW.
CONNECT GOVERNOR CONTROL
UNIT TO TEST EQUIPMENT AS
SHOWN.
ADJUST Rll AND Rl2 FOR BALANCED READING OF 450 MA ON
M2 AND M3.
TURN R12 FULL CW. M2 AND M3
SHALL READ 0-300 MA, AND BE
BALANCED WITHIN 50 MA.
TURN R12 FULL CCW. M2 AND
M3 SHALL READ 600-1000 MA,
AND BE BALANCED WITHIN 50 MA.
READJUST Ml AND R12 FOR BALANCED READING OF 450 MA ON
M2 AND M3 AND LOCK Rll AND
Rl2 FOR REMAINDER OF TEST.
TEST EQUIPMENT
REF DES
M2, M3
V1
QUANTITY
2
1
1
DESCRIPTION
MILLIAMMETER, DC, 0-1000 MA
DC POWER SOURCE
AC POWER SOURCE
ME 6115-545-34/7-7
Figure 7-7. Electric Governor Control Unit, Magnetic Amplifier Bias Test (400 Hz)
7-11
FREQUENCY SENSING CHECK (HIGH AND
LOW FREQUENCY)
CONNECT GOVERNOR CONTROL UNIT TO
TEST EQUIPMENT AS SHOWN
TURN Ra SO THE RESISTANCE BETWEEN
P1-M AND P1-T IS 250 OHMS.
REDUCE THE FREQUENCY OF THE APPLIED 120 ± 2 VOLT SUPPLY UNTIL M2
AND M3 BALANCE.
THE FREQUENCY SHALL BE 375-380 Hz.
TURN Ra SO THE RESISTANCE BETWEEN
P1-M AND P1-N IS 250 OHMS.
INCREASE THE FREQUENCY OF THE
APPLIED 120 ± 2 VOLT SUPPLY UNTIL
M2 AND M3 BALANCE.
THE FREQUENCY SHALL BE 420-425 Hz.
TEST EQUIPMENT
REF DES
Ra
Rb, RC
M2, M3
QUANTITY
1
2
2
1
1
DESCRIPTION
POTENTIOMETER, 10 TURN, 500 OHMS, 5 WATT
RESISTOR, FIXED, 250 OHMS, 5 WATT
MILLIAMMETER, DC, 0-1000 MA
DC POWER SOURCE
AC POWER SOURCE
ME 6115-545-34/7-8
Figure 7-8.
7-12
Electric Governor Control Unit, Frequency Sensing Check (400 Hz)
TEST EQUIPMENT
REF DES
Ra
Rb, Rc
Rd
Re
Rf, Rg
Rh, Ri
Rj
Ml
M2, M3
M4
Figure 7-9.
QUANTITY
1
2
1
1
2
2
1
1
2
1
1
1
1
1
1
1
DESCRIPTI0N
POTENTIOMETER, 10 TURN, 500 OHMS, 5 WATT
RESISTOR, FIXED, 250 OHMS, 5 WATT
RESISTOR, FIXED’ 5000 OHMS, 1 WATT
RESISTOR, FIXED, 50,000 OHMS, 10 WATT
RESISTOR, FIXED, 32 OHMS, 10 WATT
RESISTOR, FIXED, 15 OHMS, 5 WATT
RESISTOR, FIXED, 25 OHMS, 5 WATT
OHMMETER, 100,000 OHMS SCALE
MILLIAMMETER, DC, 0-1000 MA
MILLIAMMETER, DC, ZERO CENTER, 10-0-10 MA
SWITCH, ROTARY, 3 POSITION, 1 POLE, 1 AMP
GOVERNOR ACTUATOR, P/N 1321 7E5390
DC POWER SOURCE
DC POWER SOURCE
AC POWER SOURCE
AUTOTRANSFORMER 2:1 RATIO
ME 6115-545-34/7-9
Electric Governor Control Unit, Rectifier Bridge and Feedback Winding Test (400 Hz)
7-13
PARALLEL WINDNG TEST.
CONNECT GOVENOR CONTROL
UNIT TO TEST EQUIPMENT AS
SHOWN
M2 SHALL READ 0-300 MA.
M3 SHALL READ 600-840 MA.
REVERSE POLARITY OF CONNECTIONS TO PINS J1-E AND J1-G.
M2 SHALL READ 600-840 MA.
M3 SHALL READ 0-300 MA.
TEST EQUIPMENT
REF DES
Re
M2, M3
V1
V2
QUANTITY
1
2
1
1
1
DESCRIPTION
RESISTOR, FIXED, 50,000 OHMS, 10 WATT
MILLIAMMETER, DC, 0-1000 MA
DC POWER SOURCE
DC POWER SOURCE
AC POWER SOURCE
ME 6115-545-34/7-10
Figure 7-10. Electric Governor Control Unit, Parallel Winding Test (400 Hz)
Figure 7-11.
7-14
Electric Governor Control Unit, Test Position for Unpotted Units
ME 6115-545-34/7-12 (1)
Figure 7-12. Electric Governor Wiring Board Assembly (Sheet 1 of 2)
7-15
Figure 7-12. Electric Governor Wiring Board Assembly (Sheet 2 of 2)
7-16 Change 1
KEY to fig. 7-12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
Nut (2)
Lock washer (2)
Flat washer (2)
Screw
Transformer (T1)
Nut (2)
Washer (2)
Washer (2)
Screw
Reactor (U)
Nut (2)
Washer (2)
Washer (2)
Screw (2)
Reactor (22) (L2)
Resistor (R5)
Capacitor (C7)
Resistor (R23)
Nut (2)
Washer (2)
Washer (2)
Screws (2)
Transistor (Q1 & Q2)
Nut (2)
Washer (2)
Screw (2)
Washer (2)
Heat sink (2)
Reactor (L3)
Transformer (T2)
Rectifiers (CR3, CR4, CR5, CR6)
Capacitor (C9)
Resistor (R20)
Resistor (R22)
Nut (1)
Mug amp (ARl)
Nut (2)
Washer (2)
Washer (2)
Board assy
41.
42
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
Resistor (R37)
Rectifiers (CR7, CR8, CR9, CRl0)
Capacitor (C2)
Board
Capacitor (C5)
Resistor (R4, R8)
Nut (2)
Washer (2)
Washer (2)
Washer (2)
Washer (2)
Nut (2)
Studs (2)
Nut (1)
Washer (1)
Flat washer (1)
Screw (1)
Washer (2)
Washer (2)
Resistor (R10)
Rectifiers (8)
Capacitor (C6)
Nut (2)
Washer (2)
Washer(2)
Screw (2)
Washer (4)
Washer (4)
Resistor (1 & R1A)
Nut (1)
Washer (1)
Washer (1)
Screw (1)
Washer (2)
Washer (2)
Resistor (R2)
Rectifier (CR2)
Capacitor (C4)
Capaciitor (C3)
Board
Change 1 7-17
Figure 7-13. Electric Governor Control Unit, Location of Adjustments and Controls
7-18 Change 8
7-10 GOVERNOR CONTROL UNIT (MEP-115A).
a. General.
(1) The electric governing system Is a speed
(frequency) sensing system used to maintain constant
engine speed and generator output frequency during
periods of unchanging load and when load additions
or deletions occur. The system consists of a
control unit, magnetic pickup and an electric
throttle actuating unit. The engine speed signal
is obtained from a magnetic pickup mounted in the
flywheel housing in close proximity to the flywheel
ring gear. The frequency of the pickup signal is
proportional to engine speed. Figure 7-14 shows
the functional theory of operation.
(2) The control unit has four distinct circuits; pickup signal amplifier, frequency reference
oscillator, phase comparator and output circuit.
to the average current from the transistor and moves
in proportion to position the engine throttle. The
output transistor is switched on and off to reduce
power dissipation.
b. Malfunction.
The following procedures are to be performed with
the Governor Control Unit in the generator set.
(1) Connect the breakout cable between
wiring harness plug P17 (1, figure 7-15) and the
electric governor.
(2) Using a digital
voltage readings in table
cable plug. All readings
the terminal and ground.
are ground.
c.
(a) The Frequency Reference Oscillator is
voltage controlled. The frequency setting is
adjusted by applying zero to 10 volts at the
Frequency Reference Oscillator input. The internal
frequency adjust provides this voltage setting when
the control unit is in operation. The Reference
Oscillator does not maintain a constant frequency.
It deviates from its nominal frequency as the engine
speed changes during load changes. The Reference
Oscillator is forced by the Phase Comparator to
track the amplified pickup signal representing
engine speed. The voltage representing speed
error is the amount of voltage required to drive
the Reference Oscillator off frequency in proportion to the engine speed deviation.
(b) The Phase Comparator Circuit receives
signals from the Pickup Signal Amplifier and the
Reference Frequency Oscillator and compares the
difference in frequency. The Phase Comparator
measures the amount the engine signal is ahead
or behind the Reference Oscillator signal. Its
voltage output is used to force the Reference
Oscillator to the same frequency as the signal
from the engine. The Phase Comparator output
is proportional to the speed error. The gain
control is used to couple the Phase Comparator
output to the Reference Oscillator. By increasing the coupling, a small voltage change from
the Phase Comparator represents a large frequency
change and vice-versa.
(c) The Output Circuit allows governing by
introducing a temporary drop during a load change
for stability purposes. It has an adjustable means
to control the magnitude and time constant of the
drop to match the dynamic characteristics of the
engine. The output current switching portion of
the circuit provides current to drive the actuator.
The output transistor is switched on and off at a
frequency of 200 Hz. This is above the natural
frequency of the actuator. The actuator responds
voltmeter, make the
7-4 at the breakout
are measured between
Terminals F, G, H and T
Removal.
(1) Disconnect electrical connector P17
(1, figure 7-15).
(2) Remove 4 hex head screws (2), lock
washers (3) and nuts (4).
(3) Remove the control unit.
d.
Installation.
Install the Governor Control Unit in reverse order
of removal procedures.
e. Adjustment Procedure.
(1) Disconnect the actuator linkage rod from
the engine fuel shutoff lever.
(2) Place the generator set START-RUN-STOP
switch (located on the generator set control panel
in the RUN position.
(3) Place the generator set BATTLE SHORT
WITCH (located on the generator set control panel
in the ON (override) position.
(4) Beginning at the fully counterclockwise
position, rotate the engine fuel shutoff lever in
a clockwise direction until a slight resistance is
felt; hold the lever in this position.
NOTE
This resistance is the fuel injection
pump’s internal governor linkage hook
engaging the metering valve arm.
(5) Move the actuator 1 ever to the “full fuel”
position. This is the direction against the spring
resistance (fully counterclockwise).
Change
9
7-19
7-20
Figure 7-14.
Table 7-4.
TERMINAL
S
PROBABLE
CAUSE OF NON-NORMAL READING
NORMAL VALUE
1.0 volt AC-RMS minimum
while cranking.
1.
2.
3.
K
10.1 + .20 volts DC while 1.
energized (Internal regulated D.C. supply).
2.
3.
4.
L
Governor Malfunction Testing
Above 5.1 volts D.C. while 1.
running. (inverse speed
2.
error signal).
CORRECTIVE ACTION
1. Replace magnetic pickup.
Defective magnetic pickup.
Gap too large between magnetic 2. Readjust magnetic pickup.
pickup and gear teeth.
Improper or defective wiring 3. Replace wiring harness.
to the magnetic pickup.
D.C. power not connected or 1. Connect D.C. power supply;
replace D.C. battery.
low battery voltage.
Frequency trim potentiometer
2. Replace Control Unit.
shorted, grounded or miswired.
3. Replace wiring harness.
Wiring error.
4. Replace control unit.
Defective control unit.
Frequency adjust set too low. 1. Turn Frequency adjust screw
clockwise.
Defective control unit.
2. Replace control unit.
Above 5.1 volts is under
speed signal. Below 5.1
volts is over speed
signal.
On speed will indicate a
steady 5.1 volts.
N
R
8.5 to 9.5 volts D.C. while 1. Battery voltage may be too
low while cranking.
cranking.
(Proportional
actuator voltage).
2. Defective Control Unit.
2.5 volts D.C. maximum
while cranking. (Transister voltage).
1.
2.
3.
1.
2.
Charge D.C. battery; replace
D.C. battery.
Replace Control Unit.
Output transistor open (defec- 1. Replace Control Unit.
tive Control Unit).
2. Replace Actuator.
Defective Actuator.
Error in wiring to Actuator. 3. Replace Wiring Harness.
(6) Measure the center to center distance
between the hole in the fuel shutoff lever and
the hole in the actuator lever. Adjust the
rod ends on the threaded linkage rod so that the
center to center distance of the rod ends is the
same or slightly longer than that measured between
the fuel shutoff lever and the actuator lever.
(The 3.75 dimension is only approximate. If the
linkage is too short, the actuator lever will
attain its “no fuel” position [full clockwise]
before the fuel shutoff lever reaches its “no fuel”
position; the fuel shutoff lever will never reach
“no fuel”. If the linkage is too long, the
actuator lever will reach its “full fuel” position
[full counterclockwise] before the fuel shutoff
lever reaches its “full fuel” position; full load
will not be reached.) It may be necessary to
readjust the position of the fuel shutoff lever
and/or the actuator lever to accommodate the
center to center distance of the rod ends and to
assure complete fuel shutoff and full load operation. Fuel shutoff and actuator lever adjustments
will be covered under replacement procedures.
Tighten the nuts on the linkage rod against the
rod ends to maintain proper spacing.
(9) Adjust the control unit gain control to
its approximate mid-range position.
(10) Adjust the control unit stability
control to its fully counterclockwise position.
(11) Adjust the generator set frequency
adjust potentiometer (pot) (located on the
generator set control panel) to mid-range.
(12) Using a small screwdriver, turn the
control unit frequency adjust screw (located on
the left side vertical face of the control unit)
at least 22 turns counterclockwise (opposite
increase arrow). This will give the lowest
possible engine governed speed.
NOTE
(7) Return the generator set START-RUN-STOP
switch to the STOP position and the BATTLE SHORT
switch to the OFF position.
Two people will be rewired to adjust the
control unit. Ensure that the actuator
linkage rod and all levers are securely
fastened and move freely (without binding)
before operating the engine. Manually
overcome the actuator until adjustment of
the control unit is completed and the
governor is in control. Adjustment of
the control unit will be made with the
engine operating in a no-load condition.
(8) Reconnect the actuator linkage rod end
to the engine fuel shutoff lever.
(13) Start the engine, manually operating the
fuel shutoff lever.
Change
9
7-21
(14) Turn the control unit frequency adjust screw
clockwise until the proper engine speed is obtained.
Several turns may be required. The generator set
frequency adjust pot should now have sufficient adjustment travel to cause the generator set frequency meter
to indicate beyond both of its extreme limits (388-412
Hz).
(15) If the engine is unstable as indicated by continuous movement of the actuator lever, turn the control
unit gain control counterclockwise until stability is obtained as indicated by a stationary actuator lever. Readjust the control unit frequency adjust screw to the
proper engine speed.
(16) Turn the control unit gain control clockwise until the engine becomes just unstable; back the gain control counterclockwise until the engine is again stable.
(17) Turn the control unit stability control
clockwise until the engine becomes just unstable; back
the stability control counterclockwise until the engine is
again stable.
NOTE
The governor is now set to a nominally good
operating point.
(18) Adjust control unit gain, stability and frequency under various load conditions and load changes to
obtain the desired governing characteristics.
(19) When the electric governor system is properly
adjusted, the locknuts on the control unit gain and
stability controls should be tightened.
7-11. ACTUATOR UNIT.
a. Removal.
(1) Disconnect electrical connector P22, (1, figure
7-16).
(2) Disconnect the actuator lever from the actuator
linkage rod by removing the hex head cap screw (2), flatwasher (3), and the self-locking nut (4).
NOTE
It may be necessary to remove the actuator
bracket to gain access to the hardware securing
the actuator to the actuator bracket. If this is
not necessary, proceed to paragraph (3). If
removal is required, then proceed as follows:
(a) Loosen the drive belt of the engine alternator.
(b) Remove the two hex head screws (5) and lock
washers (6) securing the actuator bracket, through
spacers (7), to the engine through the alternator mounting bracket.
(3) Disconnect the actuator from the actuator
bracket by removing two hex head screws (8), flatwashers (9), lock washers (10) and nuts (11).
Remove the actuator.
b. Testing.
(1) Using an ohmmeter, check for continuity between pins A and B and pins C and D. Replace actuator
if there is no continuity.
7-22
Change 10
(2) Check for short circuit between each pin on the
connector and the housing. Replace actuator if any pin is
shorted to case,
c. Installation.
(1) Position the actuator lever (12, figure 4-30.3)
roughly horizontal by loosening the nut on the splined
shaft end of the actuator lever, rotating the lever and
tightening the nut.
(2) Align the actuator with the two holes in the
actuator bracket, secure the actuator to the actuator
bracket with two ¾-inch long hex head screws (8), flatwashers (9), lock washers (10) and nuts (11).
NOTE
If the actuator bracket has not been removed,
proceed with paragraph (3). If the bracket must
be installed, proceed as follows:
(a) Insert the spacers (7) through the alternator
mounting bracket.
(b) Secure the actuator bracket to the engine by
inserting the two 1½-inch long hex head screws (5),
lockwashers (6), into the appropriate holes in the actuator bracket, through the spacers (7) and into the
threaded holes in the engine; tighten the two screws.
(c) Adjust the drive belt of the engine alternator
to the required tension and secure the alternator.
(3) Attach the actuator lever to the actuator
linkage rod with the 1½-inch long hex head cap screw (2),
two flatwashers (3) and the self-locking nut (4).
(4) Connect electrical connector P22 (l).
7-12. ELECTRIC GOVERNOR MAGNETIC PICKUP.
a. Removal.
(1) Disconnect electrical connector P23 (1, figure
7-17).
(2) Loosen locknut (2) and unscrew the threaded
magnetic pickup from the flywheel housing (3). Remove
the magnetic pickup.
b. Testing.
(1) Using an ohmmeter, test for continuity between
pins A and B on the connector.
(2) If the circuit is open discard the magnetic
pickup.
c. Installation.
(1) Rotate the engine until the top land of one gear
tooth is in line with the center of the threaded hole in the
flywheel housing.
(2) Replace the magnetic pickup (3) into the threaded hole in the flywheel housing until the tip contacts the
top of the gear tooth. Back the magnetic pickup out onehalf to three-quarter turn and secure with the locknut (5)
provided.
(3) Connect electrical connector P23 (1),
Figure 7-15.
Governor Control Unit Removal and Installation
Change
9
7-23
7-24
Figure 7-16.
Figure 7-17.
7-25
Figure 7-18.
7-26
Change 9
400 Hz Electric Governor System Wiring
Harness Assembly Drawfing No. 84-704
(Sheet 1 of 2)
CHAPTER 8
RELAY TABLE GROUP REPAIR INSTRUCTIONS
Section I. INTRODUCTION
relay modules for underfrequency, undervoltage, and
permissive paralleling.
8-1. Scope.
a. Section I of this chapter includes a brief description of the assemblies that make up the relay table group, overall functional operation, symptoms of
relay table group malfunction, and relay table group
equipment tests.
b . Subsequent sections of this chapter include
repair instructions for the assemblies which are part
of the relay table group.
8-2. Relay Table Group Description.
a. The relay table and related parts (fig. 8-1)
intrudes the control relay assemblies, the excitation
assembly exciter and the load measuring unit. The
load measuring unit, and the excitation assembly
exciter are common to all modes and classes of sets.
Control relay assemblies include the tactical relay
assembly (used on all sets), precise relay assembly
(used on Mode 1, Class 1 sets), and two different
special relay box assemblies (one used on Mode I
sets and the other used on Mode II sets).
b. The tactical, precise, and special relay box
assemblies contain control relay modules for overvoltage, short circuit, and reverse power on all
sets. Class 1 sets also contain additional control
c. The excitation assembly exciter system provides control of excitation voltage to the main generator to produce voltage buildup in the generator field
coils. The excitation system assembly contains a
voltage regulator that senses the generator output
voltage and uses it as a reference to control field
current in the generator and thus regulate the generator output voltage level.
d. The load measuring unit (LMU) is supplied on
all sets. The LMU provides a dc signal proportional
to the real power (kw) being delivered by the main
generator. Refer to paragraphs 7-1 and 7-2.
8-3. Relay Table Group Symptoms and Isolation of
Malfunction.
Malfunctions in the relay table group will be electrical
in nature, and will affect the generator output voltage,
via the excitation system assembly, and normal systern operation due to a malfunctioning protection relay
in the tactical precise or set special relay box assembly. If the set is in operable condition, the equipment tests listed in table 8-1 can be performed to isolate the malfunction.
Section II. CONTROL RELAY ASSEMBLIES
8-4. Scope
This section includes repair instructions for the tactical relay assembly, precise relay assembly, and
special relay box assemblies.
(a) Remove screws (1) and washers (1A) and
remove cover (2).
8-5. Removal.
leads.
See figure 8-1, unscrew electrical connectors, and
remove the tactical relay assembly (2), precise relay assembly (4), special relay assembly (14), excitation assembly (18), and relay table (52), as required.
(c) Complete disassembly in accordance
with figure 8-2.
(b) Tag and disconnect all wiring harness
(2) See figure 8-3 and disassemble the tactical
relay resistor assembly.
b.
— Precise Relay Box Assembly (Class 1 Sets).
8-6. Disassembly.
NOTE
Tag all electrical connections removed
during disassembly for position identification during reassembly.
a. Tactical Relay Box Assembly.
(1) See figure 8-2 and disassemble the tactical
relay assembly as follows:
(1) On Class 1, Mode 1 Sets, see figure 8-4 to
disassemble the precise relay box assembly.
NOTE
Tag and disconnect all electrical leads
prior to removal of wiring harness (7).
(2) See figure 8-5 for disassembly of the resistor assembly.
Change 7 8-1
Table 8-1. Relay Table Group Equipment Tests
Malfunction
On equipment test
1. Main generator
output too low,
too high, or
failure to
flash.
Separately excite
field with dc
power supply.
2. Generator runs at
less than 130
percent of rated
current for 10
minutes; CB2
drops out and
overload indicater lights.
Place battle
short switch
in on position.
3. Generator runs at
normal voltage,
set shuts down
and overvoltage
indicator lights.
Malfunctioning
assembly
Location
a. Output normal.
a. Excitation
system
assembly.
a. Relay table
group.
b. Output low,
high, or
will not
flash.
b. Generator
assembly.
b. Generator
assembly.
a. Overload
indicator
lights and
CB2 remains
close.
a. Overload
relay.
a. Tactical relay
box.
b. Unit operates
normally.
b. See table 2-2.
b. See table 2-2.
Place battle short switch in on
position; overvoltage indicator
lights but the set does not
shut down.
Overvoltage relay.
Tactical relay
box.
4. Generator runs at
rated voltage,
CB2 drops out
and undervoltage
indicator lights.
Place battle short switch in on
position; undervoltage indicator
lights and CB2 remains
close.
Undervoltage
relay.
Mode I - Precise
relay box.
5. Generator runs at
rated load, CB2
drops out, and
short circuit indicator lights.
None required.
Short circuit
relay.
Tactical relay
box.
6. Generator runs at
rated load, CB2
drops out, and
reverse power
indicator lights.
Place battle short switch in on
position; reverse power indicater lights and CB2
remains close.
Reverse power
relay.
Mode I - Precise
relay box.
7. Generator runs at
rated load, CB2
drops out with no
malfunction indicated.
Place battle short switch in on
position; unit operates nor mally.
Permissive
parallel
relay.
B. Generator runs at
rated frequency,
CB2 drops out,
and underfrequency indicator
lights.
Place battle short switch in on
position; underfrequency indicater lights and CB2
remains close
8-2
Mode 11- Special
relay box.
Mode XI - Special
relay box.
Mode I - Precise
relay box.
Mode II- Special
relay box.
Under frequency
relay.
Mode I - Precise
relay box.
Mode II - Special
relay box.
Table 8-1. Relay Table Group Equipment Tests (Cont)
Malfunctioning
assembly
Malfunction
On equipment test
9 . Paralleling lamps
do not illuminate
when the singleparallel switch
is placed to the
parallel position
when attempting
to parallel two
generators.
Check resistance between connections
19 and 20, 7 and 8 of A5, dc relay
assembly. Resistance should be
7500 ± 5 percent ohms. An infinite
resistance indicates a malfunction.
Dc relay assembly.
Special relay box.
10. Engine generator
set cranks, but
will not start.
Check resistance between A5 connections 21 and 24 with the positive lead or connection 21. The
value indicated will be approximately 500 ohms. Reverse the
leads, the resistance shall be
infinite. An infinite resistance
in both directions indicates a
malfunction.
Dc relay assembly.
Special relay box.
1. Engine-generator
set will not
start.
Check resistance between A5 connections 11 and 10 with the positive lead on connection 11. The
value indicated will be approximately 500 ohms. Reverse the
leads, the resistance shall be
infinite. An infinite resistance
in both directions indicates a
malfunction.
Dc relay assembly.
Special relay box.
Location
Key to Figure 8-1
1. Screw
1A. Screw
1B. Washer
2. Tactical relay box assy
3. Screw
4. Precise relay box assy
Mode I. Class 1 sets only
5. Screw
6. Nut
7. Load measuring unit
8. Screw
9. (Deleted)
10. Screw
11. (Deleted)
12. Terminal lug
12A. Clamp
13. Wrench
14. Special relay box assy
15. Screw
16. Nut
17. Clamp
18. Excitation assy
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Clamp
Screw
Chain
Nut
Screw
Clamp
Nut
Screw
Clamp
Nut
Clamp
Screw
Bracket
Screw
Nut
(Deleted)
Clamp
Screw
Nut
Bracket
Screw
40. Nut
41. Clamp
42. Screw
43. Nut
44. Clamp
45. Screw
46. Nut
47. Clamp
48. Grommet
49. Screw
49A. Washer
50. Nut
51. Washer
52. Table
53. Screw
54. Nut
55. Support bracket
56. Screw
57. Nut
Change 7 8-3
ME 6115-545-34/8-1 C7
Figure 8-1.
8-4 Change 7
Relay Table and Related Parts
1. Screw
1A. Washer
2. Cover
3. Screw
4. Nut
5. Screw
6. Nut
7. Wiring harness
8. Jumper
9.
10.
11.
12.
13.
14.
15.
Screw
Terminal board
Screw
Nut
Resistor assy
Screw
Over voltage
relay module
16. Screw
17. Short circuit
relay module
18. Screw
19. Reverse power
relay module
20. Screw
Figure 8-2. Tactical Relay Box Assembly
21. Overload relay
module
22. Screw
23. Nut
24. Chassis
ME 6115 -545-34/8-2 C7
Change 7 8-5
ME
Figure 8-3. Tactical Relay Resistor Assembly
8-6
6115-545-34/8-3
1. Screw
2. Cover
3. Screw
4. Cover
5. Screw
6. Nut
7. Wiring harness
8. Switch
8A. Washer
9.
10.
11.
12.
13.
14.
15.
16.
Rheostat
Rivet
Plate
Rivet
Plate
Jumper
Screw
Nut
Terminal board
Screw
Nut
Resistor assy
Screw
Under frequency
relay module
23. Screw
17.
18.
19.
20.
21.
22.
Figure 8-4. Precise Relay Box Assembly
24. Permissive
parallel relay module
25. Screw
26. Under voltage
relay module
27. Chassis
ME 6115-545-34/8-4 Cl
Change l 8-7
8-8 Change 1
Figure 8-5. Resistor Assembly (A6)
—c. Special Relay Box Assembly.
(1) See figure 8-6 and disassemble the special
relay box assembly as follows:
(a) Remove screws (1) which secure cover
(44) to housing (79).
(b) Remove screws (1) which secure panel
(2) to housing (79).
(c) Remove screws (11, 14, 16, 18, 20, 22,
24, 26, arid 28) and nuts (12, 15, 17, 19, 21, 23, 25,
27, and 29) which secure wiring harness connectors to,
cover (44) and housing (79), and remove gaskets (31,
32, 33, 34, 35 and 37) and cover (44).
(d) Remove attaching hardware from all
components within the special relay box and remove
wiring harness (30) with components connected.
(c) Set voltage to 120 volts on terminals
1 and 2 and vary the frequency from 50 to 450 Hz.
DS1 should stay lit and DS2 shall remain extinguished.
(d) Slowly increase the voltage to 149 volts.
Vary the frequency from 350 to 450 Hz. DS1 should
stay lit and DS2 shall remain extinguished.
(c) Slowly increase the voltage to 154 volts.
Vary the frequency from 50 to 100 Hz. DS1 should
stay lit and DS2 shall remain extinguished.
(f) Set the frequency at 50 Hz and increase
the voltage to 156 volts. DS1 shall extinguish and
DS2 shall light. Repeat for the frequency at 60, 70
and 100 Hz. After each trip, remove ac power to
clear the relay.
(e) Tag and disconnect wiring harness leads
from components.
(g) Set the frequency at 350 Hz and increase
the voltage to 151 volts. DS1 shall extinguish and DS2
shall light. Repeat for the frequency 400 to 450 Hz.
After each trip, remove ac power to clear the relay.
(2) See figure 8-5 to disassemble the resistor
assembly of the special relay box assembly (Mode II
Sets only).
(h) Terminals 3, 4, 5, and 6, 7, 8 and
terminals–l and 2 shall be electrically isolated.
(4) Test the reverse power relay as follows:
(3) See figure 8-7 to disassemble the dc relay
assembly of the special relay box assembly.
(a) Connect relay as illustrated in figure
8-7. Inspection and Testing.
a. Tactical Relay Box Assembly.
(1) Inspect all components for signs of physical
damage.
(2) Test the short circuit relay as follows:
(a) Connect a light and a 24 Vdc power supply in series with terminals 5 and 6 (DS1), also with
terminals 7 and 8 (DS2). Relay trip will be indicated
by the two lights. DS1 shall extinguish; DS2 shall
light. See figure 8-8 for test setup.
(b) Connect a variable (0 to 120 volts) ac
voltage source (50 to 400 Hz) between terminals 1 and
4 and slowly increase the voltage. The relay shall
transfer lights when voltage equals 24 volts - 1 volt.
Repeat the test with the input connected to 2 and 4, and
then again, between 3 and 4 by moving switch S2. The
trip points should be within 1 volt of each other.
(c) Terminals 5, 6, 7, 8 and terminals 1,
2, 3, 4 shall be electrically isolated with the relay in
either position.
8-10.
(b) With all switches open, energize 5 Vdc
variable power supply and adjust until V1 reads 3
volts .
(c) Position switch S2 to B. Energize 24
Vdc supply and close switches S4, S1, and S5. Lamp
DS2 should light and DS1 should be extinguished.
(d) Energize 0 to 10 Vac power supply and
adjust voltage until V2 indicates 5 volts. Adjust O to
5 Vdc supply to a value less than 1 Vdc shown on V1.
Position switch S2 to A and close switch S3. Raise
voltage of 0 to 5 Vdc power supply until DS2 extinguishes and DS1 lights. DS1 should light when V1
indicates 1 to 3 volts.
(5) Test the overload relay as follows:
(a) Connect the relay in the test setup shown
in figure 8-11.
(b) With the 120/208 Vac power source energized, turn on the 24 Vdc power supply and close switch
S1. Lamp DS1 should light and DS2 should be extinguished.
(3) Test the overvoltage relay as follows.
(a) Connect a variable (0 to 160 volts) ac
voltage source and variable frequency (50 to 450 Hz)
source to terminals 1 and 2. (See fig. 8-9. )
(b) Connect a lamp and 24 Vdc power supply
in series with terminals 3 and 4 (DS1), also with
terminals 7 and 8 (DS2).
(c) Adjust autotransformers T1. T2 and T3
until ammeters Al, A2, and A3 indicate 0.75 ampere.
DS1 and DS2 should not change states.
(d) Adjust autotransformer T1 until ammeter
Al indicates O. 975 ampere. After ± 2 minutes, DS1
and DS2 should transfer states.
Change 1 8-9
Key to fig. 8-6.
1. Screw
2.
Panel
3.
Screw
4. Nut
*5.
Connector assy
*6.
Connector
*6A. Screw
*7.
Chain
8. Screw
9.
Nut
10. Dust cap
11. Screw
12. Nut
13. Dust cap
14. Screw
15. Nut
16.
Screw
17.
Nut
18. Screw
19.
Nut
20. Screw
21• Nut
22. Screw
23.
Nut
24. Screw
25. Nut
26. Screw
27. Nut
28. Screw
29. Nut
30. Wiring harness
31. Gasket
32. Gasket
33. Gasket
34. Gasket
35.
Gasket
36. Gasket
37. Gasket
38. Screw
39.
Nut
- Mode I sets
** - Mode II sets
8-10 Change 1
40.
41.
42.
43.
44.
**45*
**46.
**47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
**71.
72.
**73.
74.
**75.
76.
77.
**78.
79.
Washer
Washer
Nut
Washer
Cover
Rheostat (R28)
Rivet
Plate
Rheostat (R29)
Rivet
Plate
Nut
Screw
Transformer
Screw
Nut
Resistor
Bracket
Nut
Dc relay assy
Jumper
Screw
Terminal board
Screw
Terminal board
Screw
Shunt
Nut
Screw
Relay
Nut
Relay Permissive Parallel
(K16)
Screw
Relay Underfrequency (Kl2)
Screw
Relay Under voltage (Kl1)
Nut
Screw
Resistor assy (A6)
Housing
ME 6115-545-34/8-6(1) Cl
Figure 8-6. Special Relay Box Assembly (Sheet 1 of 2)
Change l 8-11
8-12 Change 7
Figure 8-6. Special Relay Box Assembly (Sheet 2 of 2)
ME 6115-545-34/8-7 Cl
Figure 8-7. DC Relay Assembly (A5)
Change 1 8-13
ME 6115-545-34/8-8 Cl
Figure 8-8. Short Circuit Relay Test Set-up
(e) Repeat paragraph (d) for autotransformers T-2 and T3. The test results should be
the same as for T1. Repeat paragraph (d) for all
3 autotransformers. The test results should be
the same.
(6) Make a point-to-point check of all wiring
and chassis -mounted components. (See schematic
diagrams in Chapter 1.)
8-14 Change 1
b. Precise Relay Box Assembly (Mode I, Class
1 Sets).
(1) Inspect all components for signs of physical damage.
(2) To test the underfrequency relay, see
figure 8-12 and test as follows:
ME 6115-545-34/8-9 C1
Figure 8-9. Overvoltage Relay Test Set-Up
Change l 8-15
8-16 Change 1
ME 6115-545-34/8-10 Cl
Figure 8-10.
Reverse Power Relay Test Set-Up
REF DES
DS1 , DS2
R1, R2, R3
S1
Tl, T2, T3
DESCRIPTION
INDICATOR LIGHT
RESISTOR, FIXED
SWITCH, DC POWER
3 PHASE VARIAC
ME 6115-545-34/8-11 C1
Figure 8-11. Overload Relay Test Set-Up
(a) Connect an external switch across
terminals and 8. Close switch.
(b) Adjust the frequency to 50 Hz and the
input voltage to 120 volts. Relay contacts should
pick up; lamp DSl should light and DS2 should extinguish.
(g) Open switch between terminals 7 and 8,
and adjust input frequency to 60 Hz. Repeat steps
(b) through (f). Drop out should occur at 55 ± 1 Hz;
pick up at 58 + 1 Hz.
(3) To test the undervoltage relay, see figure
8-13 and refer to paragraph 8-7c (4), but adjust
frequency for 50/60 Hz operation.
(c) Lower frequency slowly until relay contacts drop out (lights transfer). Contacts should
drop out at 46 +— 1 Hz.
(4) To test the permissive parallel relay,
perform the procedure in paragraph 8-7c (6), but
adjust frequency for 50/60 Hz operation.
(d) Raise frequency slowly until contacts
pick up (DS1 should light and DS2 should extinguish).
Contacts should pick up at 45 to 49 Hz.
(4a) To test the resistor assembly (A6), refer
to figure 1-7 and proceed as follows:
(e) Raise voltage to 132 volts and check for
drop out lights transfer). Drop out should occur
within + 1 Hz of drop out at 120 volts.
(a) Check the resistance of R4 between
points 1 and 2 on terminal board TB1 06. Resistance
should be 250 ohms.
(f) Lower voltage to 108 volts. Drop out
(lights transfer) should occur within ± 1 Hz of drop
out at 120 volts.
(b) Check the resistance of R5 between
points 3 and 4 on terminal board TB106. Resistance
should be 250 ohms.
Change 1 8-17
REF DES
DS1, DS2
F
S1
DESCRIPTION
INDICATOR LIGHT
FREQUENCY METER, 0-400 Hz
SWITCH
Figure 8-12. Underfrequency Relay Test Set-Up
(c) Check capacitor Cl between points 5 and
6 on terminal board TB106. Capacitance should be 60
uf.
(d) Replace components found to be defective.
(4b) Test the total resistance of rheostat (R28).
Total resistance should be 15,000 ohms + 10%. Test
resistance between wiper arm and either–end of
rheostat. Resistance should vary between 0 and
15,000 Ohms.
(5) Make a point-to-point check of all wiring
and chassis mounted components.
c. Special Relay Assembly.
(1) Check all components for signs of physical
damage.
(2) To test the crank relay (K3), apply 24-28
Vdc across the two small terminals and check for
continuity across the two large terminals.
(3) See figure 8-12 and connect the underfrequency relay (Kl2) (Mode II Sets) as shown.
Test as follows:
8-18 Change 1
ME 6115-545-34/8-12 C1
(a) Adjust the frequency to 400 Hz and the
input votage to 120 volts. Relay contacts should
“pick up”; lamp DSl should light and DS2 should
extinguish.
(b) Lower frequency slowly until relay contacts drop-out (lights transfer). Contacts should
drop out at 370 + 5 Hz.
(c) Raise frequency slowly until contacts
pick up. DSl should light and DS2 should extinguish.
Contacts should pick up at 370 to 395 Hz.
(d) Raise voltage to 132 volts and check
drop out (lights transfer). Drop out should occur
within ± 1 cycle of drop out at 120 volts.
(4) To test the undervoltage relay (Kll),
(Mode XI) connect the relay in a test circuit as illustrated in figure 8-13, and proceed as follows:
(a) Adjust ac power supply to 120 volts,
400 Hz. Lamp DSl should extinguish and DS 2
should light.
(b) Reduce voltage slowly to 104 volts and
hold for 2 minutes. Lamp DS1 and DS2 shall maintain states.
ME 6115-545-34/8-13 Cl
Figure 8-13.
Undervoltage Relay Test Set-Up
(c) In one step, reduce voltage to 99 volts.
DSl and DS2 shall transfer states within 4 to 8
seconds.
(d) Increase voltage slowly to l13 volts.
Lamps DSl and DS2 shall transfer states.
(e) In one step, lower voltage to 48 volts.
Transfer of states of DSl and DS2 shall be instantaneouss.
(f) Reduce frequency to 50 Hz and repeat
the procedures in paragraphs (a) through (f)— with the
same results.
(5) TO test the DC relay assembly (A5),
connect the dc relay assembly in a test circuit as
illustrated in figure 8-13A and proceed as follows:
(a) Connect 120 VAC, 400 hertz supply
across terminals 18 and 22 of dc relay assembly and
close Sl switch. Measure resistance between terminals 7 and 8 and 19 and 20. Measured resistance
should be 2500 ohms for both measurements. If this
reading is not obtained check for defective resistors
R3, R7, R8, defective rectifier CR4 or defective
relay K7.
(b) Remove power from assembly and
measure resistance between terminals 19 and 20,
and 7 and 8 of dc relay assembly. Resistance
should be 7500 ohms for both measurements. If this
reading is not obtained check for defective relay K7.
(c) Check continuity. between terminals 11
and 10 and 21 and 23. (Ohmmeter + lead placed on
terminals 11 and 21). There should be continuity.
If there is no continuity check for defective diode
CR3 or CR6.
Change 1 8-18A
Figure 8-13A. DC Relay Assembly (A5) Test Setup
(d) Connect 24 vdc across terminal 6 (+)
and 15 (—) and close S2 switch. There shouldn‘t be continuity between terminals 4 and 16, and there should be
continuity between terminals 5 and 17. If this is not obtained, check for defective relay K8.
(e) Remove 24 vdc from terminals 6 and 15
and connect across terminals 13 and 15 and close S3
switch. Measured voltage between terminals 3 and 15
should be 24 vdc; zero between terminals 3 and 13. Continuity should exist between terminals 1 and 14 and 2
and 15. If these readings are not obtained, check for
defective relay K5.
8-18B
Change 10
(6) TO test the permissive parallel relay (K16) (Mode
11 Sets), see figure 8-14 and test as follows:
(a) Apply 24 vdc to terminals 3 (+) and 4
(–).
(b) Apply 20 volts, 400 Hz across terminals
1 and 2.
(c) Normally open contacts 5 and 6, and
normally closed contacts 7 and 8 must transfer.
(d) Slowly decrease the voltage at terminals
1 and 2. The relay must reset when the voltage is
8 ± vo1t ac.
(7) To test the current transformer, proceed
as follows:
(a) Connect an ohmmeter across terminals
1 and 2, and across 3 and 4. In each case, the
resistance must be 0.34 ohms ± 10 percent.
(b) Apply 15 Vac to terminals 1 and 2 with
secondary open circuit. The existing current must
be less than 0.24 ampere.
(c) Apply 15 Vac to terminals 1 and 2 with
secondary-Open circuit. The voltage across terminals 3 and 4 must be 15 volts ac ± 1 percent.
(7a) Test the total resistance of rheostat
(R28), (Mode II). Total resistance should be
15,000 ohms ± 10%. Test resistance between wiper
arm and either end of rheostat. Resistance should
vary between 0 and 15,000 ohms.
(7b) Test the total resistance of rheostat
(R29). Total resistance should be 12 ohms. Test
resistance between wiper arm and either end of
rheostat. Resistance should vary between 0 and
12 ohms.
(7c) To test resistor assembly (A6) (Mode II)
refer to paragraph (4a) and proceed as instructed.
(7d) Check resistance of resistor (R31). Resistance should be 10 ohms.
Change 1 8-19
ME 6115-545-34/8-14 C1
Figure 8-14. Permissive Parallel Relay Test Set-Up
(7e) To test shunt (R13), apply 20 amperes
to input of shunt and measure output with a millivoltmeter. Output should be 50 millivolts.
(8) Make a point-to-point check of all wiring
and chassis mounted components. (See schematic
diagrams in Chapter 1.)
8-8. Repair, Reassembly, and Installation.
a. Repair.
(1) Replace any relay found to be defective
during testing.
(2) Replace all defective diodes, resistors,
and transformers.
8-20 Change 1
(3) If any connections are opened or bared
for test purposes, or if any defective components
are replaced the effected area and component must
be coated with polyurethane resin to prevent oxidation or other corrosion. The coating must be of a
minimum thickness of 0.007 inches and air bubble
entry into the applied polyurethane must be controlled so that the legibility of component coding
and identification is not impaired.
(4) Replace defective connectors.
(5) Repair or rebuild wiring harnesses as
required. See wiring schematics in Chapter 1 and
wiring harness diagrams in Chapter 5.
(3) See figures 8-2 and 8-3 to reassemble the
tactical relay assembly. Rewire relay resistor
assembly as shown in figure 8-3.
b . Reassembly.
(1) See figure 8-6 and 8-7 and paragraph 8-69
and reassemble the special relay box assemblies in
reverse order of disassembly. The dc relay assembly
will be coated in accordance with the requirements of
paragraph 3-3c(5).
(2) See figures 8-4 and 8-5 to reassemble the
precise relay assembly.
c. Installation.
(1) See figure 8-1 and install special relay
box, precise, and tactical relay assemblies on the
relay table.
(2) See figure 8-1 and install relay table.
Section III. EXCITATION SYSTEM ASSEMBLY
Key to fig. 8-15.
8-9. Scope.
This section contains repair and adjustment instructions for the excitation assembly exciter.
8-10. Removal.
See figure 8-1 and remove the excitation assembly
exciter (18) as follows:
—a. Unscrew the two electrical connectors.
b. Remove screws (19) which secure exciter (18)
to relay table (52).
8-11. Disassembly.
NOTE
Tag all electrical leads removed during
disassembly for positive identification
during reassembly.
a. Excitation Assembly Exciter. To disassemble
excitation assembly exciter. See figure 8-15 and
proceed as follows:
(1) Remove screws (1) which secure cover (2)
to chassis (3) and remove cover.
(2) Remove screws (4) which secure harness
connector to chassis (3).
(3) Unscrew connector from voltage regulator
(8).
(4) Remove screw (9) and clamp (10).
5 ) Tag and disconnect all electrical leads and
remove wiring harness (6).
(6) Remove semiconductors (11, 12 and 13).
(7) Remove heatsinks (18, 19, and 24) by
removing associated hardware (14 thru 17 and 20
thru 23) and remove insulators (25 and 26).
(8) Remove resistors (29, 30 and 31) by removing screws (27) and washers (28).
1. Screw
1A. Washer
2. Cover
3. Chassis
3A. Screw
4. Screw
5. Nut
6. Wire harness assy
7. Screw
8. Voltage regulator (A10)
9. Screw
10. Clamp
11. Semiconductor
12. Semiconductor
13. Semiconductor
14. Screw
15. Nut
16. Screw
17. Washer
18. Heats ink
19. Heatsink
2 00 S c r e w
21. Nut
22. Screw
23. Washer
24. Heatsink
25. Insulator
26. Insulator
27. Screw
28. Washer
29. Resistor
30. Resistor
31. Resistor
32. Screw
33. Bracket
34. Bracket
35. Screw
36. Terminal block
37. Screw
38. Transformer
39. Screw
40. Electronic component assy
41. Spacer
42. Bracket
43. Screw
44. Screw
45. Filter
Change 7 8-21
ME 6115-545-34/8-15
Figure 8-15. Excitation System Assembly
8-22
Change 7
C7
(9) Remove screws (32) which secure brackets
(33 and 34) to chassis (3) and remove brackets.
(3) Check A201 RFI filter by disconnecting
filter leads and checking resistance across terminals
1 and 1A, and across terminals 2 and 2A. Resistance should be less than two ohms.
(10) Remove screws (35) which secure terminal
board (36) to chassis (3) and remove terminal board.
(4) Check SCR (Q205) as follows:
(11) Remove screws (37) which secure transformer (38) to chassis (3) and remove transformer.
(a) Disconnect lead from terminal 1 of
voltage regulator circuit card assembly.
(12) Remove screws (39) which secure electronic
component assembly (40) to bracket (42) and remove
electronic component assembly and spacers (41).
(b) Set ohmmeter to RI scale. Connect meter
positive lead to stud of SCR and negative lead to large
terminal of SCR. Ohmmeter should indicate open circuit. Reverse leads.
(13) Remove screws (43) which secure brackets
(42) to chassis (3) and remove brackets.
(14) Remove screws (44) which secure filter
(45) to chassis (3) and remove filter.
(c) Short small terminal (gate) of SCR to
ground. Ohmmeter, connected as in (b), should
read between 10 and 40 ohms.
b. Voltage Regulator. See figure 8-16 to disassemble the voltage regulator.
(5) Check voltage regulator and electronic
component circuit board assemblies as follows:
c. Voltage Regulator Printed Circuit Board Assembly: See figure 8-17 to disassemble the voltage regulator printed circuit board assembly.
(a) Interconnect excitation system assembly
to test setup as shown in figure 8-19.
(b) Adjust variac for 70 volt ac input indication on ac voltmeter. Dc voltmeter should read
approximately 25 volts.
d. Electronic Component Assembly. See figure
8-13 to disassemble the electronic component
assembly.
(c) Increase ac input to 80 volts. Dc voltmeter should increase proportionally and read
approximately 30 volts.
8-12. Inspection and Testing,
a.. Inspection.
Proceed as follows:
(d) Increase ac input gradually. At approximately 95 volts input, dc voltmeter should drop to
zero (indicating zero field voltage output). If dc voltage does not drop to zero, replace both the electronic
component and voltage regulator circuit boards and
repeat steps (a), (b), (c), and (d).
(1) Inspect the complete assembly and all components for signs of physical damage.
(2) Inspect electrical components for signs of
overheating.
b. Testing. See figure 1-8 and proceed as follows:
(6) See figure 1-8 and check the 50/60 Hz
electronic component assembly as follows:
(1) Disconnect diodes CR201 through CR206
from heat sinks and test each diodes per paragraph
14-10.
(2) Refer to table 8-2. Disconnect one side of
each resistor, and use ohmmeter to check resistance.
(a) Connect one end of a 1000 ohm 1/2 watt
carbon resistor to terminal 4.
Table 8-2. Excitation Assembly Resistor Values
Reference
Designation
R201
R202
R203
R204
R205
R206
R207
R208
R209
R210
R211
R212
R213
R214
Mode 11 Sets
Mode I Sets
(50/60 Hz) (ohms) (400 Hz) (ohms)
220
2000
100
3300
680
100
1000
1000
1000
2700
50000
10000
3000
5000
220
2000
100
3300
680
100
1000
1000
1000
2700
50000
10000
3000
5000
Reference
Designation
-
R215
R216
R217
R218
R219
R220
R221
R222
R223
R224
R225
R226
R227
Mode II Sets
Mode I Sets
(50/60 Hz) (ohms) (400 Hz) (ohms)
150
1000
1000
5100
15
5000
30
30
30
0.5
300
100
120
150
1000
1000
5100
6.8
5000
30
30
30
0.5
300
100
120
Change 6
8-23
ME 6115-545-34/8-16 Cl
Figure 8-16. Voltage Regulator
8-24 Change 1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Transistor
Transistor
Semiconductor
Semiconductor
Semiconductor
Resistor
Capacitor
Capacitor
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Resistor
Resistor
Resistor
Transistor
Transistor
Resist or
Transformer
Resistor
(Deleted)
Transipad
Transipad
Screw
Washer
Nut
Terminal board
Printed circuit board
ME 6115-545-34/8-17 C7
Figure 8-17. Voltage Regulator Printed Circuit Board Assembly
Change 7 8-25
1.
2.
3.
4.
5.
6.
7.
8.
Screw
Nut
Washer
Terminal block
Semiconductor
Resistor
Resistor
Semiconductor
9.
10.
11.
12.
13.
14.
15.
Transistor
Pad
Capacitor
Clip
Eyelet
Capacitor
Resistor
16.
17.
18.
18A.
18B.
18C.
19.
Resistor
Resistor
Capacitor
Capacitor
Clip
Eyelet
Printed circuit board
ME 6115-545-34/8-18 Cl
Figure 8-18.
Electronic Component Assembly
(b) Connect the positive output terminal (4)
of a variable 24 Vdc power supply to the other end
of the resistor. Connect the negative (-) terminal
of the power supply to terminal 3.
(e) Slowly raise the ac power supply to
37 volts rms. The dc voltage at terminals 3 and 4
shall drop sharply to below 1 volt.
(c) Connect a variable 100 Vac power subply to terminals 1 and 2.
(f) For the 400 Hz electronic component
assembly, repeat steps (a) thru (e) using a 400 Hz
variable ac power supply.
10 volts.
(d) Adjust the dc power supply voltage to
8-26 Change 1
ME 6115-545-34/8-19
Figure 8-19. Excitation Assembly System Test Set-Up
8-13.
Repair. Reassembly and Installation.
a.
— Repair.
(2) See figure 8-16 and 8-17 to reassemble the
voltage regulator assembly.
(1) Relay circuit board assemblies found to be
defective during testing.
(3) See figure 8-15 and refer to paragraph 8-11,
and reassemble the excitation system assembly in
reverse order of disassembly,
(2) Replace all defective diodes, resistors, and
transformers.
c. Installation. See figure 8-1 and refer to paragragh 8-10 to install the excitation system assembly.
(3) Replace defective connectors.
(4) Repair or rebuilt wiring harnesses as required. See wiring schematics in Chapter 1 and
wiring harness diagrams in Chapter 5.
b . Reassembly.
(1) See figure 8-18 to reassemble the electronic
component assembly.
8-14. Adjustments.
After the excitation system assembly is reinstalled,
perform the following operational adjustments:
—a. Voltage Adjustment
(1) With Voltage Adjust control on generator
control panel set at approximately midpoint, start
generator set.
8-27
TM 5-6115-545-34
(2) Adjust Set Point (R212) control to obtain rated
voltage at generator output terminals.
b. Stability. Adjust R207 for optimum stability.
—
(2) Perform checks in accordance with paragraph 16-11.
e. Equipment Test. If the excitation assembly has been
replaced, repaired or adjusted refer to Chapter 16, Section II and
conduct the following tests.
c. Gain. Adjust R211 for 14K ohms nominal.
(1) Regulation range test. Refer to paragraph 16-14.
d. Parallel Adjustment Procedures - Reactive Load
Sharing.
(2) Frequency and voltage regulation, stability and transient
response test, short term. Refer to paragraph 16-15.
(1) Connect an external load bank capable of loading
the generator set to full load at 0.8 power factor.
Section IV. LOAD MEASURING UNIT
8-15. Scope.
This section contains repair instructions for the load
measuring unit.
b. With 120 volts on M3, no load on load bank (Rd), and 0
volts indicated on voltmeter (M1), voltmeter (M2) shall indicate 0 to 0.4 Vdc. Resistor RI (17, fig. 8-20), internal to
load measuring unit, may be adjusted to obtain this
reading.
8-16. Removal.
See figure 8-1 and remove the load measuring unit (7) as
follows:
a. Unscrew electrical connector.
b. Remove screws (5) which secure load measuring unit
(7) bottom of relay table (52).
NOTE
Tag all electrical leads removed during
disassembly for positive identification during
reassembly.
See figure 8-20 to disassemble the load measuring unit.
8-18. Testing.
a. Connect load measuring unit in test circuit as illustrated in figure 8-21.
Change 8
d. Select intermediate loads of Rd, and observe that the
—
voltage relationships indicated by Ml and M2 are identical
to the relationships indicated by the graph in figure 8-22.
Adjust R1 to obtain this relationship.
e. Replace a defective load measuring unit, if voltage
relationships do not match the graph.
8-17. Disassembly,
8-28
c. With load on Rd, and 5.6 volts ac indicated on Ml,
voltmeter M2 shall indicate 9.4 to 9.8 Vdc.
8-19. Repair, Reassembly and Installation.
a. Repair. Replace load measuring unit that does not
meet testing requirements.
b.
— Reassembly. See figure 8-20 and reassemble the load
measuring unit.
c. Installation. See figure 8-1 and install the load measuring unit (7) on relay table (52) with screws (5).
ME 6115-545-34/8-20 Cl
Figure 8-20.
Load Measuring Unit Disassembly
Change l 8 - 2 9
TEST EQUIPMENT
REF
DESIGNATION
QUANTITY
DESCRIPTION
Ga
1
Ta, Tb, Tc
3
Ra, Rb, Rc
3
Load resistors 7.5 ohms, 10 watts
Rd
1
Load bank
Ml
1
Voltmeter 0-10 Vac
M2
1
Voltmeter 0-50 Vdc
M3
1
Voltmeter 0-300 Vac
Power source 208 V, 3 phase, 47-430 Hz
* Current transformers
* Shall be designed to deliver 0-5. 6 volts as load is varied from
zero to full load.
ME 6115-545-34/8-21
Figure 8-21. Load Measuring Unit Test, Schematic Diagram
8-30
TM 5-6115-545-34
INSTRUCTIONAL GUIDE FOR THE MIL. DESIGN GOVERNOR
Figure 8-22.
Load Measuring Unit Test, Voltage Relationship Graph
Change 8 8-31/(8-32 blank)
CHAPTER 9
GENERATOR ASSEMBLY REPAIR INSTRUCTIONS
9-1. General.
a. The main generator is a brushless type consisting of a stationary three-phase armature and a
rotating salient pole wound field. The exciter,
mounted integrally with the main generator, consists of a three-phase rotating armature mounted on
the shaft with the generator field and a stationary
salient pole field. The exciter has ten poles.
b. A full wave bridge rectifier containing six
diodes is mounted on the shaft. Access to test or
replace the rectifiers is through the access hole on
the end of the endbell assembly. Access to the exciter stator and rotor, and inspection of the main
generator armature and field, require disassembly
of the generator.
c. The generator shaft is directly driven by the
engine shaft through flexible metal disk coupling.
The flexible coupling compensates for misalignment
between the two shafts to eliminate injurious stress
on the connecting components.
d. The main generator stator is installed in the
stator frame and is fastened to and spaced by longitudinal ribs which are part of the frame. An eye
bolt on the stator frame provides a means of lifting
the unit. The exciter stator is mounted in an endbell which positions on the stator frame rabbit.
e. The rotor is supported at one end by a single
healing in an endbell bolted to the stator frame. The
opposite end of the rotor is provided with a blower
assembly and coupling disk which bolts directly to
the engine flywheel. The rotor is skewed to improve
generator output voltage waveform.
f. The bearing is a double-seal type ball bearing,
packed with grease conforming to Specification MILG-23827. It provides a minimum of 5000 hours of
service at continuous loads.
9-2. Generator Removal and Disassembly.
a. Insulation Resistance. To test insulation resistance, use a megohmmeter to measure the resistance
between a winding and ground. The insulation resistance of each of the windings should be at least 1 megohm at 75°F. If this value is not met, clean or dry
out the winding and repeat the test. Replace if defective.
NOTE
Low insulation resistance may be caused
by dirt or excessive moisture. Insulation
failure may be caused by wrong voltages,
induced voltages caused by opening field
circuits too quickly, oil and grease, high
temperatures or excessive vibration.
(1) Generator Stator- Disconnect all leads to
voltage regulator and all other points to completey
isolate the winding before meggering.
(2) Generator Rotor - Disconnect both field
leads from the rotating diode assembly before meggering.
(3) Exciter Stator - Disconnect both field leads
from terminals 15 and 16 of TB16.
(4) Exciter Rotor - Check this only if other
windings have low insulation resistance as the leads
must be unsoldered from all diodes before meggering.
b. Electrical Malfunctions and Isolation. A malfunction of the main generator is usually indicated
by low output voltage, or no voltage output. To isolate a malfunction to the main generator, proceed as
follows:
(1) Tag and disconnect the two top leads on
terminals 15 and 16 of TB16 (located on the current
transformer mounting plate). Connect one side of
a dc ammeter to one of the terminals (15 or 16) and
an adjustable dc voltage source to the other terminal
and the dc ammeter. The adjustment shouId be set
to mint mum voltage.
(2) If the set is a 50/60 Hz set, select 60 Hz
and start the engine. Bring the speed up to 1800 rpm
manually and turn on the adjustable dc power supply.
Adjust the dc voltage so that the output voltage (no
load) reads 208 or 416 volts (depending on low or high
voltage connection). The dc ammeter should read between 1.25 and 1.55 amperes to produce either 208
or 416 volts.
(3) If the set is a 400 Hz set, start the engine
and bring it up to 2000 rpm. Turn on the adjustable
dc power supply. Adjust the dc voltage so that the
output voltage (no load) reads 208 or 416 volts, (depending on low or high voltage connection). The dc
ammeter should read between 3.0 and 3.65 amperes
to produce either 208 or 416 volts.
(4) If the dc ammeter indicates incorrect input exciter current to obtain rated voltage in steps
(2) or (3) above, the generator has failed. Proceed
with the following steps. If the output is as specified, the excitation system assembly has failed (refer to paragraph 8-1). The following steps are presented to enable isolation of the fault within the generator. Only steps (5), (6) and (7) would normally
be done without some disassembly of the generator.
(5) Remove six bolts securing air intake grille
and remove griIle. Remove screws, cover plate,
and gasket from generator endbell. See figure 9-1.
Remove bolts from the six diodes on the exciter
rotor frame, one at a time, replacing each diode
after testing. Test diodes per paragraph 14-12b.
9-1
9-2
Figure 9-1. AC Generator Assembly
Key to fig. 9-1.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Screw
Nut
Screw
Washer
Clamp assy
Screw
Screw
Plate
Gasket
Screw
Cover
Gasket
Screw
Cover
Gasket
Screw
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Washer
Screen
Screw
Washer
Screw
Washer
Exciter assy
Screw
Clamp
Pin
Stator
Screw
Plate
Shield
Screw
Retainer
If any defective diodes are replaced, repeat step (2)
or (3) above to determine if the generator defect has
been corrected.
(6) Tag and disconnect the two top leads at pins
15 and 16 of TB16 (located on the current transformer
mount plate). Read the exciter field resistance at
pins 15 and 16 with a Wheatstone bridge. The exciter
field resistance should be between 2.90 and 3.55 ohms
at an ambient temperature of 65°F.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
Bearing
Cap
Screw
Washer
Washer
Cover
Gasket
Screen
Screw
Strip
Ring
Disc
Disc
Fan
Screw
Washer
49.
50.
51.
52.
53•
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
Deflector
Rotor assy
Hub
Key
Plate
Nut
Washer
Rectifier assy
Washer
Key
Rotor
Plate
Rotor
Screw
Plate
Eyebolt
Frame and
stator assy
On a 50/60 Hz generator, the resistance should be
0.0216 to 0.0264 ohm in each circuit. On a 400 Hz
set, the resistance value should be 0.0141 to 0.0173
ohm in each circuit, at ambient temperature of
65° F.
(14) Connect all stator leads together and read
between the leads and the generator frame with a
megger (para 9-2a).
(15) Growler test
(7) Check insulation resistance with megger between pins 15 and 16 and the frame (para 9-2a). Reconnect the two leads and remove tags. Before proceeding further with fault isolation, disassemble the
endbell from the generator.
(8) Disconnect generator rotor leads from the
rotating diode assembly and measure the field resistance with a Wheatstone bridge. The resistance
value for a 50/60 Hz generator should be 0.38 to
0.46 ohms and 1.17 to 1.43 ohms for a 400 Hz generator at an ambient temperature of 65°F.
(a) Perform internal growler test on stator
by applying 110 Vac to the coil which is wound on the
cross bar of the H.
(b) Place the growler on the coil of the stator so that it is in direct contact with two adjacent
slots.
(c) A shorted coil produces a very heavy
current which is indicated by the rapid vibration of
a thin piece of metal, such as a hacksaw blade, held
over the other end of the coil.
(9) Megger between field leads and frame (para
9-2a).
(10) Disconnect diodes and use a double Kelvin
bridge to read the resistance between leads on the
exciter rotor. On a 400 Hz set, this value is 0.042
to 0.051 ohm and on a 50/60 Hz set, this value is
0.019 to 0.023 ohm at a 65°F ambient temperature.
(d) Perform a growler test on the rotor as
described in (a) above.
(e) Place the rotor on the growler and energize.
(11) Check insulation resistance with megger
between exciter armature !eads and frame (para 9-2a).
(f) Hold a thin piece of metal, such as a
hacksaw made, directly over the top slot of the rotor
and along the length of the slot. If the coil is shorted,
the blade will vibrate rapidly and cause a growling
noise.
(12) Check resistance of surge protector (varistor) when disconnected from one side of generator
field. Value should be 1 megohm or more in each
direction. Check to be sure no physical damage is
evident on the surge protector.
(16) If the above test values are not within the
limits specified, proceed with the removal and repair procedures.
(13) Tag and disconnect the twelve stator leads
at the voltage reconnection panel and measure each
of the six stator windings with a Kelvin double bridge.
c. Defective Bearing Replacement. If a defective
bearing is indicated by vibration or noise at the bearing housing on the endbell, the bearing can be replaced without removal of the generator from the set.
Change 6
9-3
d . Removal of Bearing with Generator Installed.
(1) Disconnect the positive battery cable.
(2) Remove paralleling receptacle panel.
(a) Disconnect the paralleling receptacles.
(b) Tag each receptacle for proper location.
(3) Remove manual speed control panel.
(a) Disconnect flexible cable from manual
speed control knob.
(b) Disconnect electrical connector from
the Remote Control Box.
(4) Generator rear grille and access doors are
now detached and may be removed.
(5) Remove transformer protective cover.
(6) Remove the load terminal board (TB6).
(7) Sequentially remove and tag each of the
twelve generator leads on the rear of the load terminal board.
(8) Sequentially route the generator output
leads back to the generator through their respective
current transformers. (See fig. 6-2)
(9) Disconnect the exciter field leads from
TB16 posts 15 and 16 and route the leads back to the
generator.
(10) For removal of bearing, refer to f steps
(1) through (4) inclusive.
(11) Reassemble in reverse order of disassembly.
e. Removal. Refer to paragraph 2-12 to remove
main generator.
f . Disassembly. See figure 9-1 and disassemble
in the order of sequence numbers observing the following.
(1) Break endbell fit by tapping on knock off
lugs located in the 45 degree positions. Slide endbell
axially off the bearing. Pass stator leads through
endbell opening as endbell is removed from the stator.
(2) The exciter stator maybe removed from
the endbell assembly by removing or drilling out the
dowel pin (26). only a small force is needed to remove the stator.
(3) Remove screw with an Allen wrench and
9-4
then remove bearing retainer.
(4) Pull the bearing (33) with a suitable bearing puller and replace with new bearing.
(5) To remove the rotating diode assembly,
bend up the lock tab on lockwasher and unscrew the
locknut.
(6) Unscrew the generator field leads from the
plate (8), (fig. 9-2) and unsolder the six exciter
leads from the diodes. These leads should be tagged
to maintain the polarity of the diodes when reassembled.
CAUTION
Use a soldering iron no larger than 100
watts and as little time and force as possible to unsolder the leads. The diodes
can be damaged by excess heat or force
sufficient to bend the stem or break the
glass seal.
(7) The surge protector may be removed from
the rotating diode assembly.
(8) After the leads are disconnected, the rec
tifier assembly (fig. 9-2), key and spring washer
will slide off the shaft.
(9) To remove the rotor assembly from the
stator proceed as follows: Slide the rotor through the
stator toward the drive end far enough so that a sling
may be placed under the generator field core. Hoist
the rotor slightly to free it. Pull the rotor axially
while applying leverage at the drive end to balance
the rotor on the sling. It may take one or two repositioning of the sling to get the sling near the center
of the rotor core for proper balancing of the assembly,
(10) The exciter rotor may be removed from
the shaft by using a bearing puller near the outside
diameter. Be careful not to bear on windings if exciter rotor is to be reused.
(11) Balance plates are shrunk on the shaft
and may be removed with heat. Apply heat with a
torch to the hub of the balance plate. Move the torch
around the periphery of the hub using care not to
apply the torch to the shaft. The balance plate bore
will expand and the balance plate may be removed
manually.
(12) The coupling hub is
To remove, use a cutting torch
at the keyway to prevent shaft
through, use a chisel in the cut
remove the hub.
shrunk fit on the shaft.
to cut through the hub
damage. After cutting
to open the bore and
(13) The generator stator core is not to be removed from the stat or frame because the concentricity between bore and rabbit fits would be disturbed
and cause voltage modulation problems. When removing the rotor stack from the shaft, remove in the
direction, that the stack was pressed on.
1.
2.
3.
4.
5.
6.
7.
8.
Nut
Washer
Rectifier
Rectifier
(Deleted)
Washer
Surge protector
Plate
ME 6115-545-34/9-2 C1
Figure 9-2. Rectifier Assembly
9-3. Generator Cleaning and Inspection.
a. Cleaning. Clean all metal parts with Federal
Specification P-D-680 and dry thoroughly. Uses
clean cloth to clean the stator frame. Use low pressure compressed air (10 to 15 pounds pressure) to
remove dust and dirt from inside the frame and core,
and from the rotor windings.
b. Inspection. Proceed as follows
(1) Inspect stator frame for cracks and burred
mating surfaces.
(2) Inspect rotor and stator of generator and
exciter for loose, frayed, or burned windings.
(3) Inspect coupling disks and fan for distortion and excessive wear.
(4) Inspect for missing or defective hardware.
(5) Inspect rotating diode assembly for broken
diode cases. Test diodes per paragraph 14-10.
9-4. Generator Repair and Rebuild.
a. Generator Repair. Proceed as follows:
(1) Replace or rebuild all defective parts (refer to paragraph 9-2d for disassembly information.)
To remove coils from an iron core, it is recommended that the part be heated in a moderate oven
temperature (1500 C) to facilitate removal. Single
coils should not be replaced as adjacent parts of
the winding may be damaged during coil removal.
(2) Apply varnish to any damaged areas of
insulation.
(3) Replace damaged exciter rotor or stator.
b. Generator Rebuilding (50/60 Hz). Proceed as
follows:
(1) Stator winding procedures.
(a) Single wires may be spliced by brazing.
The splice is to be insulated by sliding sleeving over
the wire prior to brazing and relocating the sleeving
over the splice after completion. The sleeving is
to extend a minimum of 1/2-inch beyond the bare uninsulated portion of wire. The sleeting material i S
to be the same as that used for cross-overs on the
connection end. Splices shall be made in the end
turn of the coil only and shall not be made in the
straight leg. Where more than one splice is required, the second splice must not occur on the same
coil end and must not occur in adjacent coils. Where
more than one splice is necessary in the same coil
or an adjacent coil, the splice may be made in the
connection end of the coil.
Change 1 9-5
(b) Enamel is to be cleaned from coil extensions. Cleaning is to start as near sleeving as
possible. Clean a 1/2-inch section of wire end projecting from a sleeving. Maximum uncleaned wire
projecting from a sleeving section shall be 3 inches
minimum to 5 inches maximum. Wire diameter is
to be reduced a maximum of 5 percent. Cleaned
area shall have enamel removed over 80 percent of
the surface.
(c) Slot tubes should be inserted with overhang equally divided on ends. Minimum slot tube
overhang (distance from core to end of slut tube)
shall be 1/4 inch. Position of the tubes should be
adjusted so that height of sides is equal. (fig. 9-3)
(d) After the slot tubes have been inserted,
insulating tape shall be placed into the stator to
form a bridge between slot tubes. It will be placed
so as to bridge every other tooth in the stator core
in one continuous length by stringing it through one
slot, crossing over at the end of the slot to the next
slot, back through and on to the third slot, continuing until it is back at the starting point. The starting and finish ends shall be securely tied together.
This bridge is to restrain the end turn tie cord.
(e) Coils shall be inserted in slots so that
overhanging ends are equally spaced. Wire bundles
at entrance to slot should be brought out as straight
and compactly as possible to reduce side pull on overhanging slot tube ends.
(f) Care should be taken to see that wire insulation is not scratched or otherwise damaged. Coil
wires should not be kinked or crossed in the slots.
Tools inserted into slots to adjust position of wires
or separators should be free from burrs or sharp
edges to prevent damage to wire or slot insulation.
If it is necessary to use a mallet when tamping down
wires or separators in slots, tap the slot tools lightly. Heavy pounding will ruin the insulation.
(g) After bottom coil sides are in the slots,
the separators are wedged in place with their overhanging ends equally spaced. These ends should project approximately 1-1/2 inches from edge of core.
The separators should fit tightly enough to hold the
coils down in the slots.
(h) Phase insulating strips are placed in the
end turns to insulate between the coil groups on both
ends of the winding. These strips should be placed so
that the back edge reaches the ends of the wedges approximately 1/2 inch from core. The strips will then
overlap the ends of the separators. After coil ends
are properly shaped, trim phase insulating strips all
around so that 1/16 to 1/4 inch of edge projects beyond edge of wires. Phase insulating strips may extend 1/2 inch beyond wire on coil outer diameters.
(i) Top sticks shall be carefully inserted so
that slot fibes and wire are not damaged. The overhanging ends should be equal and they should be level.
Top sticks which are broken or split during insertion
should be replaced.
9-6
Change 4
(j) Connections shall be twisted together
and brazed using brazing alloy. The distance from
the first twist to the film coating on the wire must
not exceed 1-1/2 inches. End of connection forming
pigtail shall be fusion welded as much as possible
with addition of alloy. When coil pole leads and ends
consist of multiple wires, care must be taken to insure that each wire is securely connected. All sharp
wire ends or spikes of solder remaining on brazed
joints should be trimmed off or flattened down to prevent puncturing of insulation tape.
(k) When connectors are used instead of
brazing connections, wire must extend completely
through the connector. The connector should be located as close to the insulated portion of the wire as
is possible. Connectors must be applied using a
wire crimping tool -- crimping is not to be done using pliers, hammers or other make-shift arrangements.
(1) Sleeving must be positioned to cover the
coil extension from the coil to which it is attached to
a point at least 1/2 inch under two layers of tape.
The sleeving at the coil end must be positioned to
provide a minimum of 3/8-inch creepage path from
the coil extension to adjacent coils.
(m) All connections in stator winding shall
be covered-with sleeving, MIL-I-3190/3. Where tape
is wide enough to cover the uninsulated wire and extend
a minimum of 1/2 inch over insulated portion of wire,
wrap one layer of tape over the connection, pressing
the two adhesive sides together for approximately
1/4 inch. The remaining length of tape should be
long enough to make two or more wraps over the connection. The connection and any uninsulated part of
the wires adjacent to the connection will be covered
with three thicknesses of tape.
(n) Where the tape is not wide enough to
provide coverage for the connection, the tape shall
be wrapped around the connection such as to provide
l/2-inch lap plus 1/8 inch (minimum). The overlap
is to be such as to provide a minimum of two layers
of tape. The double layer of tape is to extend a minimum of 1/2 inch over the insulated portion of wire.
(o) Stator windings will be tied on lead end
Only. Use a hitch or chain stitch tie. Spacing between ties is not to exceed 3 inches. A tie must be
made over each connection. Tie on either side of
cable bundle will be a double lace. Tie must pass
through space between coils bridged by tape specified
under tie cord bracing ( (d)
— above).
(P) End turns on opposite lead side will not
be tied. However, the string ties, placed on the individual coils during coil winding operation, will be
left on untaped coil after insertion, to help keep
wires from being displaced.
(q) Refer to table 9-1 for winding data.
(2) Stator dip and bake (50/60 Hz).
Table 9-1. Stator Winding Data (50/60 Hz)
Type of winding
3 phase, dual voltage
No. of slots and coils
84 slots 84 coils
No. of coils per group
7
Turns per coil
4
Span
1-15
Conductor
6 of AWG #15 (0. 0571 dia)
Connection
4.2 ckt, (See fig. 9-3)
Resistance
0.026 ohm at 25° (T1-T4, etc.)
(a) Preheat wound core for 1 1/2 hours (2
hours maximum) in forced convection oven maintained at 170° C.
(b) Cool core down to a temperature of 1050
to 115° C and dip at this temperature-into varnish,
connection end up, until all bubbling stops, or for 3
minutes, whichever is longer.
(c) Remove wound core and drain connection
end up for four minutes.
(e) With the rotor body turning on the machine, guide the wire into the slots for the specified
number of turns. Hold the wire with enough tension
on the tension blocks to assure a hard firm winding.
Traverse the wire at the end turns and not in the
slot, as much as possible. This prevents excessive
build up of the wire in the slot.
(f) Place one spacer tool at the end of stack
and another in the approximate middle of the winding.
(d) Rotate wound core so connection end is
down and drain for one minute.
(g) Place winding clamp in position over
stud and force into position so that nut can be tightened over end of stud.
(e) Bake wound core with slots in horizontal
position for 2 hours in forced convection oven maintained at 170° C.
(h) Connect poles and leads per connection
diagram. See figure 9-4. Use cold connectors and
insulate with tubing.
(f) Repeat steps b, C , d, e and f two times
so that a total of three dips and bakes are performed.
(g) The wound stator should be examined
for complete coverage, uniform coverage with no
strings or beads and with openings between extended
position of slot tubes, free of varnish, blistering or
peeling, and complete cure with tack-free surface
and good bonding strength.
(i) Tie the end turns with glass roving.
(j) Seal all knots by momentarily pressing
with “hot” pliers long enough to fuse the roving.
Heat pliers in gas flame to “Black Heat” about
300° F.
(k)
— Refer to table 9-2 for winding data.
(4) Rotor dip and bake.
(3) Rotor coil winding.
(a) Inspect winding slots for any sharp corners at edge and in slot. Clean up as necessary.
(b) Screw support studs into tapped holes
at bottom on slots. See figure 9-4.
(c) Examine the bore and determine the
direction in which it was removed. Place the leads
on the end where the shaft left the bore. This is so
the shaft can be pressed thru the bore in the direction it was removed. The center of the rotor stack
must be located 11.48 inches from the hub end of
the shaft.
wound.
(a) Preback wound core for one hour in
forced convection oven at 165° C.
(b) Dip hot wound core in varnish for one
minute with leads up.
(c) Remove wound core and drain for three
minutes with leads up.
(d) Rotate wound core with leads down and
drain for one minute.
(d) Insert slot liners as the poles are
Hold in place with sacrifice adhesive tape.
9-11
Table 9-2. Rotor Winding Data (50/60 Hz)
Resistance
0.390 ohms at 25° C
Connection
1 circuit (refer to fig. 9-4)
Conductor
9 of AWG #16 (0.0508)
Turns per coil
103
No. of poles and coils
4
(e) Reverse wound core so leads are horizontal and bake for one hour in forced convection
over at 165° C.
bore. This is so the shaft will be pressed through
the bore in the same direction as the broach.
(f) Repeat steps b, c, d, and e two times
so that a total of three dips and takes are performed.
(c) Insert slot liners (3) in the slots and
position with equal overhang of the core on each end.
See figure 9-6.
(g) The varnished wound rotor core should
be examined for complete coverage, uniform coverage with no strings or beads and with openings between extended position of slot tubes free of varnish,
blistering or peeling, and complete cure, with tackfree surface and good bonding strength.
(d) Insert the coils in the usual manner.
Position the coils as evenly as possible on each end.
Consult the coil limit diagram to be sure that the
two ends are adjusted to allow room for the connections, which must be within the coil limit diagram.
c. Generator Rebuilding (400 Hz). Proceed as
follows:
(1) Stator coil winding procedures. See figure
9-5 and table 9-3, and perform the procedures provided in step b (1).
(2) Stator dip and bake. Perform the procedure
defined in step b (2).
(3) Rotor coil winding.
(a) Inspect winding slots for any sharp corners at edge and in slot. Clean up as necessary.
(b) Examine bore and determine the direction in which the broach passed through the bore.
Place the leads on the end where the broach left the
(e) Insert tapered edge top stick and drive
into position.
(f) Make interpole and lead connections as
required by internal connection diagram. See figure 9-6.
(g) Over each end, turn-wrap 20 turns of
double glass roving to provide banding support of
end turns.
(h) With double roving, loop over the banding and connnections and run on continuous piece of
double roving over all 24 coil ends. Burn all knots
with red hot duck bill pliers.
(i) Refer to table 9-4 for 400 Hz rotor
winding data.
Table 9-3. Stator Winding Data (400 Hz)
9-12
Type of winding
3 phase, dual voltage
No. Of slots and coils
108 slots 108 coils
No. of coils per group
36 groups of 2 and 36 groups of 1
Turns per coil
5
Span
1-4
Conductor
AWG #16 (0.0508) and AWG #17 (0.0453)
Connection
12/6 ckt, (see fig. 9-5)
Resistance
0.017 ohm at 25° C (T1-T4, etc.)
9-17
Figure 9-5. Stator Winding and Coil Connection (400 Hz)
(Sheet 2 of 2)
Table 9-4. Rotor Winding Data (400 Hz)
Resistance
1.43 ohms at 25° C
Connection
1 ckt, series, see schematic diagram
Conductor
4 of AWG #15 (0.0571)
Turns per coil
30
No. of pole and coils
24
(4) Rotor dip and bake.
(a)
— Preheat wound core for one hour in
forced convection oven to 170° C.
(1) Replace or rebuild any defective parts.
(2) Apply varnish to any damaged areas of
insulation.
(b) Dip hot wound core in varnish, connection end up, for three minutes.
(c) Remove wound core from varnish and
drain, connection end up, for four minutes.
—b. Rebuild.
(1) Exciter stator. See figure 9-7 and table
9-5, and perform the procedures provided in paragraph 9-4 (1) and (2).
(2) Exciter rotor.
(d) Rotate wound core so connection end is
down and drain one minute.
(e) Bake wound core with slots in horizontal position for two and one-half hours, at 170° C,
in forced convection oven.
(f) Repeat paragraphs (b) through (e) above
two more times so that a total of 3 dips and bakes is
applied.
Proceed as follows
(a) All wound cores will have leads connected and tied on the inside diameter of end turns.
(b) All connections will be brazed using
brazing alloy per MIL-S-15395 as a filler material.
End connections forming pigtails will be fusion
welded as much as possible with addition of brazing
alloy per above.
(g) The varnished wound rotor should be
examined for complete coverage, uniform coverage
with no strings or bends and with openings between
extended position of slot tubes free of varnish, blistering or peeling, and complete cure, with tack-free
surface and good bonding strength.
(c) All connections in the rotor winding
will be covered with sleeving MIL-I-3190/3. Tape
should be 1/2-inch lapped over connections and extended 3/8- inch beyond connection.
9-5.
(e) The rotor end turns and connections
are bound and laced in two stages.
Exciter Repair and Rebuild.
(d) For binding end turns use glass roving.
a. Repair.
Table 9-5. Exciter Stator Winding Data (50/60 and 400 Hz)
9-18
Type of winding
Salient pole, dc
No. of slots and coils
10 slots 10 coils
No. of coils per group
1
Turns per coil
196
Span
1-2
Conductor
1 of AWG #21 (0. 0285) 1 of AWG #22 (0. 0253)
Resistance
3.2 ohms at 25° C
Connection
2 circuit (see fig. 9-7)
Change 4
(f) Using a zig-zag motion, place a band
of one continuous piece over and near the end of the
end turns. Using enough spread to keep the band
below the line of the rotor outer diameter, secure
the end by lapping over the end. Binding must not be
loose.
lent. Do not allow the lubricant on the threads of
the diode or the torque measurements will be incorrect.
CAUTION
There are three forward polarity diodes
(arrow towards threaded stud) and three
reverse polarity diodes (arrow away from
threaded stud). The diodes must be assembled with the three forward polarity
diodes on one heat sink and the three reverse polarity diodes on the other heat
sink. Assemble the diodes with nuts and
lockwashers, using a torque wrench.
Assemble with 30 inch pounds of torque.
(g) After all coils are inserted and bound
as in (a) above, lace continuously using at least two
turns at each location with a slip tie on the second
turn. Lace at each tooth, separating the top coils
and the bottom coils.
(h) Place the connection bundle beneath the
end turns and lace as in (g), being sure to lace in
the connection bundle.
(i) Refer to table 9-6 and figure 9-8 for
exciter rotor winding data.
9-6. Generator Reassembly and Installation.
(4) Use balance weights assembled in holes of
balance plate to dynamically balance complete rotor
assembly within 2 inch-ounces.
a. Reassembly. See figure 9-1 to reassemble
the ac generator.
(5) Tighten screw (41) to 950-1100 inchpounds and bend up corners of strips (42) against a
flat side of screw (41).
(1) Balance plates should be shrunk on the
shaft. Heat balance plates in an oven to approximately 200° C. Place heated balance plate on shaft
and with a pipe or sleeve with a bore slightly larger
than the balance plate bore, tap the balance plate
onto the shaft until it registers against the shaft
shoulder.
(6) At assembly apply light coating of grease
(MIL-G23827) to the bearing bore of the end
shield. Also add 0.9 to 1/4 cu. in. (1.0-1.5
tablespoons) of grease to the bearing cavity on the
outboard side of the bearing and 0.45 to 0.7 cu. in.
(0.5 to 0.75 tablespoons) of grease to the bearing
cavity on the inboard side of the bearing.
(2) The coupling hub is reassembled to the
rotor assembly by placing the hub in an oven and
heating to 200° C. The hot coupling hub then slides
on the shaft and key.
(3) The diodes should be placed on the rotating diode assembly, using a thermal conduction
lubricant such as Burndy “Penetrox A“ or equiva-
b. Installation Refer to paragraph 2-12.
9-7. Generator Tests after Reassembly.
Perform tests 1, 2 and 3 of operating tests (refer to
table 16-1).
Table 9-6. Exciter Rotor Winding Data (50/60 and 400 Hz)
Type of winding
3 phase
No. of slots and coils
36 slots 36 coils
No. of coils per group
6 groups of 2 24 groups of 1
Turns per coil
3 for 50/60 Hz -5 for 400 Hz
Span
1-4
Conductor
5 of AWG #16 (0.0508) - 50/60 H Z
3 of AWG #16 (0.0508) -400 Hz
Connection
Parallel 2 circuit WYE, (see fig. 9-8)
Resistance
0.023 ohm at 25° C - 50/60 Hz
0.050 ohm at 25° C -400 Hz
Insertion sequence
211/112/111/121/111 and repeat
Change 4
9-25/(9-26 blank)
CHAPTER 10
DAY TANK ASSEMBLY REPAIR INSTRUCTIONS
10-1. General.
a. The day tank is provided to receive fuel from
the–main fuel tank through the fuel transfer pump and
primary fuel filters and to supply fuel to the fuel injection pump via the secondary fuel filter.
b. The day tank is mounted on a support bracket
above the fuel injection pump on the right side of the
engine. Fuel is transferred by two electric pumps
from the main fuel tank to the day tank.
10-2. Removal.
Refer to the Operator and Organizational Maintenance Manual to remove the day tank.
10-3.
Cleaning, Inspect ion and Repair.
a. Cleaning.
(1) Clean exterior of day tank with cleaning
solvent, Federal Specification P-D-680 and dry
thoroughly.
(2) Remove all gasket and adhesive materials
from mating surfaces.
(3) Flush tank thoroughly with hot water or
steam under pressure. Clean interior with solvent
and dry thoroughly.
b . Inspection
(1) Inspect hardware and thread areas for
damage.
(2) Inspect fuel passages for obstructions.
(3) Inspect interior to insure that scale and
sediment have been removed.
c . Repair.
(1) Repair all threaded areas with a fine
mill file. Retap threaded holes.
(2) Use compressed air to clear fuel
passages.
10.4 Installation.
Refer to the Operator and Organizational Maintenance
Manual.
10-1/(10-2 blank)
CHAPTER 11
LIFTING FRAME REPAIR INSTRUCTIONS
11-1. General.
KEY to Fig. 11-1.
The lifting frame provides center support for the
housing and mounts to lift eye devices for hoisting.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
11-2. Removal and Disassembly.
a. Remove generator set housing and lifting
frame components. Refer to the Operator and Organizational Maintenance Manual.
b. Refer to Operator and Organizational Maintenance Manual and remove the fuel tank to allow removal of bottom bolts holding supports. (30 and
31, fig. 11-1.)
c. Remove and disassemble the lifting frame as
illustrated in figure 11-1.
11-3.
Cleaning and Inspection.
Refer to Operator and Organizational Maintenance
Manual.
a. Clean the lifting frame with cleaning solvent,
Federal Specification P-D-680.
b. Use a stiff bristled brush to remove heavily
concentrated grease and dirt.
c. Inspect the lifting frame for cracks and distortion.
11-4.
Repair.
Repair the lifting frame by replacement of damaged
parts. (fig. 11-1.)
11-5.
Nut
Washer
Screw
Bracket
Nut
Washer
Screw
Washer
Bracket
Nut
Washer
Screw
Nut
Washer
Screw
Nut
Washer
Screw
Bracket
Bracket
Screw
Washer
Nut
Washer
Screw
Washer
Washer
Washer
Nut
support
support
Rivet
Plate
Reassembly and Installation.
Reassemble and install lifting frame in reverse order
of disassembly. (fig. 11-1.)
11-1
ME 6115 545-34/11-1 C7
Figure 11-1. Lifting Frame Assembly
11-2
Change 7
CHAPTER 12
COOLING GROUP REPAIR INSTRUCTIONS
12-1. General.
a. The cooling group consists of the radiator
grille, shutter assembly and the shutter thermostat.
C . Shut the engine down. Examine the pulley
belts for tension. If they are tight examine the
fan for bent or broken blades and freedom of
motion.
b. The radiator is mounted at the front end of the
engine generator set just behind the grille and shutter
assembly. It is equipped with inlet and outlet hose
connections, a filler cap and an overflow tube. A
drain valve is located on the lower right side of the
radiator. A shroud and fan guard are mounted on
each side behind the radiator, enclosing the fan.
d. When it is determined that there has been a
failure of the radiator, fan, or shutter assembly,
remove the radiator, grille, shutter assembly,
shroud and fan guard. (Refer to the Operator and
Organizational Maintainance Manual).
c. The radiator shutter is mounted on the front
of the radiator. The shutter control is mounted on
the lower right side of the radiator and operates by
thermal expansion. A plunger inside the thermostat,
which is affected by temperature in the radiator,
actuates the linkage system to the shutter. The
shutter will remain closed until the engine warms up,
at which time it will open upon action of the shutter
control. A control lever is provided for manual
operation of the shutter control in case of thermostat
failure.
a. Clean all parts with cleaning solvent Federal
specification P-D-680 and dry thoroughly with
compressed air at 10 to 15 pounds pressure.
d. The fan is located behind the radiator on the
front of the engine. Driven by belts when the engine
is running the fan draws cooling air through the doors
at the rear of the unit and exhausts it through the
radiator core, shutter and grille.
12-3. Radiator and Shutter Repair and Test.
b. Inspect all hardware and threaded areas for
damaged or crossed threads.
c. Inspect shutter control body for damage and
proper operation.
d. Repair control assembly and shutter assembly
by Emplacement of defective parts. (See figures 12-1
and 12-2).
e. Using compressed air, remove all dirt and
foreign material from the radiator core.
(1) Solder or braze any radiator core leaks.
12-2. Radiator Assembly Removal.
(2) Straighten bent cooling fins.
A malfunction of the radiator, shutter assembly or
thermostat is usually indicated by an abnormally high
reading on the coolant temperature gauge located on
the engine control panel. To isolate the cause proceed as follows:
a. If the shutter assembly is closed, operate the
manual control and open it. If the temperature begins
to drop toward normal, the probable cause is a faulty
shutter thermostat. (Refer to the Operator and
Organizational Maintenance Manual).
b. Open the radiator fill cap and check for a suffcient amount of coolant. Add coolant if necessary and
observe temperature gauge for a drop in temperature.
f. Replace all worn, damaged, or defective parts.
g. Test the radiator for leaks by placing the
radiator with outlet connection sealed in a tank of
water. Apply compressed air of 10 to 15 psi at
filler opening and observe for leakage indicated by
air bubbles in the water.
12-4. Radiator Assembly Installation.
Install the fan guard, shroud, radiator, shutter assembly, grille and shutter thermostat. (Refer to the
Operator and Organizational Maintenance Manual. )
12-1
12-2 Change 1
Setscrew
Ring, Retaining
shaft
Yoke and plunger
assy
15. Pin
16. Plunger
17. Bearing
18. Yoke
19. Power element
and flange assy.
Figure 12-1. Control Assembly
Nut
Preformed packing
Retaining ring
Seat
Felt
30.
31.
32.
33.
34.
Seat
Spring
Seat
Bushing
Flange
ME 6115-545-34/12-1 Cl
1.
2.
3.
4.
5.
6.
Spring
Nut
Retaining ring
Rod Assy
Pin
Block
Spring
Rod
Tape
10. Rivet
11. Vane Assy
12. Shutter Assy
ME 6115-545-34/12-2 C1
Figure 12-2. Shutter Assembly
Change 1 12-3(12-4 blank)
CHAPTER 13
HYDRAULIC ACTUATOR, SUMP AND FILTER REPAIR INSTRUCTIONS
Section I. HYDRAULIC ACTUATOR (CLASS I, PRECISE SETS ONLY)
13-1. General.
assembly and repair instructions.
The hydraulic actuator (figures 13-1 and 13-2) is part
of the generator set electro-hydraulic governing
system (para. 7-1 and 7-2) and is used to control the
speed of the generator set. An error voltage sensed
by the governor system control unit is magnetically
amplified to control the power to energize the solenoid of the hydraulic actuator, thus changing the
high pressure input oil into a differential pressure
across the piston. This is accomplished by a solenoid controlled teeter bar within the actuator that
controls the position of the actuator piston.
13-3. Removal and Disassembly.
13-2. Malfunction.
A malfunction of the hydraulic throttle actuator is
usually indicated by engine shutdown or overspeed
when the START- STOP-RUN switch is transferred
from the START to the RUN position, frequency
drift observed on the frequency meters, sluggish
response to load changes, or no response to load
changes. To isolate the malfunction, proceed as
follows
a. Clean all hydraulic fittings and couplings
throughly to prevent contamination of system
b. Remove drain plug on bottom of hydraulic
sump and drain and discard hydraulic oil (Refer to
Operator and Organizational Maintenance Manual for
draining procedures.)
c. Remove hydraulic actuator as illustrated in
figure 13-1.
d. Remove four bolts securing bracket to
activator and remove bracket.
Disassemble actuator as illustrated in figure
13-2
f . To remove connector (34) tag and unsolder all
wires attached to connector.
13-4.
a. Check for 4-6 Vdc at test points AB and CD
(see figures 1-4 and 1-5) of electric governor control
unit (A and D are positive), with engine operating. If
voltage at either point is approximately 15 volts, the
malfunction is a result of an opening in an actuator
valve coil, or connecting circuit.
b. Check that the throttle linkage (see figure 13-1)
is not badly worn or disconnected. A worn linkage
can cause sluggish response or drifting frequency. A
disconnected or broken linkage can cause overspeed,
shutdown, or no response. Also check linkage for
binding due to dirt or distortion.
c. Check condition of hydraulic filter and the level of hydraulic oil. Either a clogged or dirty filter
or low oil level can reduce the hydraulic pressure
required to operate the actuator.
Cleaning, Inspection and Repair.
a. Clean all parts thoroughlv with cleaning
solvent Federal Specification -P-D-680 and dry
thoroughly.
b. Inspect all parts for damage or defective
condition.
co Inspect ball joints and linkage for excessive
wear.
d. Inspect actuator packing and piston for damage;
—e. Replace all defective parts.
13-5.
Reassembly and Installation.
a. Reassemble the hydraulic actuator as illustrated in figure 13-2.
d. Check pressure output of hydraulic actuator
by removing plugs in ports Al and A2 and inserting
0-400 psi range gages. The pressure at each port
should be 160 + 25 psi and equal, with engine operating under governor control. Operating under manual
control, with J6 disconnected, the pressure at port
A2 should be 180 + 20 psi and approximately 50 psi
higher than the pressure at port Al.
C . When installing connector (13), locate keyway
at 12 o’clock position. (See figure 13-2.)
e. Check the transducer in the actuator far freedom of movement. The transducer must move freely
for good response.
d. When installing connector (34), locate keyway
at 6 o’clock position, viewed from top of valve block
(48). (See figure 13-2.)
f. If any of the above examinations indicates that
the–actuator has failed, proceed with removal, dis-
13-6. Actuator Valve and Piston Test.
b. Install set screw (37) in core assemblv (40)
finger tight. Then install locknut (36). Proceed
with care.
13-1
1.
2.
3.
4.
5.
6.
7.
8.
Nut
Screw
Rod end
Nut
Rod
Nut
Screw
Nut
9.
10.
11.
12.
13.
14.
15.
16.
Rod end
Clevis
Nut
Screw
Hydraulic actuator
Screw
Washer
Bracket
ME 6115-545-34/13-1
Figure 13-1. Hydraulic Actuator and Related Parts
13-2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Screw
Washer
Cover
Gasket
Setscrew
screw
Washer
Plate
Setscrew
Screw
11.
13.
14.
15.
16.
17.
18.
19.
20.
Washer
Spacer
Connector
Transducer assembly
Core
Retaining ring
Washer
Packing
Collar
Quad-ring
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Piston
Retaining ring
Washer
Packing
Collar
Quad-ring
Pin
Filter plug assy
Packing
Plug
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
Packing
Screw
Washer
Connector
Gasket
Nut
Setscrew
Screw
Washer
Core armature assembly
41.
42.
43.
44.
45.
46.
47.
48.
Valve
Restrictor
Packing
Valve
Spacer
Restrictor
Packing
Block
ME 6115-545-34/13-2
Figure 13-2. Hydraulic Actuator
13-3
a. See figure 13-3 to perform the valve and piston
test.
b. Connect dc power supply (ps) and switch (S1)
to J6 as illustrated. Connect voltmeter (Ml) with
resistor (Rl) to pins A and B of J4.
e. When final adjustment is made, lock the transducer core in place with the transducer core set
screw.
f. Remove the gages, meter, and power supplies.
13-8. Installation.
c. Attach gage G1 and G2 as shown. Connect hydraulic power source (310-320 psi, 2 gpm) and gage
G3 and provide a return line from port R to the
hydraulic sump.
d. To adjust the valves, remove the large round
cover and replace it with a similar diameter collar
which will allow access to the adjustment screws and
jam nuts. This is necessary to contain the hydraulic
fluid which is ported within this cover.
e. With hydraulic power but no electric power,
applied, adjust the valve with Allen set screw to
yield 200 psi - 10 psi at Al port (gage Gl) and 150 psi
+ 10 psi at A2 port (gage G2). (See figure 13-3.)
CAUTION Avoid overadjusting to prevent pressures or forces which could bend valve push rods.
f. After adjusting, lock Allen adjusting screws
with jam nuts, and install cover.
g. Set S1 to the center position (solenoid coils in
series). Apply 350 ± 20 ma through the coils. Pressures at Al and A2 ports shall remain the same
(para 13-6.e).
h. Set switch Sl to connect power (PS) to coil L2
and apply 700 ma ± 40 ma. Pressure at Al port
(gage Gl) shall be 310 to 400 psi. pressure at A2
port (gage G2) shall be 0 to 20 psi.
i . Set switch Sl to connect power (PS) to coil L1
and apply 700 ma ± 40 ma. Pressure at Al port
(gage Gl) shall be 0 to 40 psi and pressure at A2
port (gage G2) shall be 310 to 400 psi.
a. Install the hydraulic actuator with attaching
hardware. (fig. 13-1.)
b. Connect hydraulic pressure and return lines to
the–actuator pressure and return parts. Different
line sizes prevent inadvertent crossing of lines.
(fig. 13-2. )
C . Connect electrical connectors J24 and J25.
Electrical connectors cannot be interchanged due to
differing number of pins. (fig. 13-2.)
d. Attach rod-ends, shaft and clevis.
Adjust the linkage in accordance with para.
13-9
13-9.
Throttle Linkage Adjustment.
a. Place the Stop-Run-Start switch in the RUN
position. (DO NOT - start the set.)
b. Place the battle short switch in the OVERRIDE or UP position.
c. Remove the bolt connecting the linkage rod to
the fuel injection pump shut-off arm.
d. Starting at the full counter clockwise position,
move the fuel injection pump shut -off arm clockwise
until a slight resistance is felt. When this resistance
is felt, hold the shut-off arm in that position.
NOTE
13-7. Throttle Position Transducer Test.
a. With voltmeter (Ml), resistor (Rl) and 120
(+ 1%, 60 Hz) power source connected as shown in
figure 13-3, move piston to fully open throttle position.
b. With the transducer body locked in place by
its set screw, loosen the transducer core set screw
and move the core relative to the body until a minimum voltage (0, 5 to 2.5 volts) is obtained on the
transducer secondary, as indicated on Ml.
c. Move the piston gradually towards the fully
closed throttle position. The transducer secondary
voltage, indicated by meter Ml shall increase in a
linear manner to a maximum of 48 to 55 volts.
d. Repeat these adjustments until the transducer
secondary voltage increases linearly from the lowest possible value to a maximum value over the
entire 1.0 inch displacement of the piston.
13-4
This resistance is the fuel injection
pump linkage coming into contact
with the arm which moves the metering valve and starts in the direction of no fuel.
e. Move the actuator piston to the full OPEN
(DOWN) position.
f. Make the necessary adjustment to the linkage rod, such that it will fit between the actuator
piston and the fuel injection pump shut-off arm.
g. Start the generator set. Refer to the Operator
and Organizational Maintenance Manual.
h. Observe the frequency meter on the panel in
the control cubicle.
Figure 13-3. Hydraulic Actuator Tests, Schematic Diagram
Change 1 13-5
i. Adjust the governor in accordance with
para. 7-8.
j. (Delete)
Section II. HYDRAULIC SUMP AND FILTER (CLASS 1, PRECISE SETS ONLY)
13-10. General.
b. Repair cracks by welding.
a. The hydraulic sump is mounted on the left side
of the engine, on Class 1 precise generator sets.
The sump acts as a reservoir for the hydraulic oil
pump, used to supply hydraulic power to the hydraulic throttle actuator.
c. Replace all defective parts.
d. Replace a defective filter.
13-13. Equipment Test.
b. The hydraulic oil filter is mounted on the
sump and provides predection against contaminant in
the hydraulic oil pressure system.
If the electro-hydraulic actuator has been renewed
or repaired, refer to Chapter 16, Section II and
conduct the following tests.
13-11. Removal, Cleaning and Inspection.
Refer to the Operator and Organizational Maintenance
Manual.
a. Frequency and voltage regulation, stability,
and transient response test, short term. (para
16-15. )
13-12. Repairs.
a. Repair threaded holes by retapping.
13-6 Change 1
b. Frequency adjustment range test.
16-16.)
(para
CHAPTER 14
ENGINE ASSEMBLY AND COMPONENTS REPAIR INSTRUCTIONS
Section I. ENGINE ASSEMBLY
14-1. General.
The engine assembly provides the mechanical
power to drive the main generator. It consists of
a six-cylinder, turbocharged, diesel engine; batterycharging alternator, speed switch, electric starter
and fuel pump. In addition, on precise generator
sets, a hydraulic pump is provided. Maintenance
instructions for the components of the engine assembly
are provided in Sections II through XVII.
14-2. Removal.
Refer to paragraph 2-13 and remove the engine assembly, if required for the repair action to be taken.
de-energized, crank the engine until oil pressure appears on the oil pressure gauge. Crank the engine
an additional 15 seconds to insure 061 is in all parts
of the lube oil system.
(3) Recheck oil level and top off lube oil sump.
d. Engine Oerational Check
(1) With the dynamometer throttle set to the
idle position and the fuel injection pump solenoid
energized, crank the engine until the engine starts.
(2) Allow the engine to run at idle for 30
seconds, shut down engine and inspect for signs of
leakage.
14-3. Disassembly.
a. Place engine assembly on an engine stand utilizing engine stand adapter plate and spacers.
b. Disassemble the engine to the extent required
by following procedures given in Sections 11 through
XVII.
14-4. Inspection and Repair.
Inspect and repair engine assembly assemblies,
subassemblies, and components as described in
Sections II through XVII.
(3) Restart engine and allow to run at low idle
for 10 minutes.
NOTE
Monitor oil pressure and coolant temperature at all times during this test,
also check for unusual noise or vibrations. If at any time the oil pressure
falls below 20 psi, the coolant temperature exceeds 222° F, or if noise or
vibrations occur, discontinue test run.
14-5. Reassembly.
(4) Operate engine at 1800 rpm at 1/2 load for
30 minutes.
Reassemble the engine assembly by following the
procedures provided in Sections II through XVII.
(5) Operate the engine at 1800 rpm at full rated
load for 1 hour.
14-6. Testing.
(6) Check to see that the engine will produce
the following brake horsepower.
a. Service engine lube oil and fuel systems with
proper oil and fuel. (Refer to Operator and Organizational Maintenance Manual.)
b. Connect engine assembly to a suitable engine
dynamometer equipped with a cooling system and
means of monitoring engine oil pressure, coolant
temperature, and engine rpm.
c. Pre-run Checks.
(1) Manually turn engine over a minimum of
two revolutions and check for binding and mechanical
interference. Correct cause of any binding or interference prior to starting.
1500 rpm 1800 rpm 2000 rpm -
100 bhp
120 bhp
130 bhp
(7) Operate the engine with no load for five
minutes at 1800 rpm.
(8) Shut down and inspect engine for coolant,
oil and leaks.
14-7. Installation.
Refer to paragraph 2-14 and install the engine assembly in the generator set.
(2) With the fuel injection pump solenoid
Change 6
14-1
Section II. BATTERY CHARGING ALTERNATOR
14-8. General.
(5) Shut down the engine-generator set and disconnect the test equipment.
a. The 28 volt, 35 ampere battery charging alternator system is specifically designed for applications
which require enclosed brush and slip ring construction. All of the aluminum casting and exposed parts
are coated or plated to prevent corrosion. Both front
and rear bearings are sealed and lubricated for life.
b. The brush assembly, enclosed by the rear
housing cover, positions the brushes and provides
the necessary pressure for good electrical contact
with the slip rings. The voltage adjusting rheostat is
a screwdriver adjustment accessible through a hole
in the rear cover of the alternator. Remove battery
charging alternator in accordance with Operator and
Organizational Maintenance Manual.
14-9. On Equipment Test.
a. Rear Cover Removal. With the engine generator get stopped remove the 3 self tapping screws
securing the rear cover of the battery charging
alternator to the alternator housing. Remove the
rear cover plate and leave it suspended by the attached wiring. Remove the 40 ampere fuse from
its receptacle.
CAUTION
Insulate all wiring to the rear cover plate
by inserting insulating material between
the alternator housing and wiring to the
rear cover plate.
b. Voltage Regulator Test Connections. Connect
the test equipment to the alternator as shown in
figure 14-1.
c. Voltage Regulator Test and Adjustment.
—
(1) Start the engine, allow a few minutes for
warm up. Assure that the alternator drive sped is
between 2000 to 3000 rpm. Indicated frequencies
for 50, 60 or 400 Hz will provide the required battery
charging alternator drive speeds for the respective
engine-generator sets.
(2) Observe the test ammeter. A test ammeter
reading in excess of 10 amperes is indicative of low
batteries. If the test ammeter reading exceeds 10
amperes, remove the jumper from the 1/4 ohm 50
watt resistor thereby reducing alternator output current, by its insertion in the circuit.
(3) Observe the test voltmeter. The test
voltmeter should indicate 28.0 Vdc ± .3 V at 75
degrees F.
(4) If the test voltmeter does not indicate the
required voltage, use a small screw driver to adjust
the rheostat on the voltage regulator to raise or
lower the charging voltage.
14-2
d. Alternator Output Test Connections. Connect
the test equipment to the alternator as shown in figure
14-1.
(1) This test will determine if the alternator is
capable of producing its minimum rated output. This
is an evaluation of the rotor, stator and all diodes and
their ability to produce current. While maximum atput depends on alternator temperature, the minimum
acceptable output is used for reference. The charging
system is also tested under partial load to determine
if excessive voltage loss exists between the alternator
and the battery through the circuit conductors.
(2) Start the engine-generator set, run the engine at approximately 750 RPM. If the test ammeter
indicates less than 10 amperes charge, slowly apply
the load across the battery until the ammeter indicates 10 amperes. Let the engine run in this manner for 5 minutes to stabilize component temperatures within the alternator and its integral solid
state regulator.
(3) Note voltage loss incurred by moving the
positive voltmeter lead from the positive output terminal to the battery positive post, with the alternator
producing 10 amperes. If the loss exceeds 0.2 volts,
check for poor connections or undersized conductors,
repair as necessary.
(4) Increase set speed to rated speed (50, 60
or 400 Hz). Increase load on the battery causing
the alternator to deliver its maximum current capacity of 35 amperes indicated on the test ammeter.
(5) Shut down the engine-generator set and disconnect the test equipment.
e. Voltage Protector Test Connections.
—
(1) The voltage protector test configuration is
that which occurs when the rear cover of the battery
charging alternator is removed from the alternator
housing, with the additional connection of the test voltmeter according to polarity, to the positive and negative output terminals.
(2) Start the engine-generator set, adjust the
throttle to obtain rated speed, run a few minutes to
normalize temperature of the charging system, note
the charging voltage.
(3) Remove one cable from, one battery post,
and note the charging voltage.
(4) If the charging voltage without the battery in
the circuit exceeds 31.0 volts, the voltage protector is
defective and must be replaced.
(5) Shut down the engine-generator set. Dis-
Figure 14-1. Voltage Regulator and Alternator Test
14-3
connect the test voltmeter, replace the 40 amplere fuse
and reassemble the rear plate to the housing with 3 self
tapping screws.
The resistance should infinite. Replace voltage regulator
if it fails inspection and/or tests.
14-10. Disassembly, Cleaning and Inspection.
(1) Inspect for excessive wear, broken leads,
dirt and electrical requirements.
a. Disassembly. See figure 14-2 and disassemble
the battery charging alternator as illustrated.
h. BrushAssembly.
(2) Check brush spring tension. Tension
should be 4 to 6 ounces to move brush against spring.
b. Cleaning. Blow out all dirt from inside and wipe
interior and exterior surfaces with a clean dry cloth.
(3) Check assembly for excessive wear.
Replace if 3/16 or less extends beyond bottom.
c. Inspection. Inspect all components of alternator
assembly for heat damage, excessive wear, broken parts,
and corrosion.
(4) Insulation test, point E to A, B, C, D, no
circuit, indicate no short circuit, assembly correct. See
figure 14-4.
(5) Continuity test, point A to B and C to D,
continuous circuit indicates no open circuit, assembly
correct. See figure 14-4.
14-11 Repair.
(1) Inspect bearings for rough motion or
seizure.
(2) Inspect housing for distortion or cracks.
d. Diodes. Inspect diodes. Perform following check
with multimeter.
(1) With multimeter on RXl scale, check
continuity in opposite direction. This check should show
a resistance of less than 20 ohms in one direction and
OPEN CIRCUIT in the reverse direction.
(2) A high resistance or low resistance in both
directions indicates a defective diode. Replace a defective
diode.
a. Diodes. Discard and replace defective diodes.
b. Rotor.
(1) Smooth minor scratches, burrs, and dents
on shaft with fine mill file.
(2) If shaft is bent or rotor is beyond repair,
replace defective battery charging alternator rotor.
c. FieldAssembly.
e. R o t o r .
(1) Inspect rotor shaft for scoring and
distortion.
(2) Test rotor for short circuits using a growler.
(3) Check rotor resistance. Resistance value
shall be 11 to 14 ohms.
f.
Field Assembly
(1) Inspect field assembly case for cracks or
distortion.
(2) Inspect for openings in insulating
materials.
(3) Check resistance with ohmmeter.
Resistance value shall be approximately one ohm.
(4) Minimum insulation resistance (one
terminal to ground) shall be one megohm.
g. Voltage Regulator
(1) Inspect voltage regulator for cracks,
broken leads or other physical damage.
(2) Perform the following tests for the voltage
regulator. See figure 14-3.
(a) Connect the positive lead of an ohmmeter
to the yellow lead of the voltage regulator and check
resistance to the red lead of the voltage regulator. The
correct resistance is 600 to 900 ohms.
(b) Connect the positive lead of an ohmmeter
to the red lead of the voltage regulator and check
resistance to the yellow lead of the voltage regulator.
14-4 Change 11
(1) Repair insulation damage with air-dry
varnish.
(2) Smooth minor scratches, burrs, and dents
on machined surfaces of case with fine mill file.
(3) If field assembly is beyond repair, replace
defective battery charging alternator field assembly.
14-12. Reassembly, Test and Installation.
a. Reassembly. See figure 14–2 and reassemble
battery charging alternator except for cover assembly.
NOTE
After installation of pulley nut, see figure 14-2,
torque nut (item 33) to 40–50 foot pounds.
b. Tests See figure 14–3 and perform the
following tests:
(1) Remove black leads from negative terminal.
(2) Set ohmmeter to RX1 scale. Connect positive lead to regulator positive stud.
(3) Connect negative ohtnmeter lead to
negative stud.
(4) Ohmmeter should indicate 30 to 40 ohms.
(5) Reverse ohmmeter leads. Ohmmeter
should read infinity.
(6) Re–install cover assembly.
c. Installation Refer to the Operator and Organ–
izational Maintenance Manual and install the battery
charging alternator.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
20.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
Screw
Screw
Nut
Nut
Circuit protector
Fuse
Fuseholder
Cover assy
Screw
Housing
Nut
Washer
Sleeve
Diode assy
Screw
Regulator
Electrical lead
Screw
Cover
Brush assy
Washer
Washer
Bolt
Nut
Housing
Sleeve
Washer
Diode assy
Sleeve
Washer
Diode assy
Stator
Nut
Washer
Pulley
Fan
Woodruff key
Spacer
Retainer
Bearing
Housing
Bearing
Rotor assy
Figure 14-2. Alternator Assembly
14-5
ME 6115-545-34/14-3
ME 6115-545-34/14-4
Figure 14-3. Regulator Excitation Test Circuit
Figure 14-4. Two Terminal Brush Assembly
Section III. HYDRALIC PUMP ASSEMBLY
(CLASS 1, PRECISE SETS ONLY)
14-13. General.
The hydraulic pump assembly supplies oil under
pressure to the electro-hydraulic actuator on Class 1
generator sets. The hydraulic pump is located on
the left side of the engine at the rear of the timing
gear housing and is driven by the hydraulic pump
drive assembly. The drive assembly is driven by
the camshaft gear and contains two tapered roller
bearings which are lubricated by engine oil splashed
by other gears in the timing gear train. The pump
assembly is lubricated by circulating hydraulic oil.
14-14. Hydraulic Pump Malfunctions, Removal and
Disassembly.
a. Symptoms and Isolation of Malfunction. A malfunction of the hydraulic sump is usually indicated by
fluctuating frequency observed on the frequency meter
as a result of erratic hydraulic oil pressure, sluggish
response of the actuator to load changes as a result of
low hydraulic oil pressure, or failure of the governor
system due to loss of hydraulic oil pressure. To isolate a malfunction of the hydraulic oil pump, proceed
as follows:
(1) Check hydraulic oil level by observing
sight glass on hydraulic oil sump. Insure that oil
level is sufficient.
(2) Check all hydraulic lines and fittings for
signs of leakage.
14-6
(3) Carefully examine pump and mounting adapter for signs of leakage.
(4) Thoroughly clean area around fitting on
pump for hydraulic line to filter and around drain
valve on hydraulic pump.
(5) Remove drain valve and drain hydraulic
oil.
(6) Insert 0-400 psi gauge between pump and
hydraulic line to throttle actuator.
(7) Refill sump and start engine.
(8) Pressure should be 310 to 330 psi. If the
reading shows erratic pressure or low pressure,
then there is a malfunction of the hydraulic pump
assembly. Proceed to the removal, disassembly and
repair procedures.
b. Removal and Disassembly.
(1) Open left hand area engine door, drain
hydraulic oil pump and discard oil. Thoroughly clean
area around hydraulic oil fittings. Disconnect lines
from hydraulic pump. Remove pump as illustrated
in figure 14-5. Cap all hydraulic fittings when
opened.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Nut
Washer
Nut
Washer
Screw
Screw
Washer
Screw
Washer
Hydraulic pump
Cap
Washer
Gasket
Drive assy
Packing
Screw
Washer
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
Gear
Shaft
Bearing
Spacer
Bearing
Spacer
Bearing race
Bearing race
Housing
Nut
Washer
Nut
Washer
Screw
Plate
Gasket
Adjustment Control Screw
ME 6115-545-34/14-5
Figure 14-5. Hydraulic Pump and Related Parts
14-7
(2) Secure the drive gear in a vise with protective copper jaws. Remove capscrew and washer
securing gear to shaft. The fit of the gear to the
shaft is 0.0017 to 0.0002 inch loose. Remove gear
from shaft. If necessary, use gear puller.
d. Replace all defective parts as required. Bearinga, O-rings, and gaskets must be replaced during
overhaul.
(3) The clearance of the bearing assembly on
the shaft is 0.0000 inch to 0.0013 inch interference
fit and the clearance of the bearing in the housing is
0.000 to 0.002 inch interference fit. The bearing
outer diameter is 1.980 to 1.981 inches.
a. Place drive assembly in a press with the hydraulic pump mounting side down and press rear
bearing race into housing so that it is approximately
1/4 inch below the mounting surface.
(4) Place drive assembly in a press with the
hydraulic pump mounting side down and drive shaft
from the housing,
NOTE
When removing the shaft from the
housing, one cone will remain on the
shaft and the other will fall out. The
bearing races will remain in the
housing.
(5) Remove front bearing cone and cone spacer
from housing.
NOTE
Do not intermix front and rear bearing
cones and races if bearings are to be
reused.
(6) If the bearings require replacement, press
rear bearing cone from shaft.
(7) Using a puller, remove front bearing race
from housing. Remove bearing race separator from
its groove in the housing. Remove rear bearing race
from housing.
14-15. Cleaning, Inspection, and Repair.
a. Wash all parts in cleaning solvent, Federal
Specification P-D-680.
b. Inspect hydraulic pump drive gear and replace
if gear is worn, scored, chipped, or has broken
teeth.
c. Replace bearings if races or rollers are worn,
pitted, or scored. Bearings must be replaced when
rebuilding pump.
NOTE
The tapered bearings must be replaced
as an assembly. The assembly consists of the bearing cones, cone spacer,
races and race spacer. The spacers
are factory selected to give the proper
end clearance.
14-8
14-16. Reassembly, Installation, and Adjustment.
b. Position bearing race spacer in housing next
to the rear race. Slowly press both the spacer and
bearing race into the housing until the spacer snaps
into place.
c. Press the front bearing race in the housing
until it contacts the race spacer.
d. Press the rear bearing cone onto the shaft
until it contacts the shoulder.
e. Install the shaft into the housing from the hydraulic pump side.
f. Position the cone spacer on the shaft.
g. Press the front bearing cone onto the shaft.
h. Install gear on shaft with washer and capscrew.
i. Lubricate bearings with engine oil. Tighten
capscrew to 95-105 foot-pounds. Strike both ends of
the shaft with a soft-headed hammer. Again tighten
the capscrew to 95-105 foot-pounds. Shaft and bearings should turn freely when spun by hand.
—j. The mounted end play is 0.001 to 0. 013 inch.
k. Install hydraulic oil pump on hydraulic pump
adapter with three screws and lock washer.
l. Use a new 0-ring and install the hydraulic
pump adapter and drive assembly and pump to the
front support plate with lock washer, nuts and bolts;
tighten the nuts securely.
m. Connect oil return line to pump.
NOTE
To facilitate assembly and prevent
galling, coat all mating and bore
surfaces of bearing with clean engine oil, or other suitable lubricant.
n. Connect a 0-400 PSI gauge with tee to the output
of the hydraulic pump.
o. Connect hydraulic oil line between filter and
pressure gauge.
p. Fill hydraulic system with hydraulic oil MILH-5606.
q. Start the engine. (Refer to Operator and
Organizational Maintenance Manual).
Remove the hex cap (11, fig. 14-5) and washer
(12) located on top of the pump housing, and adjust the
slotted adjustment control screw (34) to obtain a
pressure of 320 ± 10 psi.
s. Replace hex cap, shut down engine, drain hy–
draulic system, remove pressure gauge, connect
hydraulic output line to pump, and refill system with
hydraulic oil, MIL-H-5606.
Section IV. SPEED SWITCH, TACHOMETER DRIVE AND ADAPTER
14-17. General.
a. The speed switch, driven by the camshaft
through a tachometer drive assembly and an angle
adapter, provides sequenced control of circuits during
engine startup and protection against engine overspeed
during operation. Three sets of contact elements, S9–1,
S9-2, and S9–3, contained in the speed switch, are set
to open, close, or transfer by centrifugal force at certain
engine speeds. The speed switch drive gear is designed
to drive the speed switch at one–half engine speed
b. At an engine speed of 580 to 620 rpm (accelerating) element S9–1 transfers two sets of contacts,
energizing the field flash circuit and de-energizing the
crank relay to stop the starting motor.
On Class 1 sets, when the engine reaches the
speed range of 1180 to 1220 rpm (Mode I); 1650 to 1700
rpm (Mode H) element S9–2 closes, energizing the
electro-hydraulic governor which takes over control of
engine speed.
d. Speed switch element S9-3 consists of two sets
of contacts which are set to transfer at an engine speed
of 2425 ± 25 rpm to shut down the engine and prevent
damage to the equipment. Shutdown is achieved by
de-energizing the stop-run relay and the fuel solenoid,
cutting off fuel to the engine.
2. Elements S9–1 and S9–2 reset at 100 rpm (decreasing) below actuation speed. Element S9–3 is
manually reset by a pushbutton on the speed switch
housing.
14–18. Speed Switch Removal.
Refer to Operator and Organizational Maintenance
Manual for removal of the speed switch.
14-19. Speed Switch Tests, Adjustment, Repair and
Installation.
a. Connect a variable speed drive device to the
speed switch drive. The drive device must have a
tachometer in order to determine the speed of the device
in rpm’s.
b. With an ohmmeter on the R1 scale, reading
from the speed switch connector, check for the contact
conditions of elements S9–1, S9-2, and S9-3 illustrated
in figure 14-6.
c. When contact conditions are verified, as shown
in figure 14-6, start variable drive and gradually
increase speed, with ohmmeter connected to pins B and
A. At a speed of 300 ± 15 rpm, the ohmmeter should
indicate that contact A–B opens. Hold the variable
speed drive at that speed and transfer the ohmmeter
leads to pins A and C. The ohmmeter should indicate a
closed contact.
d. Leave the ohmmeter leads connected to pins A
and C and gradually reduce speed. In the range of 190
to 210 rpm, the contacts of element S9–1 should reset to
the condition illustrated in figure 14–6. To verify
operation of element S9-1 contacts A and C, increase
drive speed gradually and observe that the contacts
close at 300 ± 15 rpm range.
e. Connect ohmmeter leads across pins D and E
and verify an open circuit. Increase drive speed and
observe that element S9–2 (contacts D and E) closes in
the speed range of 600 ± 20 rpm (Mode I); 840 ± 20 rpm
(Mode II). Gradually reduce speed to 490 minimum rpm
(Mode I); 725 minimum rpm (Mode II). Observe that
element S9–2 resets to the condition shown in figure
14-6.
NOTE
(Required for P/N 70-1105-3 and P/N 701105-4 switches only) In order to bench
check the trip speeds, apply +24VDC to
terminals E and G of the MS3102R–18-1P
connector with the case negative.
f. Connect ohmmeter across pins H and G and
verify a closed circuit. Increase drive speed gradually.
The contacts should open at a speed of 1200 to 1250
rpm. Hold drive speed and read contacts F and J.
Meter should indicate a closed circuit. Reduce drive
speed to less than 1000 rpm, press the manual reset
switch and observe with the meter that element S9–3
contacts reset to the condition shown in figure 14–6.
g. To obtain the required performance character–
istics during tests c through f adjustments can be made.
By loosening screws (1, figure 14-7) and rotating the
cap and cover assembly relative to the body assembly,
the trip points of all three elements can be raised or
lowered. In addition, the trip speed of each individual
element can be raised or lowered by removing cover
screws as shown in figure 14-6 and turning appropriate
set screw located beneath cover screws with a 1/16 inch
allen wrench.
Change 11 14-9
Figure 14-6. Speed Switch Sensitivity Tests.
NOTE
No adjustments required for Speed Switch
Forester (figure 14-7A) used on Serial Num–
hers FZ–01299 on, for 50/60 Hz and Serial
Numbers FZ-06399 on, for 400 Hz. Speed
setting can be checked, but not adjusted.
14–20. Speed Switch Disassembly.
Refer to figure 14-7; cut safety wire and disassemble in
sequence of index numbers observing the following:
g. If either the rotor assembly, the body assembly
or the spacer are damaged or defective, replace defective
part. Reassembly is the reverse order of disassembly.
Refasten with lockwire after readjustment.
b. Repeat the test and adjustment procedures in
paragraph 14–19.
Refer to Operator and Organizational
Maintenance Manual and install speed switch.
14-10 Change 11
14-21. Tachometer Drive and Adapter Removal and
Disassembly.
See figure 14-6 and proceed as follows:
a. Adapter. Uncouple adapter from tachometer
drive.
b. Tachometer drive. Remove screw and clamp.
Lift tachometer drive up and out of engine housing.
c. Disassemble tachometer drive:
(1) By means of a gear puller, remove gear from
shaft.
(2) Remove shaft from top of housing.
(3) Remove preformed packing.
14-22. Tachometer Drive and Adapter Inspection and
Repair.
1.
2.
3.
4.
5.
Screw
Washer
Rotor assembly
Counterweight
Spacer
6.
7.
8.
9.
10.
11.
Packing
Body assembly
Retaining ring
Cap and cover assembly
Screw
Plate
ME 6115-545-34/14-7
Figure 14-7. Speed Switch
Change 8 14-10A/(14-10 blank)
1.
2.
3.
4.
5.
6.
Screw
Lock Washer
Base Assembly
Rotor Cap
Cotter Pin
Rotor
7.
8.
9.
10.
11.
12.
13.
Retaining Ring
Retaining Ring
Bearing
Keyed Shaft
Base
Label
Electronics Assembly
Figure 14-7A. Speed Switch
Change 3 14-11
ME 6115-545-34/14-8 C1
Figure 14-8. Tachometer Drive
Inspect all parts for signs of chipping, cracking,
and/or excessive wear. Replace as required.
means of a small press. Refit gear to shaft.
14-23. Tachometer Drive and Adapter Reassembly
and Installation.
c. Coat housing and preformed packing with
film of light engine oil. Refit preformed packing.
See figure 14-8 and proceed as follows:
d. Hold tachometer drive vertical and insert down
into engine.
a. Reassemble shaft, retaining ring, retaining
bushing, bushing and housing as shown.
e. Install clamp (tightening action of screw will
seal tachometer drive in engine).
b. Reassemble bushing and thrust washer by
14-12 Change 1
f. Refer to Operator and Organizational Maintenance Manual and install speed switch.
Section V. ELECTRIC STARTER
14-24. General.
The engine generator set is equipped with a 24-volt shift
lever type electric starter. It is mounted directly to the
flywheel housing at the engine’s right rear and is connected to the batteries by a solenoid switch. It rotates
clockwise as viewed from the drive end. Battery voltage
is supplied to energize the starter solenoid which
energizes the electric starter to crank the engine.
c. Remove four brush springs (21) by lifting end
of spring from slot and sliding spring from mounting
arm. Remove four brushes (22) from brush plate (18).
(1) Tag and disconnect electrical leads from
brushes (22) by removing screw (19) and washer (20).
(2) Measure the length of each brush. If any
brush is less than 3/8 inch long, replace the complete set of
brushes with new brushes.
14-25. Starter Replacement.
d. Install the brushes as follows:
a. See figure 14-9 and proceed as follows. Remove
starting motor. Refer to Operator and Organizational
Maintenance Manual as follows.
(1) Disconnect the negative cable from the
battery.
(1) Clean all brushes with a clean, dry cloth only.
Do not permit dry cleaning solvent to come in contact
with the brushes.
(2) Install brushes in reverse order of removal.
(2) Tag and disconnect battery cables and electrical wires from starter (3, fig. 14-9).
e. See figure 14-10 and install the commutator
end head (11) in reverse order of removal.
(3) Remove tool box to gain access to starter
screws (1).
14-27. Starter Solenoid.
(4) Remove three 12-point screws (1) and three
washers (2). Remove starter (3) and starter adapter (4).
To replace the starter solenoid (29, fig. 14-10) proceed as
follows:
a. Removal.
NOTE
(1) Disconnect electrical connections to solenoid.
Check ring gear to assure that teeth are not
damaged.
b. Installation. Install the starter (3, fig. 14-9) on
the flywheel housing in reverse order of removal.
(2) Remove screws (26, fig. 14-10).
(3) Remove plug (23) and gasket (24).
(4) Slide solenoid (29) toward brush end of motor.
14-26. Brushes Inspection and Replacement.
(5) Slip back rubber boot and insert screwdriver
in slot of solenoid core to prevent core from rotating
while removing nut (25).
ceed as follows:
a. Gain access to the starter motor as in
paragraph 14-25.
(6) Remove solenoid (29).
b. Installation.
b. Remove the starter commutator end head
assembly, (11) (fig, 14-10) as follows:
(1) Scribe a mark on end head (11) and frame to
locate relative position at assembly.
(2) Remove lead assembly (3, fig. 14-10) by moving nut (l), washer (2) and nut (4), lockwasher (5), flat
washer (6), phenolic washer (7), flat washer (8), and rubber washer (9).
(3) Remove seven bolts (10).
(4) Remove commutator end head assembly (11),
gasket (12), and washer (13).
(1) Install starter solenoid in reverse order of
removal and perform steps (2) and (3) below.
(2) Place starter on bench and apply 24 vdc to the
starter solenoid terminals.
(3) With 24 vdc applied to starter solenoid terminals, the starter drive pinion should be observed moving forward and spinning.
c. Disassemble
Disassemble as illustrated in
figures 14-11 through 14-13.
(1) Refer to figure 14-11 and disassemble major
subassemblies as follows:
(5) Remove insulator (14) and insulating bushing
(15).
All data on page 14-14, including Figure 14-9, is deleted.
Change 10
14-13
14-15
Figure 14-10.
Electrical Starter Brush and Solenoid Assembly
14-16 Change 4
1.
2.
3.
4.
5.
Screw
6. Plug
Housing assy 7. Wick
Bearing
8. Screw
Seal
9. Washer
Plug
10. Packing
11.
12.
13.
14.
15.
Screw
Washer
Pin
Cover
Gasket
16.
17.
18.
19.
20,
Washer
Drive
Yoke assy
Screw
Screw
21.
22.
23.
24.
25.
Housing
Packing
Packing
Bearing
Washer
26.
26A.
26B.
27.
28.
29.
Washer
Thrust washer
Thrust washer
Armature
Insulator
Frame-field assy
ME 6115-545-34/14-11 C4
Figure 14-11.
Electric Starter Assembly
1.
2.
3.
4.
5.
Screw
Washer
Plate assy
Nut
Washer
6.
7.
8.
9.
10.
Washer
Washer
Washer
Washer
Screw
11.
12.
13.
14.
15.
Screw
Screw
Screw
Coil
Coil
16.
17.
18.
19.
20.
Washer
Bushing
Screw
Plate
Housing
ME 6115-545-34/14-12
Figure 14-12. Frame and Field Assembly
14-17
14-18
1. Nut
2. Lockwasher
3. Nut
4.Washer
5. Washer
6. Bushing
7. Nut
8. Cover
9. Bushing
10. Insulator
11. Stud
12. Screw
13. Washer
14. Lug
15. Cover & Contact Assy
16. Gasket
17.
18.
19.
20.
21.
22.
23.
24.
Nut
Washer
Contact
Spring
Washer
Retainer
Ring
Retainer
Figure 14-13. Solenoid Assembly
25.
26.
27.
28.
29.
30.
31.
32.
33.
Spring
Retainer
Boot
Washer
Core aS Sy
Pin
Shaft
Core
Case
ME 6115-545-34/14-13
(a) Remove item 1 through 12 as shown on
figure 14-11.
(3) Inspect all drive assembly splines and pinon teeth for nicks and burrs.
(b) Lift packing (23) and knock out pin (13).
Remove cover (14).
(c) Disassemble the remaining parts in
accordance with index numbers 16 through 29.
(4) Test field coils for insulation breakdown
with megger connected between frame and one coil
terminal. Minimum resistance reading permissible
is one megohm. Replace starter assembly if coil is
defective.
(2) Disassemble frame and field coil assembly
as illustrated in figure 14-12.
(5) Inspect coil terminal lugs for damaged
threads.
(3) Disassemble solenoid assembly as illustrated in figure 14-13.
(6) Test armature for grounds with a test light.
Touch a test light probe to the armature core and the
other probe to a commutator bar riser. If test light
glows, armature is grounded. Repeat test for all
commutator bars.
14-28. Cleaning and Inspection.
a. Cleaning.
(1) Blow out all dirt from inside field frame
and wipe interior with a clean cloth.
(7) Test armature for short circuits using a
growler.
(8) Check brushes for excessive wear.
CAUTION
14-29. Repair.
Do not submerge armature, field
coils, solenoid or clutch drive in
solvent.
(2) Clean field coils and frame thoroughly with
a cloth dampened with cleaning solvent Federal
Specification P-D-680. Be careful not to damage
protective insulation and fungus coating. Dry thoroughly with compressed air.
(3) Remove loose particles from armature with
compressed air and wipe with a clean cloth dampened
with cleaning solvent. Clean commutator lightly
with No. 00 sandpaper and remove all traces of dust
with low-pressure compressed air.
(4) Clean brush holders and springs with a
brush and cleaning solvent, Federal Specification
P-D-680, and dry them thoroughly with compressed
air. Clean insulation and plate with a clean cloth
dampened with cleaning solvent and dry with compressed air.
(5) Clean solenoid relay assembly parts with a
clean cloth dampened with cleaning solvent, Federal
Specification P-D-680, and dry with low-pressure
compressed air.
a. Pinion Housing and Commutator End Head.
(1) Smooth minor scratches, burrs, and dents
on machined surfaces using a fine mill file.
(2) Repair damaged threads.
(3) Smooth minor rough spots, score marks,
and scratches from inside bore of bronze bearing
using a fine stone or crocus cloth dipped in cleaning
solvent, Federal Specification P-D-680.
b. Brush Holder Assembly. Replace a defective
brush holder assembly.
c. Armature.
—
(1) Resurface commutator removing no more
than 0.005 inch during any one cut and no more than
0.002 inch on final cut. Check that final diameter of
commutator is not less than 1.6470 inches.
(2) If commutator diameter is satisfactory,
undercut mica to a depth of 0.025 to 0.032 inch below
commutator surface.
NOTE
(6) Clean brushes with a clean, dry cloth only.
Do not permit cleaning solvent to come in contact
with the brushes.
b. Inspection and Tests.
(1) Inspect drive assembly drive pinion for
broken, chipped, or badly worn teeth. Replace drive
assembly if defective.
(2) Inspect internal splines in drive assembly
shell and pinion for cracked, chipped, or broken condition. Replace drive assembly if defective.
Use care in undercutting. DO not widen
commutator slots by removing metal
from segments, and do not leave thin
edge of mica next to segment.
(3) After the mica has been undercut, remove
all copper and mica particles with compressed air.
Polish the commutator in a lathe with number 2/0
sandpaper while the armature is rotating at 1500
rpm. After polishing the armature, check that commutator diameter is not less than 1.6470 inches.
Replace if diameter is less.
14-19
d. Drive Assembly.
(1) Smooth burrs, nicks and rough spots on
splines and pinion teeth using a fine stone or crocus
cloth dipped in cleaning solvent, Federal Specification
P-D-680.
(2) Smooth rough spots, scoring, scratches and
nicks on inside bore of sleeve bearings and all surfaces of bronze bearings using crocus cloth dipped in
cleaning solvent, Federal Specification P-D-680.
(a) See figure 14-15 for adjustments.
(b) Remove motor field coil connector
from the motor switch terminal stud.
(c) Remove ground lead assembly connecting motor solenoid relay terminal and starter ground
terminal stud.
(d) Remove solenoid relay lead assembly
connecting battery switch terminal stud and battery
solenoid relay terminal.
e. Solenoid Assembly Repair.
(1) Check relay windings for shorts or grounds
with ohmmeter. Replace relay if windings are defective.
(2) Replace relay if contact assembly shows defects such as warpage, cracks, or broken springs.
(3) Minor burns or pits on contact surfaces
are permissible. If conditions are severe, replace
relay. Do not use a file to dress severely burned or
pitted contact surfaces.
f. Field Coil Assembly.
(1) Smooth minor scratches, burrs, and nicks
on machined surfaces of frame using fine mill file,
(2) Repair damaged threads in frame. Repair
damaged threads on field coil terminal stud.
(3) Replace starter assembly if field coil insulation resistance is less than one megohm.
14-30. Reassembly and Adjustments.
a. Reassembly. Reassemble electric starter in
reverse order of disassembly. See figures 14-11
through 14-13.
b. Adjustments. Perform the following adjustments during reassembly.
(1) Solenoid relay plunger shaft.
(a) See figure 14-14. Connect 12 Vdc
across relay terminals A and B. Using a jumper,
momentarily connect lead terminal C to terminal A to
pull the relay plunger into the sealed position. Place
a straight edge across the relay case as shown.
Measure the distance from the shaft shoulder to the
straight edge. This dimension should be 7/32 inch
maximum for proper assembly, and the self-locking
nut will be tight after assembly. Disconnect power
from terminals A and B.
(b) If the shoulder to straight edge dimension exceeds 7/32-inch, the self-locking nut must be
installed and tightened until the end of the nut and the
end of the shaft are flush as illustrated in figure 1414. This procedure will provide adequate overtravel.
(e) Connect a 24-volt battery supply to
battery solenoid relay terminal and motor solenoid
relay terminal.
(f) Momentarily hold a jumper lead from
the motor switch terminal stud to the motor solenoid
relay terminal. The pinion will now shift into
cranking position and remain so until the battery
is disconnected.
(g) Push pinion back toward armature to
take up slack movement.
(h) Check for 0.020- to 0. 050-inch clearance between thrust washer and pinion. To adjust,
remove inspection plug and gasket. Adjust clearance to 0. 020 to 0. 050 inch by turning shaft nut as
shown in figure 14-15.
(i) Connect a test light or other continuity
checker between the battery switch terminal and
motor switch terminal stud.
(j) Connect one of the posts of a 24-volt
battery to the battery solenoid relay terminal.
Connect the other battery post to the motor solenoid
relay terminal.
(k) Place a 0. 983-inch spacer block
(figure 14-15) between the pinion and thrust washer
and momentarily hold a jumper lead from the motor
switch terminal stud to the motor solenoid relay
terminal. The pinion will now shift against the
spacer block and remain so until the jumper lead is
disconnected. The motor must not run. The motor
must run when the distance between the pinion and
thrust washers is 0. 500 inch.
(1) An open circuit should be indicated between the battery switch and motor switch terminals.
If continuity exists, decrease the pinion clearance
((a) above) to the minimum limit of 0.020 inch and
recheck to make sure an open circuit now exists.
(m) Disconnect battery and test equipment
and install motor field connector, ground lead and
solenoid relay lead.
(n) Install inspection plug and gasket,
14-31. Test and Installation.
(2) Drive assembly pinion clearance.
14-20
a. See figure 14-16 and connect the electric
starter in the no-load test circuit illustrated. Perform no-load test as follows:
(1) Energize the test circuit and obtain a voltage
of 22 volts by varying the variable resistance.
(2) Check the speed of the armature on the
tachometer. Minimum speed should be 7000 rpm.
(3) Check the current draw on the ammeter.
Maximum current draw should be 90 amperes. If a
low-speed, high-current condition exists, possible
causes are excessive armature arcing, armature
ground, armature short, or armature drag caused
by loose pole shoes or faulty bearings. A low-speed,
low-current condition indicates faulty brushes or
faulty connection.
b. See figure 14-16 and setup for lock torque
ted as illustrated.
CAUTION
Never operate the electric starter with all
resistance removed from the circuit. Failure to adhere to this caution will result in
extreme motor speeds which can cause
damage to the motor and possible injury to
personnel.
The variable resistance should be
one with a high current capacity.
(1) Energize the circuit and check the scale to
determine the torque output of the motor.
(2) Scale should indicate 22 pound-feet (minimum), at 400 amperes and approximately four volts,
as indicated on the meters.
C . Installation. Install the starter motor on the
flywheel housing using the disassembly steps in reverse order. See figure 14-9.
Figure 14-14. Solenoid Adjustments
14-21
14-22
Figure 14-15. Drive Assembly Pinion, Clearance Adjustments
14-23
Figure 14-16. Electric Starter, Test Circuits
Section VI.
LUBE OIL COOLER AND FILTER BYPASS VALVE
14-32. General.
The lube oil cooler is mounted on the right side of the
engine cylinder block and receives coolant from the
water pump. Engine lubricating oil is pumped
through a chamber in the lube oil cooler. The chamber walls are cooled by the coolant and, in turn,
maintain the engine lube oil at a safe operating temperature.
14-33. Removal, Disassembly, and Cleaning of Oil
Cooler.
a. Removal. Refer to the Operator and Organizational Maintenance Manual for removal procedures.
b. Disassembly. See figure 14-17 and disassemble the lube oil cooler as shown.
c. Cleaning. Clean all metallic park with cleaning-solvent, Federal Specification P-D-680.
14-34. Inspection and Repair.
a. Inspection.
(1) Inspect cooler housing, bonnet, and header
for cracks, distortion, and scoring of mating surfaces.
(2) Inspect cooler assembly passages for obstructions.
faulty, the oil cooler must be replaced. If the shell
is damaged it must be replaced.
b. Reassembly.
(1) See figure 14-17 and reassemble the lube
oil cooler.
(2) After reassembly, place the lube oil cooler
on a surface plate as if it were being mounted. Using a feeler gauge, check to see if all machined surfaces contact the plate within 0. 005 inch. Loosen
and retighten screws to obtain this clearance.
c. Installation. Refer to the Operator and Organizational Maintenance Manual.
14-36. Lube Oil Filter Bypass Valve.
a. General.
The lube oil filter bypass valve is part of the header
block of the engine lube oil filter assembly. If the
filters become clogged, such that the differential
pressure across the combination of both filters
rises to 45 psi the bypass valve opens permitting
unfiltered oil to bypass the filters and go directly
to the main oil gallery.
Cold weather induced thickening of the oil will cause
the filters to be bypassed. As the engine oil warms
the by-pass valve will close inserting the filter elements into the oil stream.
b. Repair.
b. Removal.
(1) Clean passages with steam under pressure
to insure that there are no obstructions.
(2) Smooth burrs or scoring on mating surfaces
with a fine mill file.
(See figure 14-18)
(1) Both oil filters must be removed. Refer to
Operator and Organization Maintenance Manual.
(2) Remove the oil filter header block by removing six cap screws.
(3) Replace any parts damaged beyond repair.
(4) Discard all gaskets and preformed packing.
14-35. Test, Reassembly, and Installation.
a. Test.
(1) Make up two plates, one with a drilled and
tapped hole to accept an air hose fitting, and secure
them with C clamps to cover the oil inlet and outlet
openings in the side of the oil cooler. Use the preformed packing to seal the plates.
(3) Thoroughly clean the area at the rear of the
header block where the bypass valve is located.
(4) Remove the cap, gasket, spring, piston
sleeve and seat.
c. Cleaning and Inspection.
Wash valve parts in cleaning solvent. Inspect carefully for wear or damage. Replace any worn or
damaged parts.
d. Installation.
(2) Attach an air hose to the drilled and tapped
plate; submerge the oil cooler in hot water until the
oil cooler temperature is up to approximately 150°F.
Test for leaks with air pressure of 100 psi.
(3) No air bubbles shall appear at either open
end of the lube oil cooler. If the cooling core is
14-24
(1) Install valve in reverse order of disassembly.
(2) Renew filter header gaskets and lube oil
bypass valve gasket.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Screw
Washer
Header
Gasket
Screw
Washer
Bonnet
Gasket
Cooler
Figure 14-17.
ME 6115-545-34/14-17
Lube Oil Cooler
14-25
(2) Observe the oil pressure gauge located in
the control cubicle.
(3) Mount filter header to oil gallery with 6
cap screws.
(4) Mount engine lube oil filter to filter
header. Refer to Operator and Organizational
Maintenance Manual.
(3) If the oil pressure is abnormally high or
low after the engine has warmed, then a failure in
the relief valve has occurred.
e. Test.
(1) Start engine. Refer to Operator and Organizational Maintenance Manual.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10,
Screw
Washer
Header assembly
Cap
Gasket
Spring
Piston
Sleeve
Seat
Gasket
ME 6115-545-34/14-18
Figure 14-18.
14-26
Lube Oil Bypass Valve
Section VII. NOZZLE HOLDER ASSEMBLIES
14-37. General.
At completion of repair, check operation in accordance with paragraph 14-40.
a. Each engine cylinder is provided with a multihole, differential needle, hydraulically lifted, nozzle
holder assembly. The function of each nozzle holder
assembly is to direct a metered quantity of fuel received from the fuel injection pump into the corresponding engine combustion chamber in a highly atomized, pre-determined spray pattern in such reamer
as to produce the most efficient performance. Each
nozzle holder assembly consists of two assemblies,
an injection nozzle holder and an injection nozzle.
b. The holder assembly positions the nozzle in the
cylinder head and provides a means of conducting
fuel received from the fuel injection pump to the
nozzle. The holder consists of a steel holder body,
two locating dowels, spindle, spindle spring, pressure adjusting screw, adjusting screw locknut, gaskets, cap nut, and a nozzle retaining nut.
c. The nozzle assembly consists of a nozzle valve
and–a nozzle body in which are located four spray
orifices equally spaced 90 degrees apart. The
nozzle valve is operated hydraulically within the
valve body by fuel delivered under pressure by the
fuel injection pump. The nozzle is positioned on the
holder by two dowels whereby the four spray orifices
are fixed on a plane parallel to the piston top, and
the nozzle fuel duct is registered with the holder fuel
duct .
d. Fuel enters the nozzle holder fuel inlet passage,
passes through the holder fuel duct into the nozzle
fuel duct via an annular groove in the nozzle body,
and then into the pressure chamber above the nozzle
valve seat. At the instant the fuel pressure in the
pressure chamber exceeds pressure exerted on
spindle and nozzle valve by the spindle spring, the
nozzle valve is lifted off its seat (popped) and fuel is
forced through orifices in the valve body end and into
the corresponding engine combustion chamber. The
nozzle valve is returned to its seat by pressure exerted by the spindle spring when the fuel injection pump
has ceased to deliver fuel to the nozzle holder.
The nozzle valve and nozzle valve body are mated
parts, and must be kept together. If replacement of
either part is necessary, both parts must be replaced as matched sets. Remove, clean, and inspect the nozzle valve body and valve as follows:
a. Clamp nozzle holder body in a suitable holding
fixture.
b. Remove cap nut (10) and gasket (11) from upper
end of nozzle holder (15). Loosen pressure adjusting
screw locknut (8) and turn pressure adjusting screw
(9) out sufficiently to release spring tension on spindle
spring (12). See figure 14-19.
c. Using a suitable socket or box wrench, loosen
and remove the nozzle retaining nut (5). Remove
the nozzle valve body (3) and nozzle valve (4) from
the retaining nut. Start the nut back onto the holder
body to protect the lapped end of the holder body
(15).
CAUTION
Do not allow the solution to get on
the hands or body; use tweezers or the
basket method to handle the parts.
d. Withdraw the valve from the valve body and
plate it in a carbon and rust remover solution for
cleaning. Normally, the valve can easily be withdrawn from the valve body, however, in some cases
it may be necessary to soak the valve body and valve
in carbon removing compound Type 2 per Federal
Specifications P-C-111 before the valve can be withdrawn. For faster and better cleaning results, the
carbon removing compound should be heated to
approximately 200° F. The parts generally can be
separated in two or three minutes; however, if
necessary they can be left in the solution longer.
After removing the parts from the solution, immediately place them in clean diesel fuel for neutralizing.
Always handle the parts carefully to protect the
lapped surfaces.
14-38, Removal.
Refer to the Operator and Organizational Maintenance
Manual to remove the nozzle holder assembly.
14-39. Disassembly, Cleaning and Repair.
The valve (4) and the seat in the valve body
(3) are originally ground to slightly different
angles to provide a line contact seat between the
two parts. Practically all the wear occurs in the
seat in the valve body. The valve should never be
lapped to the seat in the valve body.
NOTE
When more than one nozzle holder
assembly is disassembled, keep
parts of each separate. Complete
disassembly of the nozzle holder
assembly is seldom necessary. In
most cases, only disassembly and
cleaning of the nozzle valve body and
valve is required to place the nozzle
holder in good operational condition.
f. Using a magnifying glass, inspect condition
of seat in the valve body (3). If the seat is damaged
or worn in any way to prevent proper seating of the
valve, the nozzle assembly (1) must be replaced.
g. The outer surfaces of the valve body (15) may
be cleaned with a brass wire brush. Do not scrape
carbon from the surface around the orifices in tip of
valve body with any hard object as damage may result. Clean the four orifices in the valve body tip
Change 1 14-27
ME 6115-545-34/14-19 C7
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Nozzle assembly
Gasket
Nozzle body
Nozzle valve
Retaining nut
Dowel pin
Dowel pin
Locknut
Pressure adjust screw
Cap nut
Gasket
Spindle spring
Spindle
Gasket
Holder body
Figure 14-19. Nozzle Holder Assembly
with a cleaning wire and pin vise.
h. Visually inspect the condition of the valve (4),
preferably with aid of a magnifying glass. The lapped
surface (large outer diameter) of the valve must be
smooth and free of signs of scoring. Also, the valve
must not show any wear or damage at seat location.
If the valve is damaged in any way, the nozzle assembly (1) must be replaced.
i. Thoroughly rinse the valve (4) and valve body (3)
in clean diesel fuel. The valve must fit freely in the
valve body. To check this fit, lift valve about one
third of its length out of the body. The valve should
slide down to its seat without aid when assembly is
held at a 45° angle.
14-28 Change 7
j. If the fit of the valve in the valve body is unsatisfactory, the valve may be cleaned and polished
with lapping compound and castor oil used on tissue
paper. The valve may be held by its stem in a revolving chuck for this cleaning operation. An
orange stick or round toothpick will be helpful in
cleaning the valve.
CAUTION
Hard or sharp tools, emery cloth,
crocus cloth, jeweler’s rouge, grinding compounds, or other abrasives
should never be used in cleaning.
k. Thoroughly rinse the valve (4) in clean diesel
fuel before installing it in the valve body (3).
l. Examine the flat sealing surface of the valve
body (surface which contacts lower end of the holder
body) and make certain surface is clean and free of
scratches. This surface may be lapped, if necessary, using lapping compound, castor oil, and a
lapping block. After lapping, remove all traces of
lapping compound with clean diesel fuel.
m. Make certain that the bottom flat seating surface of the nozzle holder body (15) is clean and in
good condition. Rinse the valve (4) and valve body
(3) in clean diesel fuel, then insert valve (4) into
position in the valve body (3). Place the valve body
(3) and valve (4) in position on the end of the nozzle
holder body and center the valve body with the holder
body (15). Install and tighten the nut (5) to a torque
of 40 to 60 inch-pounds.
NOTE
It is important that the valve body be
centered in the nozzle retaining nut.
Use care while tightening the nozzle
retaining nut so that the valve body
remains centered in the nut.
n. If malfunctioning of the nozzle holder assembly
was not corrected by removal and cleaning of the
nozzle valve body and valve, disassemble and clean
the nozzle holder as follows:
(1) Clamp nozzle holder (15) assembly in a
holding fixture and remove the cap nut (10) and gasket (11 ) from upper end of nozzle holder. Loosen
and remove the pressure adjusting screw locknut (8).
(2) Remove pressure adjusting screw (9),
spindle spring (12), and spindle (13).
(3) Remove nozzle retaining nut (5), and disassemble the nozzle assembly.
(4) Place all parts in clean diesel fuel. Using
filtered compressed air, blow out the fuel passages
in the holder body.
(5) Visually inspect the parts for damage or
wear; replace necessary parts. Examine the flat
sealing surface of holder body (15) (surface which contacts upper end of valve body) and make certain the
surface is clean and free from scratches. This surface should be lapped if necessary, using lapping compound, castor oil, and a lapping block. When lapping,
use care to keep the nozzle holder body square with
the lapping block to assure contact with the entire
area being resurfaced. After lapping, remove all
traces of the lapping compound with clean diesel fuel
and dry with filtered compressed air.
(6) Examine the spindle spring (12). If the
spring is scratched or pitted, it must be replaced.
Also, the spring must be replaced if the ends have
worn. Always replace springs when rebuilding
injector.
(7) Rinse spindle (13) in clean fuel and insert
it into holder body (15). Place the spindle spring (12)
in position on spindle (13). Install pressure adjusting
screw (9), pressure adjusting screw locknut (8), cap
nut (1 O) and gasket (11); do not tighten at this time.
(8) Install nozzle valve (4), valve body (3), and
nozzle retaining nut (5). Tighten nut to a torque of
40 to 60 foot-pounds.
O . When rebuilding an injector assembly, the
nozzle assembly, spindle (13), spring (12), adjusting screw (9), and all gaskets (2, 14, 11) must be
replaced.
14-40. Test and Adjustment.
WARNING
Keep hands away from nozzle tip when
popping a nozzle. The finely atomized
fuel is ejected with sufficient force to
penetrate the skin and cause blood
poisoning.
a. Use diesel injector test set tool (table 2-1)
and lest and adjust each nozzle as follows
(1) Bolt or clamp base of nozzle tester to a
work bench.
(2) Turn nozzle tester valve handle to the open
position. Loosen filler cap to prevent air lock in the
tester. Operate handle until fuel flows from end of
tester fuel line, then close valve.
(3) Install nozzle in tester and connect line.
Place spray collector under valve end of nozzle.
(4) Open nozzle tester valve. Operate handle
a few quick strokes and observe popping pressure
indicated on pressure gauge. Popping pressure for
the injectors is 2900 ± 75 psi.
NOT E
New nozzles and rebuilt nozzles with
new springs are set at 3100 to 3150
psi to compensate for initial set of
new spindle springs.
b. Adjust nozzle to obtain popping pressure as
follows
(1) Remove cap nut (12) from upper end of
nozzle and loosen adjusting screw locknut (9).
(2) While operating handle, turn pressure adjusting screw (8) into increase or out to decrease popping pressure. When pressure is obtained, hold adjusting screw and tighten locknut to 60 to 75 footpounds torque.
c. Dry the nozzle tip. Operate handle slowly until pressure is approximately 200 psi below popping
Change 1 14-29
pressure. Observe nozzle tip for fuel leakage. If
nozzle does not leak, the nozzle valve is seating
properly in the valve body. If drops of fuel collect at
a pressure of approximately 200 psi, or less, below
popping pressure, the nozzle valve is not seating
properly. In this case, the valve body and valve
must be removed for cleaning and inspection.
determine the spray pattern. If fuel is discharged
evenly through all four holes at specified popping
pressure, the spray pattern is considered satisfactory. However, if fuel is not discharged evenly
from all four holes, a plugged hole(s) is indicated,
in which case, the nozzle must be removed and
cleaned using a proper size cleaning wire.
d. If the nozzle proved satisfactory when subjected
to the leakage test above, operate handle at a speed
of approximately 100 strokes per minute and observe
nozzle spray pattern.
f. Install nozzle holder cap nut and tighten it to
60 to 75 foot-pounds torque.
e. The nozzle tip has four equally spaced holes,
90 degrees apart. Size and spacing of these holes
Install the nozzle holder assembly. Refer to opera.
tor and Organizational Maintenance Manual.
14-41. Nozzle Holder Assembly Installation.
Section VIII. FUEL INJECTION PUMP AND RELATED PARTS
14-42. General.
a. The fuel injection pump is a single cylinder,
opposed plunger, inlet metering, distributor type.
The plungers are operated by an internal cam ring.
The purpose of the pump is to accurately deliver
metered quantities of fuel under high pressure to the
nozzle holder assemblies through which the fuel is
introduced into the engine combustion chambers, at
a definite timing in relation to the engine firing cycle,
and within the required injection period.
b. On Class 1, Precise Sets, the fuel injection
pump is controlled by the hydraulic actuator. The
hydraulic actuator operates on the shut down lever
to automatically control fuel flow through the fuel
injection pump, dependent upon load conditions, and
thus controls engine speed and response to load
changes.
c. On Class 2, Utility Sets, this fuel injection
pump is manually controlled from the control located
at the rear of the set. The manual control is connected to the throttle through a cable and sleeve
assembly.
d. The fuel injection pump also has an integral
back-up governor of the mechanical centrifugal
(flyweight) type. This governor is driven directly off
the pump drive shaft without gearing.
e. The transfer or supply pump, in the opposite
end–of the rotor from the pumping cylinder, is a
positive displacement vane type enclosed by the end
plate. The pump is self-lubricated by the fuel
supply.
f. Fuel shut-off is accomplished electrically by a
solenoid mechanism within the fuel pump. When
energized, the solenoid opens the metering valve to
permit fuel flow to the engine.
g. An external adjustment knurled screw at the rear
of the pump housing provides precise control of governor sensitivity by decreasing or increasing the
effective length of the governor control spring.
Turning the adjustment screw inward shortens the
control spring, making it less sensitive and increasing
14-30
speed droop. Turning the screw outward has the
opposite effect. Regulation of 2-3 percent can be
easily attained and adjustment can be made while the
engine is operating.
14-43. Fuel Injection Pump Removal and Disassembly.
a. Symptoms and Isolation of Malfunction. A
malfunction of the fuel injection pump is usually indicated by loss of engine speed and power, erratic
engine speed, failure of engine to start (when electric
starter is working correctly), or sudden engine shutdown when there is no fault indication such as low fuel,
high coolant temperature, or low oil pressure. To
isolate the malfunction to the fuel injection pump,
proceed as follows:
(1) Check fuel lines and fuel injection pump for
visible signs of leakage.
(2) If engine cannot
down suddenly, loosen the
injection pump. If a full
may be an indication that
the coupling.
be started or if it has shut
fuel input line to the fuel
line of fuel is available, it
the pump has failed. Tighten
(3) While engine is cranking, loosen the input
to one of the fuel injectors. If there is no evidence of
available fuel, the fuel injector pump has failed.
(4) Remove timing cover on pump and observe
that pump rotates when engine cranks.
(5) Check for 24 Vdc at solenoid terminals on
top cover. of injection pump.
(6) Check solenoid (para 14-46). If no continuity, replace solenoid.
(7) Refer to table 14-1 for troubleshooting the
fuel injection pump.
b. Removal. (See figure 14-20.)
(1) Refer to the Operator and Organizational
Maintenance Manual and drain fuel day tank and disconnect fuel line to pump.
Table 14-1. Fuel Injection Pump Troubleshooting Chart
MALFUNCTION
CORRECTIVE ACTION
PROBABLE CAUSE
ON TEST STAND FOLLOWING OVERHAUL
Re-install properly. (para 14-45)
1. Fuel not reaching
pump.
Transfer pump liner locating
pin in wrong hole for correct
rotation.
2. Fuel delivered from
transfer pump but
not to nozzles.
a.
Plunger missing.
a.
Assemble new plunger. (para 14-45)
b.
Cam backwards in
housing.
b.
Reassemble correctly. (para 14-45)
c.
Metering valve incorrectly c.
assembled to metering
valve arm.
Reassemble correctly. (para 14-45)
d.
Metering valve spring
shim missing.
d.
Install as indicated in paragraph 14-45.
e.
Hydraulic head vent
wires missing.
e.
Install as indicated in paragraph 14-44.
f.
Head plug screws loose
or missing,
f.
Install as indicated in paragraph 14-44.
3. Inadequate pressure
at nozzle
Head plug screws loose or
missing.
Install as indicated in paragraph 14-44.
4. Erratic pump output
- surge, poor
governor regulation
a. Delivery valve sticking,
missing or assembled
backwards.
a.
Remove, clean or replace as needed.
(para 14-45)
b.
Metering valve spring
shim missing.
b.
Install as indicated in paragraph 14-45.
c.
Head plug screws loose
or missing.
c.
Install as indicated in paragraph 14-44.
a.
Delivery valve sticking,
missing or assembled
backwards.
a.
Remove, clean or replace as needed.
(para 14-45)
b.
Hydraulic head vent
wires missing.
b. Install as indicated in paragraph 14-44.
c.
Head plug screws loose
or missing.
c.
5. Insufficient pump
output volume.
Install as indicated in paragraph 14-44.
14-31
Table 14-1. Fuel Injection Pump Troubleshooting Chart (Cont)
CORRECTIVE ACTION
PROBABLE CAUSE
MALFUNCTION
FOLLOWING INSTALLATION ON ENGINE
1.
Fuel not reaching
pump.
Seizure of distributor rotor.
Check for cause of seizure. Replace hydraulic
head and distributor rotor assembly. (para 14-45
2.
Fuel delivered from
transfer pump but
not to nozzles.
a. One or more connector
screws obstructed.
a.
Replace. (para 14-45)
b.
b.
Remove, inspect and adjust parts. Replace
parts as necessary. (para 14-46)
Failure of electrical
shut-off.
3.
Engine starts hard.
One or more connector screws Replace. (para 14-45)
obstructed.
4.
Engine starts and
stops .
Failure of electrical shut-off.
5.
Engine does not
develop full power
or speed.
One or more connector screws Replace. (para 14-45)
obstructed.
Remove, inspect and adjust parts. Replace parts
as necessary. (para 14-46)
DURING OPERATION
Fuel delivered
from transfer
pump but not
to nozzles.
1.
2.
a.
Plungers sticking.
a.
Disassemble and inspect for burrs, corrosion
or varnishes. (para 14-44).
b.
Metering valve sticking
or closed.
b.
Check for governor linkage binding, foreign
matter, burrs, etc. (para 14-44).
c.
Passage from transfer
pump to metering valve
clogged with foreign
matter.
c.
Disassemble and flush out hydraulic head.
(para 14-45)
d.
Governor spring worn or
broken.
d. Remove and replace. (para 14-45)
e.
Governor linkage loose.
e.
Remove, replace and readjust. (para 14-45)
f.
Governor not operating;
parts or linkage worn,
sticking or binding, or
incorrectly assembled.
f.
Disassemble, inspect parts, replace if
necessary and reassemble. (para 14-45)
g.
Rotor badly scored.
g.
Replace hydraulic head and rotor assembly.
(para 14-45)
Pump timed incorrectly
to engine.
a. Correct timing. (para 14-49)
Excessive fuel leakage
past plungers (worn,
badly scored).
b,
c.
Cam, shoes or rollers
worm
c. Remove and replace. (para 14-45).
d.
Automatic advance
faulty or not operating.
d.
Fuel reaching nozzles a.
but engine will not
start.
b.
14-32
Replace rotor and hydraulic head assembly.
(para 14-45)
Remove, inspect, correct and reassemble.
(para 14-45)
Table 14-1.
Fuel Injection Pump Troubleshooting Chart (Cont)
CORRECTIVE ACTION
PROBABLE CAUSE
MALFUNCTION
DURING OPERATION (Cont)
Maximum fuel setting at
low limit or too low.
e.
Adjust per paragraph 14-45.
Throttle arm travel not
sufficient.
f.
Check installation and adjust throttle linkage.
(para 14-45)
Rotor badly scored.
g.
Replace hydraulic head and rotor assembly.
(para 14-45)
a.
Transfer pump blades
worn or broken.
a.
Replace. (para 14-45)
b.
Delivery valve retainer
screw loose and leaking
or incorrectly installed,
b.
Inspect delivery valve stop seat for erosion,
tighten retainer screw, or replace head
and rotor assembly as needed. (para 14-45)
c.
Plungers sticking.
c.
Disassemble and inspect for burrs, corrosion
or varnishes. (para 14-45)
d.
Metering valve sticking
or closed.
d.
Check for governor linkage binding, foreign
matter, burrs, etc. (para 14-45)
e.
Pump timed incorrectly
to engine.
e.
Correct timing.
f.
Excessive fuel leakage
past plungers (worn or
badly scored).
f.
Replace rotor and hydraulic head assembly.
(para 14-45)
g.
Transfer pump faulty,
pressure too 10W .
g.
Remove and inspect parts. (para 14-45)
h.
Cam, shoes or rollers
worn.
h.
Remove and replace. (para 14-45)
i.
Automatic advance
fault y or not operating.
i.
Remove, inspect, correct and reassemble,
(para 14-45)
j.
Governor linkage out of
adjustment.
j.
Adjust governor. (para 14-44)
k.
Governor not operating;
parts or linkage worn,
sticking or binding, or
incorrectly assembled.
k.
Disassemble, inspect parts, replace if
necessary and reassemble. para 14-45)
1.
Maximum fuel setting at
low limit or too low.
l.
Adjust pump per paragraph 14-48.
e.
2. Fuel reaching nozzles f.
but engine will not
start. (Cont)
g.
3. Engine starts hard.
4. Engine starts and
stops.
(para 14-49)
m. Shut-off device interfering
with governor linkage.
m. Check and adjust governor linkage dimensions.
(para 14-45)
n. Rotor badly scored.
n.
Replace hydraulic head and rotor assembly.
(para 14-45)
a.
a.
Remove, inspect and adjust parts. Replace
parts as necessary. (para 14-46)
Failure of electrical
shut-off .
14-33
Table 14-1. Fuel Injection Pump Troubleshooting Chart (Cont)
MALFUNCTION
PROBABLE CAUSE
CORRECTIVE ACTION
DURING OPERATION (Cont)
4.
5.
Engine starts and
stops. (Cont)
Erratic engine
operation- surge,
misfiring, poor
governor regulation.
b.
Transfer pump blades
worn or broken.
b.
Replace. (para 14-45)
c.
Plungers sticking.
c.
Disassemble and inspect for burrs, corrosion
or varnishes. (para 14-45)
d.
Metering valve sticking
or closed.
d.
Check for governor linkage binding, foreign
matter, burrs, etc. (para 14-45)
e.
Cam, roller, or shoes
sticking.
e.
Remove, check for size and burrs and
reassemble. (para 14-45)
a.
Transfer pump blades
worn or broken.
a.
Replace. (para 14-45)
b.
Delivery valve retainer
screw loose and
leaking or incorrectly
installed.
b. Inspect delivery valve stop seat for erosion,
tighten retainer screw, or replace head and
rotor assembly as needed. (para 14-45)
c.
Plungers sticking.
c.
Disassemble and inspect for burrs, corrosion
or varnishes. (para 14-45)
d.
Metering valve sticking
or closed.
d.
Check for governor linkage binding, foreign
matter, burrs, etc. (para 14-45)
e.
Governor spring worn
or broken.
e.
Remove and replace. (para 14-45)
f.
Cam, roller, or shoes
sticking.
f.
Remove, check for size and burrs and
reassemble. (para 14-45)
g.
Pump timed incorrectly
to engine.
g. Correct timing. (para 14-49)
h.
Transfer pump faulty,
pressure too low.
h.
Remove and inspect parts. (para 14-45)
i.
Automatic advance
faulty or not operating.
i.
Remove, inspect, correct and reassemble.
(para 14-45)
j.
Governor linkage out of
adjustment.
j.
Adjust governor. (para 14-45)
k.
Governor not operating;
parts or linkage worn,
sticking or binding.
k.
Disassemble, inspect parts, replace if
necessary and repair. (para 14-45)
1.
Wrong governor spring.
1.
Remove and replace with proper spring.
(para 14-45)
m.
Operate engine for approximately 5 minutes
until pump fills with fuel.
n.
Remove, inspect for burrs, dirt, etc.
Correct and reassemble. (para 14-45)
m.
n.
14-34
Pump housing not full of
fuel.
Governor sleeve binding
on drive shaft.
Table 14-1. Fuel Injection Pump Troubleshooting Chart (Cont)
MALFUNCTION
CORRECTIVE ACTION
PROBABLE CAUSE
DURING OPERATION (Cont)
5.
6.
Erratic engine
operation- surge,
misfiring, poor
governor regulation. (Cont)
Engine does not
develop full
power or speed.
o.
End plate regulating
piston sticking.
o.
Remove piston and sleeve and inspect for
burrs, corrosion or varnishes. Replace
if necessary. (para 14-45)
p.
Variable speed droop
device incorrectly
adjusted or faulty.
p.
Replace if necessary. (para 14-47)
a.
One or more connector
screws obstructed.
a.
Replace. (para 14-45)
b.
Transfer pump blades
worn or broken.
b.
Replace. (para 14-45)
c.
Delivery valve retainer
screw loose and
leaking or incorrectly
installed.
c.
Inspect delivery valve stop seat for erosion,
tighten retainer screw, or replace head
and rotor assembly as needed. (para 14-45)
d.
Plungers sticking.
d. Disassemble and inspect for burrs, corrosion
or varnishes. (para 14-45)
e.
Metering valve sticking
or closed.
e.
Check for governor linkage binding, foreign
matter, burrs, etc. (para 14-45)
f.
Pump timed incorrectly
to engine.
f.
Correct timing.
g.
Excessive fuel leakage
past plungers (worn
or badly scored).
g.
Replace rotor and hydraulic head assembly.
(para 14-45)
h.
Transfer pump faulty,
pressure too low.
h.
Remove and inspect parts.
i.
Cam, shoes or rollers
worn.
i.
Remove and replace. (para 14-45)
j.
Automatic advance fault y
or not operating.
j.
Remove, inspect, correct and reassemble.
(para 14-45)
k.
Governor linkage out of
adjustment.
k.
Adjust governor. (para 14-45)
1.
Governor not operating;
parts or linkage worn,
sticking or binding, or
incorrectly assembled.
1.
Disassemble, inspect parts, replace if
necessary and reassemble. (para 14-45)
m.
Maximum fuel setting
at low limit or too
low.
m.
Reset to pump specification. (para 14-48)
n.
Remove and replace with proper spring as in
pump specification. (para 14-45)
n. Wrong governor spring.
(para 14-44)
(para 14-45)
14-35
Table 14-1.
MALFUNCTION
Fuel Injection Pump Troubleshooting Chart (Cont)
PROBABLE CAUSE
CORRECTIVE ACTION
DURING OPERATION (Cont)
6.
Engine does not
develop full
power or speed
(Cont)
7.
8.
Engine smokes
black.
Engine smokes blue
or white.
14-36
o.
Shut-off device interfering with governor
linkage.
o.
Check and adjust governor linkage dimensions. ( p a r a 1 4 - 4 5 )
p.
Governor high-idle
adjustment incorrect
p.
Adjust. (para 14-45)
q.
Throttle arm travel not
sufficient.
q.
Check installation and adjust throttle
linkage. (para 14-45)
r.
Rotor badly scored.
r.
Replace hydraulic head and rotor
assembly. (para 14-45)
a.
Pump timed incorrectly
to engine.
a.
Correct timing. (para 14-49)
b.
Cam, shoes or rollers
worn.
b.
Remove and replace. (para 14-45)
c.
Automatic advance
faulty or not operating.
c.
Remove, inspect, correct and reassemble. (para 14-45)
d.
Maximum fuel setting
too high.
d.
Reset.
a.
Pump timed incorrectly
to engine.
a.
Correct timing. (para 14-49)
b.
Automatic advance
fault y or not operating.
b.
Remove, inspect, correct and reassemble. para 14-45)
(para 14-48)
(2) Check that the timing line on the governor
weight retainer hub is opposite the line on the pump
cam.
(3) Disconnect all fuel lines and plug all openings.
(4) Disconnect throttle and shut-off linkage and
disconnect electrical leads from solenoid.
(5) Remove mounting nuts on the pump flange.
(6) Slide pump gently from location. Be careful not to damage the pilot tube by cocking pump on
removal.
c. Disassembly. Disassemble the pump in the
numerical sequence illustrated in figure 14-21 paying
particular attention to the following
CAUTION
Never clamp the pump in a vice without
using the fixture.
(1) Mount pump in holding fixture and secure in
vice.
(2) Remove three screws (1) and remove cover
(4). Set cover containing solenoid aside for later
disassembly. Refer to paragraph 14-46.
(3) Rotate shut-off lever (21 ) to full off position;
pry gently between housing and linkage hook (45) and
remove shut-off cam (25).
(4) Partially withdraw throttle shaft assembly
(26) and lift out throttle shaft lever (40), spacers and
governor arm damper barrel assembly (86). Remove throttle shaft and shut-off shaft assemblies (24).
(5) Hold metering valve (93) and arm assembly
(91 ) down and lift linkage hook (45) from metering
valve arm pin (91 ). Disengage hook from governor
arm (86). Do not separate linkage hook from spring
unless necessary to replace one of these parts.
(6) Remove the end plate assembly (58). Remove the speed droop adjusting cap (73) by pulling to
the rear of the pump. With a pair of needle nose pliers, remove the control rod clip (78).
CAUTION
Do not bend the control rod.
Loosen and remove the control rod guide (75), O ring
(77) and guide washer (76). Disengage the governor
spring (80) from the governor arm (86) and remove
the governor spring (80) and control rod assembly
(79) as a unit.
(7) Remove metering valve (93) and arm
assembly (91) from hydraulic head.
NOTE
Metering valve is shimmed to reduce
vertical play. If valve, arm or head,
and rotor assembly are not replaced,
save shims and spacer for reassembly.
(8) Remove two head locking screws (146, 147)
from pump housing (166).
(9) Invert pump and holding fixture as a unit and
remove head locating screw (103), advance screw
hole plug (100), and remove advance pin (102).
(10) Remove the power piston plug (111 ) and advance spring components (97-113) as an assembly.
Disassemble by removing cap (115) and loosening jam
nut (114) and back trimmer screw (11 2) completely in.
Slide the piston (99) out of the plug (do not turn piston
inside of plug). Remove the retaining ring (110) from
the piston (99) and remove spring (108) and trimmer
screw (112).
NOTE
The sides of the housing just above the
advance bears a “C” denoting clockwise pump rotation as viewed from the
drive end. The power side of the piston is located on the “C” side of a
clockwise rotation pump.
(11 ) Invert the holding fixture in the vise. Grasp
the hydraulic head assembly firmly in both hands and
withdraw with a slight rotary motion. Use caution
not to drop the governor weights (116).
(12) To disassemble the governor, invert the
hydraulic head and rotor assembly (145) and let
weights (116), governor thrust sleeve (117), and governor thrust sleeve wahser (118) fall into your hand.
(13) Place the hydraulic head assembly on pump
holding fixture so that the governor weight retainer
(123) engages the bar on the fixture.
(14) Remove the pressure regulating sleeve (49)
from end plate (59). Slide off the inlet screen (51).
Remove the adjusting plug (48). Shake out the regulating spring (54) and piston (55). Reverse the
assembly and remove the regulating piston seal (56).
(15) To disassemble transfer pump, lift out
transfer pump seal (71 ), liner (72) and blades (67-70),
and springs (65, 66).
(16) Using a 5/32 inch Allen wrench, loosen the
delivery valve retainer screw (138) and remove it.
(17) Lift head and rotor assembly and shake delivery valve stop (139), spring (140), and delivery
valve (141 ) into the hand.
(18) Using a small-bladed screwdriver or a dull
14-37
14-38 Change 7
1. Screw 4. Screw
2. Cover
5. Spring
3. Gasket 6. Nut
7. Washer
8. Gear
9. Key
10. Nut
U. Washer
12. Fuel pump
13. Seal
14. Nut
15. Washer
16. Washer
17. Adapter assy
18. Performed packing
Figure 14-20. Injector Pump and Related Parts
19. Bushing
20. Stud
21. Adapter
ME 6115-545-34/14-20 C7
scribe, disengage and remove the rotor retainer
snap ring (119). This releases the rotor retainers
(120) which should now be moved outward as far as
possible to clear the rotor. Gently lift the hydraulic
head (144) off the distributor rotor (142). Invert the
head and shake out the rotor retainers (120).
(19) Lift off cam ring (122). Check and record
roller-to-roller dimension as instructed in assembly
procedure. This dimension should be 1.977 ±
0.0005. Remove rollers (129, 130), shoes (131, 132)
and plungers (133, 134), only if damaged. Otherwise
secure these parts by using the transfer pump seal
(71).
NOTE
Reassembly may be more easily accomplished if the leaf springs (127, 128) are
not removed and shoes with rollers remain installed in their original positions.
Leaf springs, if removed, should first
be marked with a dye for original position
reassembly. Do not remove locating pin
from spline end of rotor.
(20) Remove the governor weight retainer snap
ring (121) using snap ring pliers.
(21 ) Using suitable tool and supporting the head
on a flat surface, press the rotor (142 from the
weight retainer (123 ).
(22) The flexible retaining ring should be repIaced whenever the pump is disassembled. Insert the
snap ring pliers in the closed position, under the
flexible retaining ring between any two of the rivets.
Expand the pliers while applying pressure in an upward direction. A slight twisting motion wiIl snap
the ring off the rivet. Repeat this process until the
retaining ring is free from all rivets. Discard the
flexible retaining ring.
14-44. Fuel Injection Pump, Inspection and Repair.
—a. Inspection.
(1) Transfer pump blades. Inspect carefully.
Check for chipping on any of the edges, pitting, imbedded foreign particles or wear on the rounded ends.
Inspect flat surfaces visually for scores.
(2) Plungers. While holding the rotor under
clean oil, insert the plungers into their bore. With
thumb and forefinger over the guide slots, tilt from
side to side several times to insure complete freedom
of movement. Interchanging or reversing their individual position may be necessary, as these are
matched parts. Repeat with short set without removing first set. Replace defective parts. If the plungers
stick, but are not visibly damaged, clean both plungers
and bore with a soft brush and lacquer-removing solvent such as lacquer thinner or acetone. (Do not force
plungers into their bore and do not handle rotor
shank).
(3) Distributor head and rotor. Examine the
radii contacted by the springs, and the weight
retainer drive spline for wear. Check all slots,
charging and discharge ports for chipping or erosion of edges and the rotor shank for scratches. If
damage or excessive wear is apparent, the head and
rotor must be replaced as a mated unit. Examine
the rotor timing pin for damage. Check alignment
of tang (at side of rotor locating pin) with center of
shoe slot and rotor discharge port.
(4) Hydraulic head vent wires. Check the vent
wire in the hydraulic head air bl eed passage for freedom of movement. If the wire is free, flush the
head and blow out all passages with clean, dry air.
If vent wire is stuck, replace it after thorough cleaning of the passage.
(5) Cam rollers and shoes. Check each roller
in its shoe for freedom of rotation, and the top edge
of each shoe, where retained by the leaf spring, for
chipping or excessive wear. Improved roller surfaces will result from long, normal operation in
clean fuel
(6) Leaf springs. Check for cracks, nicks, or
chipping, or distortion of leaf spring and wear at
points where the radii on the rotor and along the
steps that retain the roller shoes.
(7) Governor weights and retainer. Examine
the retainer sockets where weights pivot, and pivot
points of all weights for wear and replace the flexible
retaining ring (119). If the retainer can be assembled to the distributor rotor by hand, the retainer
hub must be replaced. This assembly must be a
press fit. No free play should be evident when the
retainer is assembled to the rotor.
(8) Governor linkage. Inspect the pivot points
of the governor arm (86) and pivot shaft (85). Examine the governor arm toes where they contact the
thrust sleeve. If they are worn flat on either toe,
discard and replace. The linkage gap should not
exceed 0.025 inch Examine the metering valve pin
hole in the linkage hook, throttle lever (40), shut-off
cam (25), and especially the throttle and shut- off
assemblies where joined, for looseness or burrs.
(9) Metering valve and arm assembly. Check
the metering valve body (K3) for wear. Be sure the
metering valve arm (91) is well seated and that there
is no radial movement of the arm on the valve.
Check the metering valve arm pin for wear or looseness.
(10) Cam. Since only the working portions of
the lobes on the bore are ground, the tool marks between lobes should not be considered damaged. The
cam finish is mottled from heat treatment rather
than operation. Carefully inspect the bore and edges
of all flat surfaces. If there is evidence of spalling
or flaking out, replace with new cam. Improved
cam lobe finish wilI result from long, normal operation in clean fuel oil.
14-39
KEY to fig. 14-21
1. Screw - cover
2. Washer - cover lock
3. Washer - cover flat
4. Cover - mech. gov
5. Connector - return
6. Gasket
7. Nut - terminal
8. Nut - Iock
9. Washer
10. Washer, insulating
11. Tube - electric shut off
12. Tube - electric shut off
13. Spring
14. Spring sleeve
15. Arm, shut-off
16. Frame assy - electric shut off
17. Screw
18. Washer
19. Screw
20, Washer
21. Lever - shut off
22. Screw - stop
23. Nut
24. Shift assy - shut Off
2 5 Cam - shut off
26. Throttle shaft assy
27. Screw
28. Nut
29. Screw
30. Retainer
31. Spring throttle override
31A. Stop lever fitting screw
32. Lever assy - throttle
33. Washer
34. Washer
35. seal
36. seal
37. cap
38. Spacer
39. Spacer
40. Lever - throttle shaft
4 l . Hook assy - linkage
42. Screw - gap adj.
43. Washer
44. Linkage
45. Hook - linkage
46. Spring - linkage
47. Plug
48. Plug - adjusting
49. Sleeve - press regulating
50. Packing, preformed
51. Screen inlet
52. Seal - flat
53. Ring, retaining
54. Spring pressure regulating
55. Piston, regulating
56. Seal, regulating piston
57. Regulating sleeve assy
58. End plate assy
14-40 Change 1
59. Plate - end
60. Screw
61. Washer, lock
62. Washer, flat
63. Disk thrust
64. Pin
65. Spring - blade
66. Spring - blade
67. Blade - transfer pump
68. Blade - transfer pump
69. Blade - transfer pump
70. Blade - transfer pump
71. Seal - transfer pump
72. Liner - transfer pump
73. Adjusting cap - speed droop
74. seal
75. Guide, control rod
76. Washer
77. "O" ring
78. Clip
79. Control rod assy - speed droop
80. Spring - governor
81. Nut - pivot shaft
82. Nut - pivot shaft
83. Seal - pivot shaft
84. Seal - pivot shaft
85. Shaft - pivot
86. Arm - governor
87. Piston assy - damper
88. Barrel assy - damper
89. Spring - damper 90.
Washer
91. Arm assy - metering valve
92. Shim
93. Valve - metering
94. Spacer
95. Shim
96. Plug piston
97. seal
98. Seal
99. Piston
100. Plug, advance screw hole
101. Seal
102. Pin - advance
103. Screw - head locating
104. Seal
105. Seal
106. Seal - Piston ring expander
107 0 Ring - piston
108. Spring/s advance
109. Washer
110. Ring - retaining
111. Plug - piston (power)
112. Screw - trimmer
113. seal
114. Nut - trimmer screw lock
115. cap
116. Weight, governor
117.
118.
119.
120.
121.
122.
123.
124.
125.
126.
127.
128.
129.
130.
131.
132.
133.
134.
135.
136.
137.
138.
139.
140.
141.
142.
143.
144.
145.
146.
147.
148.
149.
150.
151.
152.
153.
154.
155.
156.
157.
158.
159.
160.
161.
162.
163.
164*
165.
166.
Sleeve, thrust
Washer
Ring, rotor retainer
Retainer/s - rotor
Ring, governor retainer
Cam, ring
Governor weight
retainer
Gasket
Screw - fuel adj.
Screw - fuel adj.
Spring, leaf
Spring, leaf
Roller
Roller
Shoe
Shoe
Plunger
Plunger
Screw - connector
Washer
Washer
Screw - delivery valve
stop
Spring
Valve - delivery
Rotor
Seal, hydraulic head
Hydraulic head
Hydraulic head & rotor
assembly
Screw - head locking
Screw - head locking
Screw - timing plate
Screw - timing plate
Cover - timing
Cover - timing
Gasket - timing plate
Gasket - timing plate
Screw - plug torque
hole.
Washer - plug torque
hole.
Screw - name plate
Plate - identification
Stop - throttle
Screw - plug, torque
hole.
Washer - plug, torque
hole.
Seal - pilot tube
Shaft assy - drive
Seal - drive shaft
seal
seal
Housing assy
ME
6115-545-34/14-21(1)
Figure 14-21. Fuel Injection Pump Assembly (Sheet 1 of 7)
14-41
14-42 Change 1
Figure 14-21. Fuel Injection Pump Assembly (Sheet 2 of 7)
ME 6115-545-34/14-21 (3)
Figure 14-21. Fuel Injection Pump Assembly (Sheet 3 of 7)
14-43
ME
Figure 14-21.
14-44
Fuel Injection Pump Assembly (Sheet 4 of 7)
6115-545-34/14-21(4)
14-45
Figure 14-21.
Fuel Injection Pump Assembly (Sheet 5 of 7)
14-46
Figure 14-21.
Fuel Injection Pump Assembly (Sheet 6 of 7)
14-47
Figure 14-21.
Fuel Injection Pump Assembly (Sheet 7 of 7)
(11 ) Drive shaft. Inspect the shaft for undue
wear or cracking. Check the shaft diameter where
the governor thrust sleeve (117) slides for scoring.
The drive shaft seal grooves must be absolutely
smooth for the seals to function properly. Check
for alignment of timing roll pin on splined drive
shafts.
(12) End plate. Check the regulating piston (55)
for freedom of movement in the sleeve (49). Check
all threads for damage. The inlet screen (51 ) must
be inspected for damage. All dirt or rust must be
removed from the screen. Do not attempt to remove liner-locating pin unless obviously damaged.
(13) Governor arm damper. Check the governor
arm damper assembly for free movement of the piston (87) within the barrel (88 ). Inspect for chipping
of the piston and for scratches on the piston or
barrel inside diameter. The bleed orifice in the
barrel should permit free fuel flow when the piston
is inserted. Replace individual components as necessary.
—b. Repair.
(1) Replace transfer pump blades (67-70) if defective. Always replace both blades if one is defective.
(2) Replace all parts worn beyond allowable
limits or found to be defective during inspection.
(3) During rebuild of pump, replace all springs,
plungers, pistons, metering valve, vent wire, and
cam roller and shoes, only if damaged.
14-45. Fuel Injection Pump Reassembly and Adjustment. Reassemble the fuel pump in the reverse
order of the numerical sequence in figure 14-21 paying particular attention to the following.
a. All parts must be thoroughly flushed in clean
oil aS they are being reassembled. Cleanliness is
most important. All seals and gaskets must be replaced, whether visibly damaged or not.
CAUTION
Install piston seal dry - do not use
grease on the seal.
b. Insert regulating piston seal (56) into the lower
end of the regulating sleeve assembly (57), far enough
to expose retaining ring groove. Install retaining
ring (53).
c. Rinse in clean oil and install regulating piston
(55) and spring (54) into the sleeve, making sure
that the piston slides to the bottom of the sleeve bore
without binding.
CAUTION
Check for tightness of the orifice plate
14-48
and replace adjusting plug if plate
is found loose.
d. Install end plate adjusting plug (48), turning in
until all threads are just below port “A”.
e. Insert regulating sleeve assembly (57) into its
bore in the end plate (59).
f. Fit the transfer pump thrust disk (63) to the
end-plate (59). The thrust disk may be reversed if
one side appears worn or scratched. A small
amount of grease will hold the disk in position during
assembly.
g. Flush distributor rotor (142) in clean oil and
assemble to the bore of the head with a slight rotary
motion. Do not use force. Binding or stickiness
indicates dirt. Remove rotor and rinse once more.
h. Flush the hydraulic head (144) and distributor
rotor (142) thoroughly in clean oil and assemble,
while immersed in oil, with a slight rotary motion.
Under no circumstances should any force be used.
Do not handle the rotor shank with the fingers.
i. Place the hydraulic head and rotor assembly
(143 in the holding fixture. Insert the plungers
(133, 134) and the leaf springs (127, 128). Insert
the rollers and shoes and check for freedom of
movement.
j . Install the centrality gauge, placing the indicator pin in the metering valve bore and securing
with a head locking screw. Use a connector screw
washer under the head of the screw. Loosen the
dial indicator retaining screw and slide the indicator
to its outer limit. Install head fitting hand tight and
connect to a supply of clean, filtered, compressed
air. Regulate the air pressure to 40-100 psi.
k. The correct roller-to-roller dimension is
1.977 ± .0005”. Set both sets of rollers (129, 130)
as required adjusting each leaf spring (127, 128) alternately. Since each roller shoe (131, 132) for a given cylinder is controlled by a separate leaf spring, it may be
necessary to invert or interchange leaf springs to obtain correct dimensions on both sets of rollers. Roller
settings of both cylinders must be within .003” of each
other.
1. Check centrality of the rollers (to assure that
each one starts its pumping stroke at the same time)
as follows a) Rotate distributor rotor until one
roller is aligned with dial indicator plunger. Slide
indicator inward until plunger depresses at least
.010”. Lock indicator retaining screw. “Zero” indicator on high point of roller by rotating knurled
dial. b) Rotate distributor rotor (either direction)
until the next roller depresses dial indicator plunger.
Allowable centrality is +— .002” (total .004 “). Before
making any correction, check and record centrality
of all four rollers. c) If roller centrality is beyond
specified tolerance, rollers anti/or shoes can be
interchanged. Recheck centrality after each change.
Be sure to recheck roller-to-roller dimension as in
step k above.
m. Place the cam ring atop the hydraulic head
with the directional arrow pointing clockwise. Remember that pump rotation is always expressed as
viewed from the drive end. The pump will not deliver fuel with incorrect assembly of the cam ring.
n. Place the governor weight retainer (123) in
position over the drive on the distributor rotor.
Make sure the assembly marks on the weight retainer and the distributor rotor line up with each other.
AssembIe the snap ring to its groove with the snap
ring pliers.
o. WhiIe holding this assembly carefully together
so file rotor will not fall out, invert the entire unit
so that the governor weight retainer engages the bar
on the holding fixture.
p. Install delivery valve (141) making sure that it
operates freely in its bore. Install delivery valve
spring (140) and a new delivery valve stop (139). The
stop screw (138) internal hex has one end which is
slightly relieved to clear the deIivery valve stop. Be
sure it faces down. Start the stop screw using the
hex head end of the delivery valve extractor and finish
tightening with a torque wrench to 85-90 inch-pounds.
q. Insert the two rotor retainers (120) by lifting
the head up slightly so that the inside face of the head
is flush with the rotor end. Position the retainers
and install the retaining ring (119).
r. Insert the transfer pump liner (72) so that the
large slot is in line with the head-locating screw hole,
and the letter “C”, which signifies pump rotation,
faces up. This wiIl correctly position the liner locating slot to accept the locating pin in the end plate.
s. Carefully p lace the transfer pump blades (6770)–in their slots in the transfer pump rotor. With
one finger, rotate the liner several times to test for
bind. Return the liner to correct position.
t. Insert the transfer pump seal (71) and mount
the–end plate (59) so that the inlet fitting is in line
with the metering valve bore, The locating pin will
now line up with the locating slot in the liner. If
these are 180 out of alignment, check the end plate
for correct location of the pin as to pump rotation
(C is on the outside of the end plate). Fasten loosely
with four screws (60) and washers (61, 62); do not
tighten screws.
u. Slip the head and rotor assembly (145), drive
end–up, into open end of holding fixture. Place the
slx governor weights (116) in their sockets with the
slots facing the bore of the assembly. Place the governor sleeve thrust washer (118) against the governor
thrust sleeve (117) so that the chamfered edge faces
the sleeve. Insert the forefinger into the bore of the
sleeve and washer, holding them together, and insert them into the slots of the governor weights by
tilting the weights slightly back. The tab on the
thrust sleeve flange should face upward. Sight
across the tops of the assembled weights to ascertain correct positioning. One weight higher than
others indicates incorrect assembly of the thrust
washer.
v. Place the governor arm (86) in position with
the–fork for the governor linkage hook facing the end
plate. Insert the pivot shaft (85) (knife edge facing
end plate) and assemble the two seals (83, 84) and cap
nuts (81, 82). Tighten the cap nuts simultaneously to
a torque of 35 to 40 inch-pounds.
w. The hydrauIic head arid rotor assembly (145),
including the transfer pump, cam ring (122), governor
weight retainer (123), weights (116), governor thrust
sleeve (117), and washer (118), should now be assembled into the housing.
x. Cover shaft knurls with tape and instaII a new
seal (143) on the hydraulic head. Rotate the cam
ring so that the threaded hole is in line with the
metering valve bore. This will insure proper position of the cam. Apply a light film of clean grease
around the inside edge of the housing to aid in
assembly.
y. Grasp the hydraulic head firmly in both hands
and insert it into the housing bore with a slight rotary motion. Do not force.
z. If the assembly should cock during insertion,
withdraw and start over. This is particularly important, as cocking can cause particles of metal to be
shaved off the housing and left in the pump, causing
serious damage in operation.
aa. When inserting, make sure the assembly is
wrong into position past the hydraulic head seal (143).
Failure to do this might cause damage to the seal,
resulting in leakage. When the head and rotor are
finally assembled in their approximate location, rotate them until the head locking screw holes line up
with their corresponding holes in the housing. Insert the head lotting screws (146, 147) finger tight.
ab. Invert the pump and holding fixture in the vise
so the bottom faces upward.
ac. Insert and tighten the head locating screw (103).
—
ad. InstalI seals on piston plugs (96, 111).
—
ae. Install piston ring seal (106) and piston ring.
—
af. Assemble advance adjusting screw (112)
(trimmer), advance spring (108) and spring washer
(109).
ag. Place trimming screw (112) and spring assembly (108) in piston cavity (power side) and secure
with retaining ring (110).
14-49
ah. Using the piston ring installing tool, slide
power piston plug (96) over piston (99) until the advance adjusting screw (112) enters threaded hole in
plug.
ai. Insert screwdriver into advance adjusting
and turn out screw until approximately one
half inch protrudes from plug. Do not turn pIug on
piston as piston ring damage may result.
S Cre W
aj. Slide assembled piston and plug into advance
bore at “C” side of advance housing and thread plug
until the cam pin bore is aligned with pin bore of
cam.
ak. Install advance pin (102).
.—
al . Place advance spring (108) into piston cavity
and thread the spring side piston hole plug (111) into
advance housing.
am. Tighten both plugs and install adjusting screw
nut (114) and seal (113).
an. Turn the pump back to its original position (top
upward) in the vise.
ao. Install the metering valve (93) and shims (95)
into its bore. Depress and rotate the valve several
times to insure freedom of movement. If valve
sticks, lap it in carefully with clean oil. Never sand
or polish off the special surface treatment provided.
ap. Pull back on the governor linkage hook (45),
stretching the spring just enough to connect the hook
correctly to the fork on the governor arm (86).
Position the opposite end over the pin on the metering
valve arm (91 ). Check all of the governor parts again
for freedom of movement.
aq. With end plate removed (59), assemble the
speed droop control rod assembly (79) through
threaded hole from inside of pump housing.
ar. Slide speed droop guide (75) with O-ring
seal (77) assembled over end of rod (79) and
thread into rear of housing. Do not overtighten;
allow O. 010” clearance between guide (75) and
pump housing face,
NOTE
The apparent looseness in the governor
parts is normal. Lost motion is immediately taken up as soon as the pump
rotates.
aw. Assemble the throttle shaft assembly (26) and
lever assembly (32) partially through its bore in the
housing. Slide the spacer bushing (38) and throttle
shaft lever (40) over the throttle shaft so that the
projection on the throttle shaft lever bore engages
the keyway on the shaft. Position the forked end of
the throttle lever so that it straddles the guide stud.
Apply a light coat of grease to the throttle and shutoff shaft seals (35, 3 6). Assemble the shut-off
shaft assembly (24) from the opposite side with a
slight rotary motion. So as not to damage the seal,
firmly seat the two levers. Locate and seat the shutoff cam (25).
ax. With the throttle lever in wide open position,
check the clearance between the rear of the shut-off
shaft (B) and the vertical tab (A) on the linkage hook.
This clearance should be O. 250 inch. (See figure
14-22)
NOTE
Adjustment of this clearance in the pump
is made by changing the effective length
of linkage hook.
ay. With adjusting screw (C) tight, apply a slight
pressure to tab (A). At the same time rotate pump
one or two complete revolutions to assure that linkage is in full forward position. Loosen adjusting
screw (C) and slide linkage to maximum open length.
Insert linkage gauge between vertical tab (A) and
shut-off shaft (B) and slide linkage hook together
from rear until face of tab is flush against gauge.
Tighten adjusting screw (C). Check adjustment and
reset if required.
az. Check all governor parts for freedom of movement. Assemble a new seal (6) to cover (4), and install cover on pump, tightening the three retaining
screws (1) securely.
14-46. Solenoid Inspection and Repair.
as.
— Insert clip (78) into hole at end of rod (79).
at. Assemble seal (74) to groove at end of guide
(75)—and adjust speed droop cap assembly (73) over
seal.
au. Install end plate making certain locating pin
enters slot in transfer pump liner. Assemble flat
(61) and lock (62) washers four end plate screws (60)
and tighten to 35 inch-pounds.
av. Thread five full turns of spring (80) onto speed
droop rod assembly (79). Slip free end of spring
(80) o er formed ends of governor arm (86) with the
bent-in ends of the spring between the two tabs.
14-50
a. Crank engine and check for 24 Vdc across solen~d leads on top of injection pump.
b. If voltage exists, loosen an injector coupling
an~check for full line of fuel. If fuel is not available,
solenoid has failed.
c. Remove the cover contact nuts (7, 8) and
was%ers (9, 10) and work the solenoid assembly out
of the cover. Remove the shut-off spring (13) guide
(14), and arm (15).
d. Examine the solenoid visually for cracks and
sw~ling in the encapsulating materiaI and looseness
coil. This can result in questionable
operation and rejection of good coils
under some conditions. Do not attempt
to check solenoid operation with the
cover removed from the pump. The
governor linkage spring aids operation
when the cover is assembled.
g. Reassemble solenoid.
—h. Install solenoid on fuel injection pump.
i. On equipment test. Energize solenoid with
24 Vdc. If a clicking sound is heard, then the solenoid is operating.
14-47. Variable Speed Droop Device.
a.
shaft
shaft
plate
ME 6115-545-34/14-22
Figure 14-22.
ThrottIe Linkage Adjustment
of the contact screws. Check the solenoid for a complete circuit with an ohmmeter.
e. Assemble the shut-off arm (15) and spring (13)
and guide (14) to the coil. Before installation of the
solenoid assembly to the cover is made, adjustment of
the arm travel and spring tension should be carried
out as illustrated in figure 14-23. Install new insulating
tubes (11, 12) to both contact screws. Insert the assembly into the governor control cover as a unit. Replace
the insulating washer (10) and assemble the contact
nuts (7,8) (20-25 inch-pounds). Mount the cover assembly, with new cover seal (6), to the pump and tighten
securely.
f. With the pump mounted on the test bench, the
electrical shut-off device must be checked with 24 Vdc
and wide open throttle at the following speeds:
(1) 400 rpm
(2) Full load governed speed
(3) High idle (shut-off only)
NOTE
If use of automotive type batteries is impractical, a good, heavy duty battery
charger can be used as long as voltage can
be selected and will hold with minimum
drop (1/2 volt max. ) during application to
the solenoid coil. Use of small, inexpensive trickle chargers is not recommended,
since a voltage drop of 2-3 volts can be
expected when current is applied to the
Remove the cover, shut-off cam, shut-off
assembly, throttle shaft assembly, throttle
lever, and governor linkage hook. Remove end
assembly.
b. Remove the adjusting cap (8, fig. 14-24) by
pulling to the rear of the pump. With a pair of needlenose pliers, remove the control rod clip (4). Do not
bend the control rod. Loosen and remove the control
rod guide (6), “O” ring (5) and guide washer (1 5).
Disengage the governor spring (2) from the governor
arm (1) and remove the governor spring and control
rod assembly as a unit.
c. Examine the governor spring for distortion and
the–spring guide and bushing for excessive wear.
Replace the two seals on the control rod guide.
Check control rod for straightness and replace, if
needed.
d. Insert the control rod assembly (3) through the
threaded hole from the inside of the housing. Slide
the control rod guide (6), O ring (5) and guide (9) over
the end of the control rod (3), and thread into housing. Tighten securely. Insert clip (4) into the control rod end being careful not to bend the rod. Slide
the adjusting cap (8) over the new seal on guide (6).
Thread five full turns of governor spring (2) onto the
spring guide (9) with the spring guide and bushing (10)
against each other as shown in figure 14-24. Slip the
free end of the governor spring over the formed ends
of the governor arm (1) with the bent end of spring
between the two tabs.
e. Install the end plate, throttle shaft assembly,
throttle shaft lever, shut-off shaft assembly, and
shut-off cam. Adjust low idle adjusting screw so
bushing (10) just touches rod guide and forked end of
throttle shaft lever straddles and engages flats on
bushing. Replace cover. The speed droop assembly
is now positioned for minimum droop.
f. During bench test, make normal check of output, metering and transfer pump pressure at full load
governed speed as called for in paragraph 14-48. High
idle adjusting screw should be backed all the way out
and throttle held open as far as possible. Refer to paragraph 14-48 for bench test of fuel injection pump. See
figure 14-24 while making adjustments an speed droop.
14-51
ME
Figure 14-23.
14-52
Solenoid Armature Adjustments
6115-545-34/14-23
ME 6115-545-34/14-24
Figure 14-24. Variable speed droop adjustment
14-48. Fuel Injection Pump, Bench Test.
a. The following bench test procedure is based on
the following conditions.
(1) Injection lines. Two standard line sizes;
1/16 inch I. D, by 20 riches and 3/32 inch I.D. by 20
inches long.
(2) Fuel. The readings are based on fuel with a
viscosity of 34-36 SSU at 100° F.
(3) Fuel Temperature. 110-115° F.
(4) Nozzles: part number 12SD12 adjusted to an
opening pressure of 2500 psi (175 ATS).
b . Use diesel injector pump test stand and proceed as follows
(1) Mount the pump securely with a suitable
adapter. A drive adapter, usually with a ball bearing, supports the shaft. This pump must be tested
using an intermediate support bearing. Install high
pressure injection lines using new gaskets. Leave
fuel line connector screws at pump and injection
line nuts at nozzles loose. Install inlet and return
lines and transfer pump pressure gauge. Use a restriction fitting on the return line. The pump comes
with one installed.
(2) Set counter and tachometer switches to
clockwise position. Remember that the test stand
tachometer registers pump speed.
14-53
Table 14-2. Fuel Delivery
Pump rpm
l
900
600
(high idle) 918
113-118 mm3
121-126 mm3
15-17 mm 3
(3) Start stand at lowest speed and check for
clockwise rotation. Move throttle to full-load position. When transfer pump picks up suction, allow
fuel to bleed for several seconds from loosened connector screws. Likewise, allow fuel to bleed from
loosened injection line nuts. Tighten securely.
(4) Operate Pump at 500 rpm for 10 minutes.
Dry off completely with compressed air. Observe
for leaks and correct as necessary. Back out the
high idle stop screw and torque screw.
NOTE
The inlet to the transfer pump should
never be pressurized during bench testing.
(5) Close valve in supply line -transfer pump
must pull at least 18 inches hg at 200 rpm.
If it does not, check for air leaks on suction side or
malfunction of end plate and transfer pump parts.
(6) Fill graduates to bleed air from test stand
and to wet glass.
(7) Observe return oil. Return should be at
rate of 100-450 cc/minute at 35 psi transfer pump
pressure.
CAUTION
Under no circumstances should 130 psi be
exceeded, as the pump will be damaged.
(8) Operate at the 900 rpm with wide
open throttle and observe transfer pump pressure.
Adjust pressure-regulating spring plug to raise or
lower transfer pump pressure.
(9) Check for minimum delivery at cranking speed of 75 rpm. The delivery rate should
be a minimum of 65 mm3/s at a minimum of 8 psi.
(10) Operate at 918 rpm. and adjust high idle
screw to obtain 20-25 percent of full-load fuel
deliver y.
(11 ) Adjust the low idle screw, if used, to
a low idle delivery of 10-12 cc/1000 strokes at
500 rpm.
(12) Check the cam position at specified points
in the speed range given in table 14-2. Attain all
speeds by first running at a higher rpm, then reduce
to normal operation speed. Adjust trimmer screw,
or shim, as required, to obtain proper advance
operation. Each mark on the timing window is
14-54 Change 1
Pressure
Delivery
60-65 psi (hold)
45-50
2 pump degrees (4 engine degrees).
(13) Record fuel delivery at check points shown
in table 14-2.
NOTE
Roller settings should not be readjusted
on the test bench. Micrometer and dial
indicator settings provide more consistent, accurate results in performance.
Variations in test benches, nozzles,
lines, and fuels in different areas sometime result in inaccurate flow readings.
(14) Recheck delivery at 900 rpm checkpoint.
(15) Check governor cutoff at 950 rpm.
(16) Speed droop device test and adjustment.
(a) After normal pump test, check full-load
governor regulation by moving the throttle lever toward the closed position until the pump is “on governor”
at full-load speed. 1800 (60 Hz), 1500 (50 Hz), 2000
(400 Hz). This will be indicated by a difference in delivery sound and a slight reduction of fuel delivery
(1-2cc/1000 strokes) when a “draw” is taken into the
graduates. Hold the throttle in this position with the
standard vernier rack positioner supplied with most
test benches. Do not position throttle by means of
high- speed adjusting screw.
(b) Increase test stand speed. Record speed
where fuel delivery falls to 116-120 cubic millimeters
per stroke (1500 rpm or 50 Hz) or 114-118 cubic millimeters per stroke (1800 rpm or 60 Hz). This speed is
known as no-load speed and should not be higher than
the percentage or the high idle speed 1836 rpm (60 Hz),
1545 rpm (50 Hz). If, for example, the unit operates
at 1500 rpm full-load and 3 percent regulation is required, no-load speed will be:
1500 x 0.03=45
1500 + 45 = 1545
At 1545 rpm, the pump should not deliver more than
116-120 cubic millimeters per stroke at 50 Hz;
114-118 cubic millimeters per stroke at 60 Hz.
(c) If high idle, no load speed, as described
above, is too low, adjust by means of the knurled
knob at the rear of the pump housing. This is the
droop adjustment. The knob should be turned clockwise to raise the no-load speed 1836 rpm (60 Hz);
1545 rpm (50 Hz).
1. Timing pointer
2. Crankshaft pulley and dampener
assembly
2.
3.
4.
5.
6.
7.
8.
Fuel injection pump drive gear
Idler gear
Camshaft drive gear
Front support plate
Dowel pin
Timing marks
Crankshaft gear
Hydraulic oil pump drive gear
1. Timing window
2. Timing marks
ME 6115-545-34/14-25 C3
Figure 14-25.
Fuel Pump and Engine Timing
Change 6
14-55
NOTE
NOTE
After each droop adjustment, check fullload delivery and reposition the throttle
lever slightly as needed to compensate
for any change in full-load fuel delivery.
During assembly of the engine or replacement
of any of the timing gears it is necessary to
align the timing marks as indicated in (fig.
14-25, View B).
(d) Disconnect vernier rack positioner.
Hold throffle lever as far open as it will go with
high- speed adjusting screw backed out. Increase
test stand speed to 10 percent above full-load
speed (900 rpm).
b. Remove timing window cover from the fuel injection pump. With a clean, wide bladed screwdriver
or the pump drive shaft inserted into the drive end of
the pump rotate the distributor rotor until the timing
line on the weight retainer hub registers with the line
on the cam as indicated in (fig. 14-25, View C).
(e) Turn high idle adjusting screw in (clockwise) until fuel delivery is 20-25 percent of full-load
quantity (900-990 rpm). Lock adjusting screw in this
position. This prevents accidental overspeeding in
the event that speed droop needs further adjustment
on engine. Do not change droop setting.
(f) Seal all throttle and shut-off lever adjusting screws with lead plomb.
(g) If fuel pump is to be used for 400 Hz
application, reset high idle speed screw to 1125 rpm.
(17) Speed droop adjustment installed on engine
(60 HZ application).
(a) after priming fuel system, start and
warm engine to operating temperature.
(b) with full-load applied and engine operating at rated speed, droop may be determined by removing load and noting no-load speed or frequency.
(c) Droop may be adjusted by turning knob
clockwise to increase, counterclockwise to decrease.
A minor correction of throttle position will also be
necessary.
14-49. Fuel Pump Installation, Fuel Pump and
Engine Timing.
a. Insure that the number 1 piston is on its compression stroke. This can be determined by removal
of the cylinder head cover so valve action can be observed.
(1) Bar the engine over by hand until number 6
cylinder exhaust valve is nearly closed and number 6
cylinder intake valve is just beginning to open. This
will position number 1 cylinder near the top of its
compression stroke.
(2) To be sure that all slack is out of the timing
gears, back up the engine (counter clockwise) past the
24° BTDC timing mark and again come up to the timing mark (24° BTDC) in the direction of normal engine
rotation (clockwise when viewed from the front) (fig.
14-25, View A).
c. Install drive shaft by greasing shaft seals with
clean grease. Do not roll ‘seals over as shaft is inserted into pump. Slot in pump end of shaft should
mate with tab on pump rotor pin.
d. Mount fuel pump and adapter in position on
engine and secure pump and adapter with mounting
bolt s.
NOTE
New injectipn pumps received from supply
have a high idle adjustment of 1860 rpm for
60 HZ applications. Installation on 400 HZ
generator sets requires resetting the high
speed adjustment screw (12, figure 14-24) to
2250 rpm. Adjustment is accomplished using
an engine speed tachometer with actuater
rod (3, figure 13-1) disconnected, the shutoff
lever, (21, figure 14-21) in the on-fuel condition then manually operating the throttle
lever, (32, figure 14-21) against high speed
stop.
e. Connect throttle and shut-off linkage.
f. Connect fuel supply, return, nozzle leak-off
lines and High pressure lines.
g. Before installing fuel pump drive gear, inspect
fuel pump drive shaft and remove any burrs if
necessary.
h. Install woodruff key and coat fuel pump drive
shaft with engine oil.
i. Position fuel pump drive gear on shaft so keyway
in gear lines Up with the woodruff key.
j. Install nut and lockwasher to secure drive
gear and tighten to torque of 35 to 40 foot-pounds.
k. Replace thrust button and spring on drive
shaft.
J. Replace timing gear inspection cover.
14-50. Equipment Test.
If the fuel injection pump has been repaired or replaced refer to Chapter 16, Section II and conduct
the following equipment tests.
14-56 Change 6
a. Frequency and voltage regulation, stability,
and–transient response test, short term. Refer to
paragraph 16-15.
Section IX.
14-51. General.
b. Frequency adjustment range test. Refer to
paragraph 16-16.
TURBOCHARGER
c. Disassemble turbocharger in the numerical
sequence illustrated in figure 14-26.
a. The turbocharger is an exhaust driven blower
used to boost the power output of an engine over that
of a naturally aspirated engine by increasing the supply of air to the cylinders. The turbocharger incorporates a single stage radial inflow turbine wheel,
mounted on a common shaft with a single stage centrifugal compressor impeller. It has a one-piece
center housing with floating sleever type bearings,
a turbine housing, and a compressor housing.
b. The turbocharger responds to engine load
demands by reacting to the flow of expanding exhuast
gases and supplying a correlated volume of air to the
engine cylinders. During a heavy load/lugging
operation, the increased flow of exhaust gases turns
the turbine wheel faster, causing the compressor
impeller to turn faster to supply more air to the intake manifold, Conversely, when engine load is light
and the radial flow of gases within the turbine decreases, the turbocharger compressor reduces the
supply of air to the intake manifold.
c. The turbocharger bearings are lubricated and
cooled by filtered engine oil circulating through the
center housing under normal oil pump pressure. This
oil is supplied to the center housing through an external line through the engine main oil filter. Oil
returns to the crankcase through an external line
which extends from the bearing housing to the side of
the cylinder block.
d. The turbine of the turbocharger is part of the
exhaust system. The exhaust manifold on a turbocharged engine is in three sections with the front and
the rear sections inserted into the center section.
The manifold is sealed to the exhaust parts of the
cylinder head with a steel gasket and secured in
place with capscrews and lock washers.
14-52. Turbocharger Removal and Disassembly.
CAUTION
While turbocharger is off engine, keep
all manifold openings covered to prevent
entry of foreign objects.
CAUTION
Do not rest the center housing with the
included stationary and rotating parts on
the compressor impeller. Weight of the
complete assembly will damage the impeller blades.
d. Mark the relative positions of the compressor
and-turbine housings to the center housing to facilitate
reassembly.
e. Apply penetrating oil, or diesel fuel, to the
bolts that secure the turbine housing and backplate
to the center housing.
f. Remove the compressor housing. If necessary,
tap the housing lightly with a soft hammer to loosen
it. Remove the diffuser (3).
g. Record the shaft radial movement and shaft
end play.
(1) Check shaft end play as follows: (Specified
end play .001” to .0042”.
(a) Clamp the turbine housing flange in a
vise.
(b) Use either a clamp or magnetic base dial
indicator .(c) Place indicator contact point on end of
impeller shaft.
(d) Press up on turbine wheel to force the
impeller to extreme up position; record indicator
reading.
(e) Press down on impeller; again record
indicator leading.
(f) The difference between the readings is
the end play,
(g) End play should be from .001” to .0042”.
a. Refer to Operator arid Organizational Maintenance Manual for symptoms and isolation of malfunction of the turbocharger.
b. Refer to Operator and Organizational Maintenance Manual and remove turbocharger,
(h) Record the end play, This will be used
to determine if thrust plate assembly or thrust bearing need to be replaced.
(i) If end play exceeds .0042”, it indicates
14-57
1. V-band clamp
2. Compressor housing
3. Diffuser
4, Bolt
5. Lockplate
6, Clamp
7. Turbine housing
8, Locknut
9. Compressor impeller
10. Bolt
11
Lockplate
12. Backplate
13, Spring washer
14. Ring
15.
16.
17.
18.
19.
20.
21.
22,
23.
24,
25.
26.
27,
28.
Ring
Thrust collar
Thrust bearing
Center housing
shaft assy
Ring
Shroud
Bearing retainer
Bearing
Bearing retainer
Bearing
Bearing retainer
Bearing retainer
Pin
Figure 14-26. Turbocharger Assembly
14-58
ME
6115-545-34/14-26
that thrust collar thrust bearing, or thrust bearing
surface of the back plate assembly are worn. If end
play is less than .001”, it indicates a carbon buildup behind the turbine wheel. Unit must be disassembled and condition corrected.
14-53. Turbocharger Cleaning and Inspection.
Refer to Operator and Organizational Maintenance
Manual.
14-54. Turbocharger Repair,
(2) Check the shaft radial movement (specified
radial movement is .003” to . 007”). Proceed as
follows:
(a) Attach a dial indicator adapter to the oil
discharge outlet, or fabricate an adapter by threading
the end of a rod approximately 8“ long. Secure the
rod to the turbine housing. Attach the dial indicator
with appropriate extensions to the adapter.
(b) Position the point of the dial indicator,
through through oil discharge outlet, on the center of the
impeller shaft.
(c) With one hand on the compressor impeller and-one hand on the turbine wheel, pull the
shaft up against the indicator. Record the indicator
reading.
(d) With one hand on the impeller and one
hand on the turbine wheel, push the shaft down, away
from the indicator. Record the indicator reading.
(e) The difference between the readings recorded in steps (c) and (d) will be the total shaft radial
movement. Repeat the procedure several times before accepting a final figure.
(f) If the radial shaft movement exceeds
,007”, it is an indication of shaft or bearing wear,
or that the bearing bore in the center housing is worn.
The unit must then be disassembled and reconditioned.
h. Use a sliding “T” handle and a 3/8 inch, 12
point socket and remove the locknut (8). Hold the
“T” handle at the ends to prevent bending of the shaft.
i. Twist and pull up to remove the compressor
impeller (9).
j. Remove the metallic seal ring from the groove
on the turbine impeller shaft.
K . Remove the thrust bearing (17) and thrust
collar (16) as a unit. Separate bearing and collar.
1. Remove the metallic sealing ring (20) from the
thrust colIar (16)
NOTE
Since the outer bearing retainers and
bearings may be removed from either end
of the center housing, it is not necessary
to remove inner bearing retainers unless
inspection reveals them to be damaged or
unseated. Always replace bearing retainers.
m. Remove outer bearing retainers with a sharp
pointed tool such as an ice pick; use a twisting motion.
Use care to avoid scoring bearing or bearing bore.
a. If the turbocharger is damaged due to lack of
lubrication and results in bearing seizure, or if the
impellers are damaged due to foreign objects passing
through the turbine or compressor, the damage will
be extensive and require replacement of the rotating
parts and possibly the replacement of the center
housing. This must be determined by inspection.
At the time of engine overhaul the turbocharger must
be disassembled and all parts inspected.
b. Burnish or polish out minor surface damage
using silicon carbide abrasive cloth for aluminum
parts and crocus cloth for steel parts; clean before
reassembling with cleaning solvent Federal Specification P-D-680,
c. At time of repair or overhaul, replace rubber
seal ring, metallic seal rings, bearing retainers, and
lock plates.
d. Make certain all parts are thoroughly clean
and-work bench area is clean and free of any abrasive
material before proceeding with inspection of individual parts.
e. Replace bearings if they indicate signs of
scoring, nicks, shellac-like deposits, or other
foreign matter. Use a micrometer and telescoping
gauge and measure the diameters. The bore of the
impeller shaft bearings must not exceed 0.4019
inch and the outer diameter must not be less than
0.6182 inch. Replace bearings at time of overhaul.
f. The thrust bearing must not show any signs of
scoring or foreign matter deposit on the grooved
side. Measure the thickness at three places along
the collar bore. The measurement must not be more
than 0.1720 or less than 0.1711 inch. Replace the
thrust bearing at time of overhaul.
g. The bore for the metallic seal ring must not
indicate signs of scoring or roughness. The seal
bore must be clean and smooth. The size of the bore
must not exceed 0.5015 inch. Replace if this measurement is exceeded.
h. Make certain that the turbine and compressor
housing are clean and have no internal obstructions
that could impede the flow of gases. Replace
damaged housing.
i. The compressor impeller must not show any
signs of rubbing with either the compressor housing
or the backplate. The bore must be smooth. The fit
should be 0.0002 inch to 0.0004 inch. The blades
must be totally free of dirt or any other foreign substance. The blades must not be bent, cracked, or
eroded to a feather edge. Replace compressor impeller if these requirements are not met.
Change 3 14-59
j. Oil passages in the thrust collar must be open
and-clean. The thrust faces must not be warped or
scored. The ring groove shoulders must be free of
step wear. The bearing area width should not exceed
0.1758 inch. The ring groove width must not exceed
0.0665 inch. Check the clearance between the thrust
collar and the thrust bearing with a feeler gauge.
Clearance should be between 0.001 and 0.004 inch at
three spots. Replace thrust collar if requirements
are not met.
k. Inspect the shroud for cracks, signs of erosion,
damage caused by rubbing, and distortion. Replace
shroud if damaged.
1. The turbine wheel must not reveal any signs of
rubbing and the vanes must not be cracked, nicked,
or eroded to a feather edge. The shaft must not show
any signs of scoring, scratching or overheating. Use
a micrometer to measure the shaft journals. Replace
turbine wheel and shaft if damaged. The journals
must not be more than 0. 003 inch out of round, and
the diameter must not be less than 0. 3992 inch. The
sealing ring groove walls must be free of step wear.
The sealing ring hub outer diameter is 0. 682 to
0. 683 inch. Ring groove width is 0.0645 to 0.0665
inch. Replace excessively worn journal.
14-55, Turbocharger Reassembly and Installation.
NOTE
The tools and workbench must be kept
clean at all times during the reassembly
to prevent the entrance of dirt or foreign
matter. All parts must be free of nicks,
burrs, scoring, and foreign matter.
a. If the inner bearing retainers have been removed from the center housing, install new retainers.
b. Place the center housing on end on the bench.
c, Oil one of the bearings and place it against the
inner bearing retainer.
d, Install the outer bearing retainer.
e. Invert the center housing and install the remaining bearing and retainer in the same manner.
f. Insert the turbine and shaft assembly, with
new–metallic seal installed, into a suitable holding
fixture.
g. Place the turbine shroud on the shaft.
14-60
h. Oil the shaft journals. Apply a light, even
coat of oil.
i. Place the center housing assembly over the
shaft. Press down to seat the metallic seal ring.
Rotate the housing to assure proper seating.
j. Install a new metallic seal on the thrust collar.
k. Insert the thrust collar in the thrust bearing so
that the metallic seal ring end of the collar is on the
smooth side of the thrust bearing.
1. Install the thrust bearing and collar assembly.
Place the thrust bearing over the pins on the center
housing. The bearing will fit only one way. Press
down to seat.
m. Install a new rubber seal ring.
—
n. Make certain the thrust spring is installed in
the backplate.
o. Install the backplate. Use care not to damage
the--metallic sealing ring on the thrust collar. Install
the lockplates. Tighten the bolts to 40-60 inch-pounds
torque. Bend up the locking tabs.
p. Install the compressor impeller. Use a
twisting motion to insure that the impeller bottoms
on the thrust collar.
q. Washer face of locknut and the face of the impeller must be smooth and clean. Lightly oil the
threads and washer face of the locknut. Install locknut; tighten to 18-20 inch-pounds. Use a sliding “T”
handle and further tighten locknut through another 90
degrees.
r. Install the turbine housing, clamps and lockplates. Tighten the bolts to 100-130 inch-pounds.
Bend up locking tabs.
s. Refer to the Operator and Organizational
Maintenance Manual and install the diffuser.
—t. Install the compressor housing.
u. Install the V-band clamp. Tighten nut to 4080 inch-pounds.
v. Refer to Operator and Organizational Maintenance Manual for installation of the turbocharger.
Section X. WATER PUMP AND FAN
14-56. General.
a. The water pump is a centrifugal type pump that
circulates coolant through the engine and radiator.
The pump is mounted on the front of the cylinder
block and is belt driven from the crankshaft pulley.
Coolant is drawn through the inlet opening by the
pump impeller and forced through the outlet in the
backside of the volute and into the cylinder block, and
the lube oil cooler.
b. The water pump shaft and bearing assembly
does not require lubrication because the bearing is of
the sealed-for-life type. A water slinger on the
pulley end of the shaft slings any coolant which might
seep past the seal assembly out the cored opening in
the pump body, thus preventing coolant from coming
in contact with the shaft bearing. The shaft and
bearing assembly is secured in the pump body by a
press fit and a retaining snap ring. The seal between the impeller and pump body is of the packless
type. The seal assembly is spring loaded and is
pressed into the pump body forming a leakproof seal
at this point,
c. The fan is located behind the radiator on the
front of the engine. The fan is belt driven from the
engine and draws cooling air through the louvered
panel at the rear of the unit and exhausts it through
the radiator core, shutter and grille.
Figure 14-27. Water Pump
is binding, running dry from lack of lubricant, or
feels rough, the shaft and bearing assembly must be
replaced. If the slinger is damaged, it must be
replaced.
CAUTION
Do not clean shaft and bearing assembly
in cleaning solvent because the lubricant
will be washed from the bearing.
14-57. Removal and Disassembly.
a. Water Pump Removal.
Refer to Operator and Organizational Maintenance
Manual.
b. Check condition of the ceramic seal insert
bonded to the pump impeller. If it is rough, cracked,
or chipped, replace the impeller.
c. Thoroughly clean pump body with cleaning
solvent, Federal Specification P-D-680.
b. Fan Removal.
Refer to Operator and Organizational Maintenance
Manual.
d. Check condition of bearing bore in the body.
Replace pump body if cracks are evident.
e. Replace the water pump seal assembly.
c. Water Pump Disassembly.
14-59. Reassembly and Installation.
(1) Place water pump in a press and remove
pulley hub.
(2) See figure 14-27 and disassemble water
pump as illustrated.
(3) Place water pump assembly in position on
a press, impeller end up. Make certain the pump
rests on back of pump body and not on the water inlet
or drain hole. Press end of shaft until shaft and
bearing assembly is out of the pump body. Remove
impeller from the pump body.
(4) Drive out seal assembly with a drift pin or
rod and a hammer. ,
14-58. Inspection and Repair.
a. Check condition O f pump shalt and bearing
assembly by rotating the bearing. If the bearing
a. Pump Reassembly.
(1) Position pump body on press, impeller end
up. Position seal assembly in the pump body. Place
seal installer tool on the seal and press seal into
pump body, making certain the carbon sealing surface is not damaged.
CAUTION
Face of seal assembly must be free of
oil, grease, and fingerprints before seal
assembly is installed.
(2) Position pump body on press, bearing bore
up. Start shaft and bearing assembly into bore,
slinger end of shaft down. Press shaft until bearing
seats on shoulder in the pump body. The slinger
must be 1-15/16 inches from the end of the shaft
Change 7 14-61
before installing in the pump body.
CAUTION
Do not force the bearing shaft assembly
into the pump body by putting pressure on
the end of the shaft. Use a tool which
puts the force on the outside race. This
will prevent the possibility of pitting the
races of the bearing by the balls within
it when more force than required is used
to seat the bearing in the pump body.
(3) Position pump on press with pulley hub end
of shaft firmly supported on the press base plate.
Position impeller on upper end of shaft. Using a
collar between the impeller and the press ram, press
impeller on shaft to attain 0.015 inch maximum
feeler gage clearance between impeller and body.
CAUTION
(4) Position water pump on a press with the
impeller end of the shaft firmly supported on the press
base plate. Use a collar between pulley hub and press
ram because the end of the shaft protrudes beyond
pulley hub; press pulley hub on shaft to within four
inches (± 0.010 inch) between bottom of pump body
and the fan side on the pulley hub flange.
(5) Rotate pulley hub and check for proper
operation of the water pump assembly.
NOTE
A slight drag caused by mating surfaces
of the seal assembly and impeller is
normal.
b. Pump Installation.
Refer to Operator and Organizational Maintenance
Manual.
c. Fan Installation.
Seal face of impeller must be free of oil,
grease, and fingerprints before installing
impeller.
Refer to Operator and Organizational Maintenance
Manual.
Section XI. CRANKSHAFT PULLEY AND VIBRATION DAMPENER, AND ENGINE FRONT SUPPORT
(5) Note the number of shimming washers removed between the upper and lower bracket.
14-60. General.
a. The crankshaft pulley, mounted on the front
end-of the crankshaft, is used to transfer drive power
from the crankshaft to belt driven accessories such
as the water pump, fan and alternator.
b. Vibration dampening is accomplished by bonding
a neoprene compound between the crankshaft pulley
and the crankshaft hub.
c. The engine front support is the trunnion type,
and mounts to the skid base.
14-61. Removal and Cleaning.
—a. Removal.
(1) Remove crankshaft pulley retaining capscrew
and washer. See figure 14-28.
(2) To remove crankshaft pulley, use universal
puller kit with threaded adapters that fit into tapped
holes on face of pulley.
CAUTION
Do not use gear puller that applies pressure
to pulley outer diameter. TO do so will
result in damage to the pulley.
(3) Remove pulley and dampener assembly, and
the woodruff key from the crankshaft.
(4) Remove the two screws in the engine front
support assembly that secure the bracket set. Remove the liners. See figure 14-29.
14-62
b . Cleaning.
(1) Clean pulley and support with cloth or
brush dipped in cleaning solvent, Federal Specification P-D-680.
(2) Ensure that neoprene dampener is not
exposed to cleaning solvent.
14-62. Engine Front Support Inspection.
Inspect front support for cracking or other signs of
damage.
14-63. Crankshaft Pulley and Vibration Dampener
and Engine Front Support Installation.
a. Remove any burrs from crankshaft with a
fine mill file, if necessary, and install woodruff key
into crankshaft keyway.
b. Align crankshaft pulley and dampener assembly
keyway with the crankshaft keyway and install
assembly on crankshaft.
c. Install retaining capscrew and washer and
tighten capscrew to 200 to 220 foot-pounds.
d . Insert liners in front support brackets.
e. Install bracket on cross-member in position on
main frame. Install bracket securing hardware.
1.
2.
3.
4.
Screw
Washer
Pulley
Key
ME 6115-545-34/14-28
Figure 14-28. Crankshaft Pulley and Related Parts
NOTE
Do not tighten at this time.
f . Lower engine into position on bracket and
install exact number of washers as noted during removal and install bracket cap and securing capscrews.
g. Tighten bracket cap securing capscrews
evenly to a torque of 95 to 105 foot-pounds. Determine the amount of shimming washers necessary to
fill the gap between ends of the bracket and cap.
NOT E
h. If original washers do not satisfy this requirement, remove capscrews and install shimming
washers to equal the gap.
i. Install capscrews and torque to 95 to 105
foot-poundsl
CAUTION
The bracket assembly must be a
tight fit on trunnion to avoid move ment of liners.
Shimming washers are 1/32 inch
thick and must be evenly distributed
on both sides of bracket.
14-63
1.
2.
3.
4.
Screw
Bracket set
Washer
Liner
ME 6115-545-34/14-29
Figure 14-29.
14-64
Engine Front Support
Section XII. OIL PUMP AND OIL PAN ASSEMBLY
14-64. General.
installed.
The gear-type oil pump is mounted on the
front of the cylinder block and the drive gear meshes
with the crankshaft gear.
(5) Disconnect coolant inlet and outlet lines
to oil pan heater element if winterization kit is installed.
Refer to TM 5-6115-545-12 for winterization kit.
b. A reIief valve, located in the oil pump outlet, bypasses oil back to the oil pan when the pressure exceeds 82 to 98 psi. This relieves excessive
discharge pressure when starting a cold engine and
cuts down wear on the oil pump gears.
(6) Disconnect oil drain hose.
(7) Refer to figure 14-30 and remove and
disassemble the oil pan and heater as follows
c. The oil pan serves as a bottom cover for
the crankshaft and a reservoir for the lubricating
oil. A finned steel tube is installed in the oil pan.
Heated coolant is circulated through the tube to preheat the oil to aid in engine starting in sub-freezing
temperatures.
(a) Remove 32 capscrews and lockwashers securing the oil pan to the flywheel housing,
timing gear cover, and the cylinder block
14-65. Removal and Disassembly.
(c) Remove the brass fittings from the
inside and Outside of the connections on the oil pan.
a. Symptoms and Isolation of Malfunction. A
malfunction of the oil pump or a leak in the oil pump
is usually indicated by 10SS of oil pressure which results in engine shutdown. To isolate the malfunction,
proceed as follows
(1) Examine the oil pan for evidence of
leakage. Leaking oil can be detected on top of the
fuel tank located directly below the oil pan.
(2) Check the oiI Ievel If the level iS suffcient for normal operation, and engine has shut-down
due to loss of oil pressure, the malfunction is probably the result of oil pump failure. Isolate oil pump
failure as follows:
(a) Remove valve cover. Refer to TM
5-6115-545-12 and start engine. Before releasing
start switch move the battle short switch to the ON
position to by-pass the low oil pressure cut-out switch.
(b) If there is sufficient pressure from
the oil pump, Gil should be forced out of the rocker
arm shaft above each cylinder. If there is no evidence of oil flow at these points, the oil pump has
failed. Stop the engine and proceed with the removal
and repair procedures.
b. Removal and Disassembly.
tank.
(1) Drain fuel system and remove main fuel
(2) Remove electric starter, tool box and
fuel-burning heater if installed. Refer to Operator
and Organizational Maintenance Manual
(3) Open oil pan drain valve and allow oil
to drain.
(4) Close valves for coolant inlet and outlet
to the engine block if a winterization kit is
(b) Jar the oil pan loose, drop the rear
end, and remove pan.
(d) Remove the nuts, lockwashers, and
capscrews securing the heater element clamps to
the inside of the oil pan. Remove the heater element
(8) See figures 14-31 and 14-32 and remove and disassemble the oil pump as follows:
(a) Remove the clamp supporting the
oil suction tube.
(b) Uncouple the brass compression
fitting securing the oil pump discharge tube.
(c) Remove the bolts securing the oil
pump to the cylinder block and remove the oil pump
assembly. The pump may have to be pried off its
mounting dowels.
(d) Remove the oil pump suction tube
support bracket from the main bearing cap.
(e) Wash the oil pump assembly in
cleaning solvent, Federal Specification P-D-680.
(f) Remove the suction tube assembly.
(g) Remove the pressure relief valve
assembly from the pump body.
(h) Depress the relief valve spring and
retainer with two screwdrivers or on improvised
two-prong tool. Drive out the roll pin and remove
retainer, spring and relief valve piston.
(i) Remove the oil pump drive gear
from the drive–shaft. Use a three-leg puller to
avoid damage to the gear.
(j) Remove the screws and washers
securing the pump cover to the body assembly and
remove the pump cover.
(k) Remove the pump driver gear and
Change 6
14-65
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Screw
Washer
Screw
Washer
Screw
Washer
Plug
Adapter
Nut
Bushing
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Nut
Washer
Screw
Bushing
Nut
Clamp
Heater
Gasket
oil pan
Plug
Connector assembly
Figure 14-30.
14-66 Change 7
ME 6115-545-34/14-30 C7
Oil Pan and Heater
1.
2.
3.
4.
5.
6.
7.
8.
9.
Nut
Washer
Washer
Screw
Washer
Clamp
Screw
Washer
Screw
10.
11.
12.
13.
14.
15.
16.
17.
18.
Washer
Nut
Tube assy
Adapter
Tube
Preformed packing
Screw
Washer
Tube assy
19.
20.
21.
22.
23.
24.
25.
26.
27.
Flange
Tube
Screen assy
Retainer
Screen
Ring
Gasket
Valve assy, relief
Pin
28.
29.
30.
31.
32.
33.
34.
35.
36.
Washer
Spring
Piston
Body
Oil pump
Screw
Washer
Washer
Bracket
ME 6115-545-34/14-31
Figure 14-31. Oil Pump and Related Parts
14-67
1.
2.
3.
4.
5.
6.
Gear
Bolt
Bolt
Washer
Cover
Gear shaft assy
7. Gear shaft assv
—.
8.
9.
10.
11.
12.
13.
14.
Gear
Gear
Shaft
Shaft
Body assy
Pin
Body
ME
Figure 14-32. Oil Pump Assembly
14-68
6115-545-34/14-32
shaft assembly from the pump body.
(1) Remove the pump driven gear and
shaft assembly from the pump body.
(m) To prevent damage to the drive gear
teeth and driven gear teeth do not remove the gears
from the shaft with a gear puller. Press the gears
from the shafts.
14-66. Cleaning, Inspection and Repair.
a. Wash all pump parts in cleaning solvent,
Federal Specification P-D-680.
b. Inspect the oil pump drive gear, the driver gear
and shaft assembly and the driven gear and shaft
assembly for wear and chipped teeth. Replace worn and
damaged parts.
h. Install the piston, spring, and spring retainer in the relief valve body. Depress relief valve
spring and retainer with two screwdrivers or an improvised two-prong tool. Insert a 3/16-inch, or
less, drift pin into the roll pin hole. Hold the retainer with the drift pin until the roll pin is installed.
i . Install the relief valve assembly into the
pump body and tighten securely.
j . Install the suction screen assembly onto the
pump body.
k. Install heater element in the oil pan and
secure it with nuts, lockwashers and capscrews.
1. Install the brass fittings on the inside and
outside of the oil pan.
c. Inspect the inside of the pump body and the
inner face of the cover for wear or scoring. Replace
damaged part.
m. Lubricate oil pump drive gear and install
oil pump assembly onto the cylinder block with the
drive gear in mesh with the crankshaft gear. Install bolts and torque to 68 to 73 foot-pounds.
d. Inspect the relief valve piston. It must
slide–smoothly in the bore of the relief valve body.
Replace a damaged relief valve or body.
n. Position brass fittings and O rings and install oil discharge tube to cylinder block and oil
pump assembly; tighten fitting securely.
e. Inspect the heater element for cracks, and
1oose or bent fins. Replace element, if it is severely
damaged.
f . Inspect oil pan for dents or cracks. Dents
must be smoothed out. Replace oil pan if badly damaged.
g. Inspect suction tube assembly for holes and
deformity.
14-67. Reassembly and Installation.
a. Heat the driven oil gear in oil to 350° + 25°
and press onto the shaft 0.848 inch from end.
b. Repeat step a. for the driver oil gear, except that the gear is pressed onto the shaft 1.812
inches from the end.
c. Lubricate gear and shaft. Install the long
end of the driven gear and shaft assembly into the
lower chamber of the oil pump body.
d. Lubricate gear and shaft. Install the short
end of the driver oil gear and shaft assembly into the
upper chamber of the oil pump body.
e. Assemble the pump cover onto the pump
body. Use the two 5/8-inch long, grade 5, lock bolts
in the top holes. The six other holes use 1-inch
bolts with a lockwasher. Tighten the bolts to a torque
of 18 to 20 foot-pounds.
f . Before proceeding make certain that the
assembled pump will turn freely without binding.
o. Install support bracket and clamp securing oil
suction line.
p. Install a new gasket set to the rails of the
oil pan.
q. For ease of installing the oil pan, make up
two guide studs and screw them into the diagonal
corners of the cylinder block.
r . Position the oil pan with the front end up and
mount the oil pan on the guide studs. Hold it in
position by inserting a capscrew and lockwasher in
each corner, but do not tighten them so that the oil
pan can be shifted.
s. Remove the guide studs. Install the 3/4inch long capscrews and lockwashers which hold the
rear flange of the oil pan to the flywheel housing.
Tighten the rear corner capscrews in the side rail
and the two upper capscrews in the flywheel housing
alternately, until secure.
t . Install the 1-inch long capscrews and lockwashers, securing the front rail of the oil pan to the
timing gear cover. Install the remaining capscrews
and lockwashers. Tighten all capscrews securely to
a torque of 28 to 33 foot-pounds.
u. Install drain valve into oil pan and tighten
securely.
v. Install oil drain hose, and connect coolant
lines to the heater element if winterization kit is installed.
g. Heat the oil gear shaft and press the drive gear
onto the shaft allowing 0.057 to 0.062 inch to protrude.
Change 6
14-69
w. Open valves for coolant in and out of the
heater element if winterization kit is installed
y. Install main fuel lines, then fill and check for
leaks.
x. Install electric starter, tool box and fuel
burning heater if used.
Fill the oil pan to the proper level with the
specified engine crankcase lubricant. Run engine
and check for oil leaks.
Section XIII. FLYWHEEL AND HOUSING
14-68, General.
The flywheel is mounted on the rear of the cylinder
block. Its purpose is to insure a smooth flow of
torque at the engine drive output. The rotor of the
main generator is attached with two disk type steel
couplings to the flywheel.
14-69. Removal, Inspection and Repair.
a. Symptoms and Isolation of Malfunction. A
malfunction associated with the flywheel is usually
indicated by excessive vibration and noise.
(8) Remove eight capscrews securing
flywheel housing to the cylinder block. Tap the
housing with a soft-headed hammer to break it loose
from the housing dowels. Remove the housing.
c.
Inspection.
(1) Thoroughly clean flywheel housing
with cleaning solvent, Federal Specification P-D680. Remove preformed packing from housing.
(See fig. 14-33)
(2) Inspect housing for cracks and other
damage.
b.
Removal.
(1) Remove engine from unit (para 2-13).
Support engine on blocks or suitable stand.
(2) Remove electric starter. Refer to @erator and Organizational Maintenance Manual.
(3) Remove six hexsocket capscrews attaching flywheel to crankshaft flange. See figure 14-33.
(4)
holes of the
on capscrew
and remove
Install two long capscrews in opposite
flywheel face to serve as handles. Pull
handles while supporting flywheel weight
flywheel.
NOTE
If flywheel cannot be removed with a
direct pull on the handles, it maybe
necessary to tap flywheel with a suitable brass bar through the electric
starter mounting opening. Turn flywheel and tap exposed part at intervals until flywheel can be remove &
(5) Remove ring gear from flywheel by
grinding a notch through the ring gear at the rod of
one of the teeth. Expand the ring and drive it from
its position.
CAUTION
Do not attempt to remove ring gear
without first expanding it.
(6) The wear sleeve is held in position on
the flywheel by a press fit. It is removed with a pry
bar or three-jawed external puller. Wear sleeve
should be removed with an even motion.
(7) Remove capscrews securing oil pan to
flywheel housing.
14-70
Change 6
(3) Inspect ring gear for nicks, cracks,
or excessive wear.
(4) Inspect flywheel for nicks, burrs or
dents. All burrs, nicks and dents must be removed
from the flywheel surface that fits against the
crankshaft flange.
14-70. Reassembly and Installation.
a. Place flywheel housing on a bench with the
preformed packing side up. Drive out the packing
from the housing with an oil seal remover.
—b. Clean oil seal bore in the flywheel housing.
c. The outer diameter of the seal comes with
a layer of red-colored sealant which eliminates the
use of a sealing compound on the outer diameter of
the seal prior to pressing it into the flywheel
housing.
d. Position seal squarely with bore in housing
and, using a seal installer, carefully drive seal into
flywheel housing until it is seated against the seal
stop in the bore.
NOTE
The seal must be installed with open
side of seal directed toward the
cylinder block
e. Make certain the crankshaft flange on which
the seal rides is free from nicks or burrs. Polish
with crocus cloth if necessary.
f . Lubricate flange and sealing lip with clean
engine oil Do not use grease, soap, white lead, etc.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Screw
Flywheel assy
Ring gear
Flywheel
Wear sleeve
Plug
Screw
Washer
Oil seal
Preformed packing
Preformed packing
Housing
ME 6115-545-34/14-33
Figure 14-33. Flywheel and Housing
NOTE
Final installation of the flywheel into
the seal is blind, therefore, extreme
care must be exercised to prevent
crimping or cutting the sealing lip
of the seal when installing the flywheel.
g. Install flywheel housing on cylinder block
and tighten securing capscrews to a torque of
73 foot-pounds. Install oil pan capscrews to flywheel housing and tighten them to a torque of 28 to
33 foot-pounds.
h. Press new wear sleeve onto flywheel flange.
not use lubricant or sealer Metal-to-metal contact is necessary for proper heat transfer.
seal on until its shoulder makes contact with the flywheel.
DO
NOTE
start ring gear on the flywheel so
that when the flywheel is installed,
the chamfered ends of the teeth will
face the cylinder block.
i . Install the ring gear onto the flywheel by
Uniformly heating the gear to 300° F (dull red heat
visible in the dark). Then, press ring gear onto the
flywheel which is at room temperature.
NOTE
DO not overheat the ring gear to a
bright red. This will destroy the
temper of the gear.
j . Drive gear down tight against the shoulder
of the flywheel. Allow the ring gear to cool slowly,
do not cool with water.
Change 1
14-71
k. Install three guide pins on flywheel housing
to aid in the mstallation of the flywheel. Lubricate
the lip of the oil seal and the wear sleeve with
engine oil.
1. Install the flywheel over the temporary
guide pins as straight as possib]e. Do not cut,
crimp, or double back the seal lip.
.m. Remove the guide pins.
n. After flywheel is assembled to the crankshaft tighten the flywheel lock bolts to a torque of
95 to 105 foot-pounds.
o. Attach a dial indicator to the flywheel housing and check flywheel face for run-out. Pry flywheel to the rear, to eliminate crankshaft end ply,
otherwise dial indicator reading will not be
accurate. Flywheel face run-out must not exceed
0.0005 inch maximum total indicator reading per
inch of flywheel diameter.
p. Readjust dial indicator so that the stem
will ride on flywheel driving ring bore. The eccentricity of the driving ring bore must not exceed
0.0005 inch maximum total indicator reading.
NOTE
Eccentricity between driving ring
bore and pilot bearing bore must
not exceed 0.008 inch total indicator
reading.
q. Attach dial indicator to the flywheel housing
and check pilot bearing bore for run-out. Eccentricity y of pilot bearing bore must not exceed 0.005
inch maximum total indicator reading.
Attach dial indicator to flywheel and check
flywheel housing bore for run-out. The bore runout must not exceed 0.008 inch total indicator reading.
s. Readjust dial indicator to check flywheel
housing face for run-out. The face run-out must
not exceed 0.008 inch total indicator reading.
t . Install electric starter. Refer to Operator
and organizational Maintenance Manual.
Install engine in unit. Refer to paragraph
2-14.
Section XIV. TIMING SYSTEM
14-71. Description.
a. Timing is preformed by a train of mechanically synchronized timing gears located at the
front of the engine. This train consists specifically
of four gears: fuel pump drive gear, idler gear,
camshaft gear and crankshaft gear. (Class 1 sets
contain an additional gear to drive the hydraulic
pump).
b. The crankshaft drive gear is the central
element of this gear train, driving the other gears
either directly or indirectly. The fuel pump drive
gear and camshaft gears are timed to the crankshaft
gear to provide timed synchronization of fuel injection and valve positions. The idler gear transfers
drive power from the crankshaft gear to the fuel
pump drive gear.
c. The timing gear cover encloses the gear
train-and the front end of the engine. The gears are
lubricated by the oil splash method.
d. A malfunction in the timing system is usually indicated by an extremely loud knocking sound
from the engine or abnormally quiet but sluggish
operation of the engine. These symptoms are an indication that the engine is not properly timed. If the
engine was operating normally prior to the occurrence of these symptoms, it is an indication that the
gear is badly worn or has lost a gear tooth.
14-72. Gears and Cover Removal.
14-72
Change 6
a. Timing Gear Cover Removal. See figure
14-34 and proceed as follows
(1) Remove engine support (para 2-13).
(2) Remove crankshaft pulley and vibration dampener assembly (para 14-61).
(3) Remove oil pan (para 14-65).
(4) Remove inspection plate, capscrews,
lockwashers and fuel pump drive gear inspection
plate. Remove thrust button with spring from fuel
pump drive shaft.
NOTE
If only the fuel pump drive gear has
to be removed and/or replaced, the
gear can be removed through the
opening in the timing gear cover.
(5) Remove capscrews on front and back
side, which secure timing gear cover to cylinder
block and engine front plate. Jar cover loose with
a soft-headed hammer. Pry cover from locating
dowels, and remove it from fencing.
b. Fuel Pump Drive Gear Removal. Refer to
note above 14-25 and proceed as follows:
(1) Rotate engine until No. 1 piston is at
top dead center on its compression stroke.
1. screw
2. Washer
3. Cover
4. Gasket
5. Screw
6. Screw
7. Screw
8. Screw
9.
10.
11.
12.
13.
14.
15.
16.
Screw
Screw
Oil seal
Pointer
Cove r
Gasket
Screw
Gear assy
Figure 14-34.
24.
Washer
Gear cluster 25.
26.
Bearing
27.
Screw
28.
washer
29.
cam shaft
30.
gear
31.
23. key
17.
18.
19.
20.
21.
22.
Timing Gear and Cover
Bolt
Screw
washer
Plate assy
Plate
stud
Gasket
Shaft
ME 6115-545-34/14-34 C6
and through the opening in the timing gear cover.
(2) Remove nut and lockwasher securing gear
to fuel pump drive shaft.
(3) Remove the fuel injection pump, from the
fuel pump drive shaft (para 14-43).
(4) Remove the two oil seals from the fuel
pump drive shaft. Inspect oil seals for wear or
damage. Replace if necessary.
(5) Withdraw the fuel P ump drive shaft, with
the drive gear attached, from the mounting adapter
(6) Position fuel pump drive shaft and drive
gear on a press and remove the fuel pump drive
gear from the drive shaft. Inspect drive gear and
replace if necessary.
c. Idler Gear Removal. See figures 14-34 and
14-35 and premed as follows:
(1) Remove capscrews and washer securing
idler gear. (fig. 14-34)
(2) Remove idler gear with bearings.
Change 6
14-73
e. Inspect all gears for excessive wear and
chipped or broken gear teeth
14-74. Timing Gears and Housing Repair.
a. Repair is limited to replacement of
housing, front support plate, or gears if badly
worn or damaged.
b. Replace idler gear shaft if scored or exexcessively worn beyond the allowable limits. Refer
to step d. above.
14-75. Installation.
a.
—
Crankshaft Gear Installation
(1) Install woodruff key in crankshaft.
(2) Heat gear in oil to a temperature of
approximately 300° F.
1. Slot
2. Oil hole
3. Idler gear shaft
ME 6115-545-34/14-35
Figure 14-35. Idler Gear Shaft Installation
(3) If idler gear shaft is scored or worn it
must be replaced The specified outer diameter on
both ends of the idler gear shaft is 0.999”-1.000”.
Install a 9/16 -18 adapter in the end of the idler
gear shaft. Install the end of the slide hammer into
the adapter and remove the idler gear shaft from the
cylinder block.
d. Camshaft Gear Removal. Refer to paragraph 14-77 for removaI procedures.
e. Crankshaft Gear Removal. Use bar type
puller and remove crankshaft gear.
f . Hydraulic Gear Removal. (Class 1 sets
only (para 14-14)
14-73. Timing Gears and Housing Cleaning and Inspection.
Clean cover and gears using cleaning solvent, Federal Specification P- D-680.
b. Clean all gasket material from timing gear
cover using care to prevent scoring or gouging of
surface.
c. Inspect front support plate for damage and
wear.
d. Inspect idler gear shaft for scoring or
wear The center diameter on both ends must be
0.999 to 1,000 inch.
14-74
(3) Coat crankshaft at gear location with
a mixture of white lead and oil.
(4) Drive or press gear onto crankshaft.
CAUTION
Use asbestos gloves when handling
the heated gear.
(5) When crankshaft is installed in engine
make certain that timing mark a crankshaft gear
is aligned with timing mark, on camshaft gear when
crankshaft gear is installed.
b. Camshaft Gear Installation. See figure
14-35 and proceed as follows:
(1) Insert idler gear shaft into cylinder.
Block bore so that oil hole on top of shaft aligns
with slot in front plate.
(2) Insert washer and capscrew into idler
gear shaft (see fig. 14-34) and tighten capscrew
until shaft bottoms in cylinder block
NOTE
The bore size of the roller bearing
is 1.000-1.008 inches and the
outer diameter of the outer race of
the bearing is 1.980-1.981 inches.
The bore size of the idler gear is
1.9785-1.9795 inches and the bore
size of the groove in the idler gear
for the spacer is 2.068-2.078
inches. If the bearing assembly is
worn, drive the outer races out with
a punch and press in the new races
until they contact the newly installed
spacer.
NOTE
(3) Position idler gear bearings with
spacer between them in idler gear.
The outer diameter of the front oil
seal has a layer of red-colored sealant which forms a seal between the
outer diameter of the seal and the
bore in the cover. The bore of the
seal has a layer of rubber compound
to prevent oil leakage between the
seal and the crankshaft.
(4) Apply a light coat of engine oil to idler
gear shaft. Position idler gear with bearings on
idler shaft making certain the timing marks on the
idler gear and the crankshaft gear are lined up properly when number 1 piston is at top dead center, as
illustrated in figure 14-25.
(5) Install capscrew with washer and
tighten cap screw to a torque of 95 to 105 foot-pounds.
NOTE
The allowable end play of the idler
gear bearing is a minimum of
0.001 inch.
(2) Place timing cover on a flat surface
with the front side to the top.
(3) Position seal in timing cover with open
side of seal facing down and positioned squarely in
bore of cover.
CAUTION
—c.
Fuel Pump Drive Gear Installation.
(1) Coat fuel pump drive shaft with engine
oil and install shaft in pump mounting adapter. Install woodruff key.
Make certain that seal is not
cocked in timing cover bore.
(4) Drive or press seal into timing cover
bore until it bottoms.
(2) Position drive gear on drive shaft with the
keyway lined up with the woodruff key. Install
lockwasher and nut on drive shaft and tighten nut to a
torque of 35 to 40 foot-pounds.
NOTE
During the assembly of the engine or
replacement of any of the timing gears
it is necessary to align the timing
marks as shown in (fig. 14-25, view B).
After aligning the marks, rotate the
flywheel counter-clockwise (view from
timing gear end) until the proper degree timing mark (for the specified
rpm) on the pulley and damper
assembly is registered with the
pointer on the front of the timing
gear cover. The engine is now properly positioned for the installation of
the fuel pump.
CAUTION
Do not press on open face of seal
or damage will occur.
(5) After seal is installed in the cover, insert fingers into inner part of seal and check for
rotation. If seal was installed properly, the inner
part will turn with a firm feel to the fingers.
—e.
Cover Installation.
(1) Inspect and remove burrs from keyway
in crankshaft, using a fine-cut mill file or stone, to
prevent damaging the inner layer of rubber of the
crankshaft oil seal.
(2) Coat crankshaft lightly with engine
lubricating oil.
(3) Cement (permatex or equivalent) a new
gasket to the timing gear cover.
NOTE
Check backlash between all gears.
Backlash between any two mating
gears must not exceed 0.015 inch.
New parts must be installed if
backlash exceeds this requirement,
Refer to para 14-74 for replacement
of gears.
Oil Seal.
(1) Clean the timing cover bore to receive
a new seal.
(4) Using a direct reversal of the removal
procedure, position the gear cover on the two dowel
pins in the cylinder block and complete the installation of the cover and the component parts. Tighten
all capscrews, securing the cover to a torque of
28-33 foot-pounds. Also tighten the six cap screws
securing oil pan to timing gear cover to a torque of
28-33 foot-pounds.
f . Crankshaft Pulley Installation. Install
crankshaft puIIey and vlbration dampener assembly.
(para 14-63)
Change 6
14-75
Section XV. CYLINDER HEAD AND VALVE OPERATING MECHANISM
14-76. General.
a. The cylinder head is a one-piece alloy iron
casting and is secured to the upper part of the cylinder block by heat-treated capscrews. Inlet and outlet
ports are provide in the cylinder head for the intake
of air and the expulsion of exhaust gases. Cored
passages are provided for the circulation of coolant.
Located in the cylinder head above each cylinder is
an intake valve, valve guide, valve spring, spring
retainer and locks, an exhaust valve, valve guide,
valve spring, spring retainer and locks, a fuel injection nozzle, and two rocker arms. The top of the cylinder head is enclosed with a cylinder head cover and
sealed with a gasket.
b. The rocker arm assembly, consisting of two
rocker arms for each cylinder, is mounted on a common rocker arm shaft supported by rocker arm shaft
brackets attached to the cylinder head. One rocker
arm actuates the Intake valve and the other actuates
the exhaust valve.
c. The camshaft rotates in bearings mounted inside
the-cylinder block. It is mechanically timed with the
crankshaft to open and close valves at proper intervals.
Valves are operated by caroming action produced by
lobes located along the length of the camshaft.
d. The push rods extend down through the cylinder
head, cylinder block, and into valve lifters which are
held in position by the camshaft. The upper end of the
push rods are concave to receive the ends of the valve
lash adjustment screws threaded into one end of the
rocker arms. The other end of the rocker arm actuates the valve through the action of the push rod. When
the push rod is forced upward by the camshaft lobe, the
rocker arm is raised on one end and forced down on the
other end, opening the valve. The tension of the valve
spring closes the valve when the push rod moves downward .
e . An oil hole through the cylinder head at the
flywheel end extends from the engine oil gallery. An oil
feed tube is connected from the cylinder head to a
restrictor elbow in one end of the hollow rocker shaft.
Excess oil is dumped through an oil drain tube at the
other end of the rocket shaft. The oil feed tube and drain
tube are formed higher than the rocker shaft to help
force oil out the holes in the rocker shaft through the oil
hole in the rockers, and keeps the shaft full of oil during
engine shutdown. The restrictor elbow controls oil flow
to the rockers and prevents excessive pressure drop of
the engine oil pressure system. Oil is forced out of the
14-76
Change 5
shaft through the oil hole at each rocker arm location
and into the drilled passage of each rocker arm, providing lubrication for the rocker arm bushing. The oil
spills down at the front end over the push rods and valve
springs and drains back to the oil pans.
14-77. Removal and Disassembly.
a. Symptoms and Isolation of Malfunction. A mal function of the cylinder head assembly or valveoperating component is usually indicated by loss of
engine power, erratic engine speed, or heavy black
exhaust smoke. These symptoms are a result of
compression losses caused by a leaky head gasket,
cracked cylinder head, burned, valve, bent, worn, or
broken push rod, or a defective rocker arm. To isolate the cause of the malfunction, proceed as follows:
(1) Remove the valve cover and observe the
rocker arms with the engine running. If one of the
rocker arms or push rods has failed, it can usually
be detected by comparing the motion of all the rocker
arms.
(2) One by one, slightly loosen the fuel input
line to each injector with the engine running. This
stops fuel to the cylinder. If the engine speed and sound
does not change when the fuel to the cylinder is reduced,
a valve in that cylinder has probably failed. Tighten
each fuel line after check has been made. To verify a
valve failure, remove one at a time the fuel injector
for each cylinder and perform compression tests using
a 0-700 psi gauge. The compression pressure at sea
level with engine at cranking speed, 150 rpm (use dead
crank switch) and hot should be 400 ±15 psi.
(3) A leaky head gasket or a crack in the head
can usually be determined by visual inspection. Signs
of coolant leakage will be evident at the point where
the head mates with the block if the gasket is bad. A
crack in the cylinder head is usually indicated by the
presence of an irregular hairline surrounded by signs
of coolant leakage or a black deposit of exhausted
carbon.
(4) If and of the above checks indicate failure of
a cylinder head component, proceed with the removal
and repair procedures.
b. Cylinder Head and Rocker Arm Shaft Assembly
Removal.
(1) Refer to Operator and Organizational Maintenance Manual to drain the cooling system, disconnect
ether starting aid and remove, the turbocharger, intake and exhaust manifold, nozzle holder assemblies
valve cover.
(2) Disconnect oil feed tube compression nut
from fitting in cylinder head at flywheel end of rocker
arm shaft. See figure 14-36.
(3) Disconnect compression nuts and remove oil
drain tube and oil feed tube at corresponding ends of
rocker arm shaft.
(4) Remove the six 3/8 inch capscrews and lockwashers securing the rocker arm brackets to the cyl -
inder head. Remove the six low capscrews securing
the rocker arm brackets; remove the rocker arms,
shaft, and brackets as an assembly.
(5) Withdraw the push rods from the engine.
(6) Remove the remaining twenty capscrews
securing the cylinder head and the two engine lifting
eyes. Use a sling and remove cylinder head.
Change 5
14-76A/(14-76B
Blank)
NOTE
Lift cylinder head straight up until it
clears the two dowel pins in the block;
then move cylinder head to the left to
avoid bending the fuel injection lines.
Remove the cylinder head gasket.
q. Rocker Arm Shaft Assembly Disassembly.
(1) Refer to figure 14-37. Remove plug, spring
washer, and washer from each end of the rocker arm
shaft.
(2) Remove shaft locating capscrew and lockwasher in the top of the rocker arm bracket (third
bracket from front end).
NOTE
Replacement brackets will all contain
threaded hole in the top of the rocker
arm bracket.
(3) Slide rocker arms, springs, and brackets
from the rocker arm shaft.
d. Cylinder Head Assembly Disassembly.
(1) Using a spring compressing tool, remove
spring retainer locks, and carefully release tension
on the valve spring. Remove spring retainer and
valve spring. See figure 14-38.
(2) Place valves in a rack as they are removed
from cylinder head so they can be identified and re installed in their original locations.
(3) The valve guides may be removed by pressing them out through the top of the cylinder head.
(4) Remove valve seats by electrically welding
three small beads on inside circumference of insert
as illustrated in figure 14-39. Allow insert to cool,
then lift or pry out with a bar.
e. Camshaft, Camshaft Gear, and Valve Lifter
Removal.
(1) Refer to para 14-72 and remove timing gear
(5) Before the camshaft can be withdrawn from
the cylinder block, the valve lifters must be positioned so that they do not interfere with the camshaft
lobes.
(6) With the engine removed from the unit for
overhaul, simply lay the cylinder block on its side
and push the valve lifters to their uppermost position
and carefully withdraw the camshaft.
CAUTION
Be careful that the camshaft lobes do not
scratch or mar the camshaft bearings as
the camshaft is withdrawn from the cylinder block.
(7) If the engine is mounted in a unit, the valve
lifters can be held in their uppermost position in the
following manner.
(a) Make up twelve pieces approximately
16 inches long of 5/8 inch wooden dowel rod and taper
one end of each slightly.
(b) Insert the tapered ends of the dowels
into the valve lifters (fig. 14-40) into the holes for the
push rods in the cylinder block and force each one
into a valve lifter.
(c) Grasp adjacent dowels for a set of exhaust and intake valves carefully pull the exhaust and
intake valve lifters up to their uppermost position
and place a stout rubber band around the two adjacent
dowels. Repeat for each set of valves.
(8) It maybe necessary to rotate the crankshaft
so that the connecting rods will not interfere with the
camshaft lobes during removal.
(9) After removing, the camshaft with gear
from the cylinder block, check the thrust plate clear ante (end play) by inserting a feeler gauge between
the thrust plate and camshaft journal. The end play
is 0.0027 to O. 0083 inch. If the end play exceeds the
maximum wear limit of O. 015 inch with a new thrust
plate, the camshaft gear must be replaced.
(10) The valve lifters may now be removed by
removing the dowels.
cover.
(2) Refer to paras 14-18 and 14-21 and remove
the overspeed switch, adapter and tachometer drive.
(11) Place the camshaft in a press and force the
camshaft from the gear. This is necessary due to the
press fit.
(3) Before removing the camshaft from the
cylinder block, check the camshaft gear backlash.
The backlash between the mating gear’s of the crankshaft and the camshaft is 0. 0015 to O. 0009 inch. New
parts must be installed when the backlash between any
two mating gears exceeds 0.015 inch. The backlash
between hydraulic pump gear and camshaft is 0.003
to 0.011 inch.
(4) Remove capscrew and washer securing camshaft gear to camshaft. (See fig. 14-35. )
Change 3 14-77
14-78. Cleaning, Inspection and Repair.
a. Cleani ng and Inspection of Cylinder Head.
(1) Inspect valve seat counterbores for cleanliness, burrs, and correct size. (1. 655 to 1.666
inches for exhaust valve, 1.809 to 1.810 inches for
intake valve, 1.670 to 1.671 inches for 0. 005 inch
oversize exhaust valve end 1.814 to 1.815 inches for
0.005 inch oversize intake valve).
(2) Depth of exhaust valve bore is 0.4735 to
0. 4755 inch and 0. 4585 to 0. 4605 inch for intake valve.
(1) Steam-clean cylinder head.
(2) Clean deposits of salt, lime or sludge
from water jacket.
(3) Chill inserts for two to four minutes in a
dry ice container or cold box.
(3) Submerge cylinder head in tank of cleaning
solution, Federal Specification P-D-680 heated to
near boiling point. Remove and dry thoroughly.
(4) Place cylinder head bottom side up on a
bench. Thoroughly clean counterbores for the inserts
with compressed air and start an insert into the countterbore (valve seat side up).
(4) Clean crossheads, valves, and valve
springs by submerging in solvent. Remove from
solvent tank and dry thoroughly.
(5) Use a valve seat insert installing tool and
drive insert down tightly into counterbore. This
operation must be done quickly while insert is cold.
(5) Clean valves with buffer and polish with
crocus cloth.
(6) Exhaust valve seat inserts must be staked
to eliminate the possibility of the insert loosening in
its bore.
(6) Examine cylinder head carefully for cracks.
d. Valve Face and Valve Seat Grinding.
b. Valve Spring, Valve Guide, Valve Seat and
Valve Inspection and Repair.
(1) Inspect valve springs for cracks. Place
spring in test stand. Both intake and exhaust valve
springs with dampers should have a load of 40-46
pounds when compressed to a length of 2.237 inches
(valve closed) and a load of 105-115 pounds when
compressed to a length of 1.780 inches (valve open).
Install new spring when old spring is 5 percent under
or over load limits.
(2) Replace intake and exhaust valves if they are
cracked, bent, burned or stems are worn. The outer
diameter of exhaust valve stem is 0.3705 to 0.371
inch. Bore of exhaust valve guide is 0.3725 inch
giving stem-to-guide clearance of 0.0015 to 0.002
inch. Replace exhaust valve and/or guide if clearance
exceeds 0.0055 inch. Outer diameter of intake valve
stem is 0.3715 to 0.372 inch. Bore of intake valve
guide is 0.3725 inch giving stem-to-guide clearance
of 0.0005 to 0.001 inch. Replace intake valve and/or
guide if clearance exceeds 0.0035 inch.
(3) Inspect valve seats. Replace if cracked,
pitted, or loose. Removal is described in para 14-77.
NOTE
Before installing either new valves or used
valves, valve seats in cylinder head should
be inspected for proper valve seating. If
used valves are to be reinstalled, valve
stems should be cleaned and valve faces
ground to angles of 30° for exhaust and intake valves. When refacing valves, remove
all evidence of pitting and grooving. The
valve guide should be cleaned with a nylon
brush. If bore in valve guide is worn oblong,
or if valve head is warped relative to valve
stem, the necessary parts must be replaced.
When new valve seat inserts are installed,
or used inserts reseated, refinishing must
be done with a valve seat grinder.
(1) The cutting face of the stone must be maintained at the correct angle and in proper condition by
frequent dressing with a diamond wheel dresser. The
frequency of dressing will be determined by condition
of the seats and amount of metal required to be removed during the grinding operation.
NOTE
c. Valve Seat Insert Installation.
NOTE
Press fit of valve seat inserts must be
maintained. If insert bores in cylinder
head are badly worn, bores must be
machined 0.005 inch larger than original’
bore. Valve seat inserts 0.005 inch
oversize must be installed.
14-78 Change 3
By grinding valve face and insert seat at
slightly different angles, a fine line contact of the face and seat is obtained, thus
eliminating the need to lap the seating surfaces with grinding compound.
(2) The difference of angles is usually 1/2 to
1-1/2°. The angle of the insert seat is made greater
than that of the valve face, so as to assure contact
1.
2.
3.
4.
5,
6.
7.
Screw
Washer
Cover
Gasket
Nut
Sleeve
Connector
8.
9.
10.
11.
12.
13.
14.
Nut
Sleeve
Elbow
Tube
Nut
Sleeve
Elbow
15.
16.
17.
18.
19.
20.
21.
Tube
Screw
Screw
Washer
Washer
Washer
Rocker arm shaft
assy
22.
23.
24.
25.
Push rod
Screw
Eye
Cylinder head
assy
26. Gasket
27. Gasket
28. Bolt
29.
30.
31.
32.
33.
34.
35.
Screw
Washer
Gear
Key
Plate
Cam
Lifter
ME 6115-545-34/14-36 C7
Figure 14-36. Cylinder Head and Valve Operating Mechanism
Change 7 14-79
1. Screw
2. Washer
3. Plug
4. Washer
5. Washer
6. Rocker arm assy
7. Adjusting screw
8. Rocker arm
9. Spring
10. Bracket
11. shaft
ME 6115-545-34/14-37
Figure 14-37.
14-80
Rocker Arm Shaft Assembly
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Retainer lock
Retainer lock
Retainer lock
Retainer lock
Roto-coil assy
Spring retainer
Intake valve
Exhaust valve
Valve spring
Valve spring
Head assy
Exhaust seat
Intake seat
Valve guide
Valve guide
Plug
Plug
Head
ME 6115-545-34/14-38 C4
Figure 14-38.
Cylinder Head Assembly
ME 6115-545-34/14-39
1. Cylinder head
2. Wooden dowel rod
3. Rubber band
ME 6115-545-34/14-40
Figure 14-40.
Figure 14-39.
Valve Seat Insert Welding Details
Installation of Wooden Dowels
in Valve Lifters
14-81
Change 4
1.
2.
3.
4.
6.
6.
7.
Retainar
Pln
Conectlng rod assy
Straw (Socket Head or 12 Pt. Head)
Connectlng rod
Bushing
Bearing
Figure 14-41.
14-82
Change 12
8. Ring set assy
9. Ring
10. Ring
11. Ring
12. Ring
13. Platen
Piston, Crankshaft, and Block
(Sheet 1 of 3)
14.
15.
16.
17.
18.
19.
20.
21.
Sleeve
Preformed packing
Preformed packing
Screw
Front cap
Center cap
Rear cap
Main bearing
22.
23.
24.
25.
26.
27.
28.
29.
Pin
Thrust flange
Main bearing
Gear
Key
Crankshaft
Main bearing
Thrust flange
30.
31.
32.
33.
34*
35.
36.
37.
Main bearing
Jam nut
Valve adj. screw
Spacer
spring
Piston
Insert
Plug
38. Pin
39. Camshaft
bearing
40. Camshaft
bearing
41. Plug
42. Valve
ME 6115-545-34/14-41 (2) C4
Figure 14-41. Piston, Crankshaft, and Block
(sheet 2 of 3)
Change 4
14-83
43.
44.
45.
46.
47.
48.
Plug
Plug
Dowel
Plug
Pipe
BIockassy
ME 6115-545-34/14-41(3)
Figure 14-41. Piston, Crankshaft, and BIock
(Sheet 3 of 3)
14-84
at the top of insert seat. Thus, for the 30° exhaust
valve face angle and a 1° interference angle, the insert seat grinder wheel must be dressed to grind the
insert seat at an axle of 31°. Likewise, the insert
seat for the intake valve must be ground at 31 . This
is a positive interference angle. A negative angle
must be avoided. The first step in reconditioning a
seat or insert is to grind the seat, removing only
enough metal to produce a pit-free continuous seat.
After the seat has been ground, use a dial gauge to
check concentricity of the seat relative to the valve
guide. The total run-out of a good seat should not
exceed 0. 002 inch total indicator reading.
(3) To determine seat contact in relation to
insert and valve face, wipe a thin film of Prussion
Blue on the valve face and bounce the valve once on the
valve seat. A thin, continuous line must be evident on
the valve face, otherwise further grinding is required.
NOTE
Do not revolve valve while checking seat.
(4) The width of the valve seat on both the exhaust and service intake inserts is 3/32 inch. If the
seats are too wide or too narrow they must be ground
to the proper width using the appropriate angle grinding wheels.
CAUTION
After valves are installed in cylinder head,
make certain the exhaust valve heads are set
in a minimum of 0.053 inch and the intake
valve heads are set in a minimum of 0.054
inch from the cylinder head gasket surface,
otherwise, serious damage will result. If
valve stand -in is less than the allowable
amount, the valve seat must be ground
lower until the allowable stand-in is obtained.
(4) Inspect both ends of push rods for signs of
wear. Polish out nicks or scores. If pushrods are
bent, twisted, or damaged, replace push rods.
f. Camshaft, Camshaft Gear and Valve Lifter
Inspection.
(1) The outer diameter of all camshaft bearing
journals is 2.130 to 2.131 inches. The inside diameter
of the camshaft bearings, when installed, is 2.133 to
2.136 inches. The clearance between the camshaft
journals and bearings is 0.002 to 0.006 inch and must
not exceed 0.008 inch. If exceeded then the bearings
must be replaced. If the installation of new standard
bearings does not reduce the end clearance to less
than 0. 008 inch, it is recommended to grind the camshaft journals to accommodate 0.010-inch undersize
bearings. Likewise, if the journals are worn or
scored to the extent that they will not accommodate
0. 010-inch undersize bearings, the camshaft must be
replaced.
(2) Inspect the intake and exhaust lobes of the
camshaft for roughness, scoring or excessive wear.
Replace the camshaft if any of these conditions are
found to exist.
(3) Inspect camshaft gear for nicked, scored,
or broken teeth. Replace as necessary.
(4) Inspect thrust plate for wear. Replace if the
wear area is rough or the wear is excessive. New
thrust plate thickness is 0.204 to 0.206 inch.
(5) Inspect valve lifters for excessive wear.
Replace a set of lifters if one or more show excessive
wear.
e. Rocker Arm, Shaft Inspection and Repair.
(1) Inspect end of rocker arm adjusting screws
and end of rocker arms. If they are worn, the rocker
arm assemblies must be replaced.
(2) Inspect rocker arm shaft bore for wear. The
bore of the rocker arm bore is 0.001 to 0.002 inches
and the outer diameter of the rocker arm shaft is
0.999 to 1.000 inch. The clearance of the rocker arm
shaft to the rocker arm is 0.001 to 0.003 inch and must
not exceed 0. 005 inch. If rocker arm shaft bore is excessively worn, the rocker arm assemblies must be
replaced.
NOTE
Bushings are non-replaceable in rocker
arm assemblies.
(3) Inspect rocker arm shaft for wear and replace
if necessary. Clean oil holes in rocker arms and rocker
shaft with solvent, Federal Specification P-D-680, a
small wire, and compressed air.
14-79. Reassembly and Installation.
—a. Valve Lifter Installation.
(1) Lubricate valve lifters with clean engine oil
and install them in their original positions in the cylinder block.
(2) Using the wooden dowel method illustrated
in figure 14-40, pull the lifters up so they do not
interfere with camshaft installation.
b.
— Camshaft and Camshaft Gear Installation.
(1) Place the camshaft in a press with the
shoulder of the first journal resting on parallel bars.
(2) Posit Ion the thrust plate on camshaft.
Change 3 14-85
(3) Heat the gear in oil to a temperature of 350°
- 400° F.
(4) Using asbestos gloves, position the gear on
the camshaft and align the gear keyway with the key
in the camshaft.
(5) press the gear onto the shaft until the gear
hub is flush with the front end of the camshaft.
(6) Check the clearance between the thrust plate
and bearing journal. The end play clearance is
.0027 to 0.0083 inch.
(7) Check camshaft journal to bearing running
clearance.
(8) Oil the camshaft bearings in the cylinder
block and carefully insert the camshaft. Be careful
not to scratch or mar the camshaft bearings.
(9) Before camshaft is completely inserted in
cylinder block, position thrust plate in place.
NOTE
Correct standout, if necessary, by reconditioning sleeve seat in the block and installi~
sleeve shims under cylinder sleeve flange to
obtain the 0. 002-inch to 0. 005-inch protrusion.
(4) Install a new cylinder head gasket over the
two dowel pins and onto the cylinder block with the
indicated side down, as stamped on the gasket. Do
not use any sealer or gasket dope. The gasket as
supplied has been pre-coated with a phenolic sealer
and an anti-stick compound.
(5) Use a sling and position the cylinder head
over the dowel pins and onto the cylinder block.
(6) Lubricate threads of 20 short cylinder head
capscrews with light coat of engine oil and install with
hardened washers in cylinder head. Tighten capscrews
to 90 to 110 foot -pounds following sequence shown in
figure 14-42. (Sect ion A).
NOTE
Make certain the timing marks on camshaft
gear and crankshaft gear are aligned when
camshaft is installed (fig. 14-25).
(10) Install the capscrews through the thrust
plate. Tighten the capscrews to a torque of 18 to
20 foot -pounds.
(11) Check the camshaft gear backlash. The
backlash between the mating gears
of the crankshaft
and the camshaft is 0.0015 to 0.-009 inch. The backlash between the mating gears of the hydraulic pump
and camshaft is O. 003 to O. 011 inch.
c. Cylinder Head Reassembly and Installation.
(1) Make certain that the machined surfaces of
the cylinder block and the cylinder head are thoroughly
clean. A new cylinder head gasket must be used before installing the cylinder head.
CAUTION
Before the cylinder head is installed, make
certain that there is not an excessive amount
of oil, or any other liquid, in the capscrew
holes in the cylinder block. Too much oil in
any of these holes may cause a hydrostatic lock
and crack the cylinder block when the capscrew
is tightened.
(7) T i g h t e n t h e 2 0 c y l i n d e r h e a d
capscrews In the numerical sequence In
figure 14-42, Section A to 155-165
foot-pound torque.
CAUTION
Torque figures in this and following steps are
based on engine oil lubricated threads and
under cap screw heads. To prevent overstressing of capscrew, use engine oil only.
Other lubricants may- cause extreme pressure.
(8) Position rocker arms, shaft, and brackets
assembly on cylinder head and align rocker arm adjusting screws in the push rod cup ends. Install the
six long capscrews; also install the six 3/8 inch capscrews and lockwashers in the rocker arm brackets.
Tighten the 1ong capscrews, starting at the center of
the head and working alternately towards each end,
to a torque of 90-100 foot-pounds and the 3/8 inch
capscrews to a torque of 28-33 foot -pounds.
NOTE
Lubricate threads and under capscrew heads
with a light coat of engine oil before installing.
(9) Tighten the 26 cylinder head capscrews in
the numerical sequence in figure 14-42 to 155-165
foot -pounds torque.
(2) Thoroughly clean top deck of cylinder block
underside of cylinder head.
(3) Make certain that the cylinder sleeve standout is within the specified limits. The standout of
each cylinder sleeve is 0.002 inch to 0.005 inch above
the top flat surface of the cylinder block.
14-86
Change 5
Tighten the 6 cylinder head
(10)
capscrews In the numerical sequence In
Torque
figure 14.42 (Section B).
capscrews to 155-165 foot-pounds.
Figure 14-42. Cylinder Head Capscrew Locations and Torquing Sequence
(11) Adjust all intake and exhaust valves to
a cold tappet clearance setting of 0.018 inch.
(12) Connect the oil feed tube to the fitting
in the cylinder head and install cylinder head cover and
gasket.
(13) Replace engine valve cover, tachometer
drive, adapter, overspeed switch, manifolds, exhaust
pipe, radiator, cooling hoses, turbocharger, and engine
area panels. Refer to Operator and Organizational
Maintenance Manual.
(14) Fill the cooling system. Run engine for
approximately one hour, perferably under load, with a
minimum coolant temperature of 160° F. Inspect engine
for leaks.
(15) Remove valve cover and rocker shaft
assembly from cylinder head to gain access to the 20
capscrews securing the cylinder head.
(16) Retighten the 20 capscrews to 155-165
foot-pounds torque following the sequence depicted in
figure 14-42 section A. If capscrew does not move when
this specified torque is reached, back off slightly by
loosening, the retighten to specified torque. This is important in eliminating possible false torque readings due
to temporary thread seizure.
(17) Position rocker arms, shaft and
brackets assembly on cylinder head and align rocker
arm adjusting screws in the push rod cup ends. Install
the six long capscrews; also install the six 3 3/8 inch
capscrews and lockwashers in the rocker arm brackets.
Tighten the long capscrews to 90-110 foot-pounds and
the 3/8 inch capscrews to a torque of 28-33 foot-pounds
following this sequence depicted in figure 14-42, section
B.
(18) Retighten the 6 long capscrews to
155-165 foot-pounds following the sequence depicted in
figure 14-42, Section B. Retighten the 3/8 inch
capscrews to maintain a torque of 28-33 foot-pounds per
capscrew.
Change 6
14-87
Section XVI
14-80 General.
The pistons are tin-plated aluminum alloy and are
precision machined, cam ground and balanced. Each
piston is fitted with a nickel alloy top ring insert. Three
compression rings and one oil control ring are located
above the piston pin. The top compression ring and the
two scraper segments of the three-piece oil rings are
chrome plated, Holes drilled through the walls of each
piston at the oil ring groove allow excess oil collected in
the groove to return to the oil pan. Pistons are the full
floating type, held in the piston by retainer rings. A
connecting rod and bearing connects each piston to the
crankshaft.
PISTON AND RINGS
(10) Drive the piston pin from the piston.
Immerse piston in 180°F water for approximately 5 minutes. Remove pin while piston is still hot.
14-81 Piston, Rod, and Rod Bearing Removal and Disassembly.
Syptoms and Isolation Of Malfunction. A mala.
function of a component of the piston assembly is usually
indicated by loss of engine power, increased oil consumption, bluish-white exhaust smoke, excessive engine knock,
or low oil pressure.
b. Removal and Disassembly.
(1) Remove engine assembly. (para. 2-13).
(2) Support engine on block or engine stand.
(3) Remove cylinder head (para. 14-77).
(4) Drain engine oil, and remove the oil pan, oil
pump and discharge tube (para. 14-65).
(5) Remove the piston ring travel ridge from the
cylinder sleeve. (para. 14-85).
(6) Remove the lock bolts securing the connecting rod bearing caps. (See fig. 14-4 1). Remove the bearing caps and free the lower end of the rods from the crankshaft. Remove the shells from the bearing.
(7) Carefully remove each piston and rod
assembly by pushing the assembly out through the top of
the cylinder sleeve.
(8) Remove the pin retainer from the groove in
the piston at each end of the piston pin.
(9) Remove the rings from each piston.
Whenever a connecting rod with the piston is
secured in a vise, be extremely careful that the
bottom of the piston skirt is not nicked. Use
lead jaw protectors to protect the bottom of the
skirt from the nicks and to prevent nicks in the
rod which will lead to piston and/or connecting
rod failure.
14-88 Change 12
NOTE
The bore in an aluminum alloy piston expands as
the piston heats but provides a tight fit between
pin and piston at room temperature.
14-82 Piston Assembly Inspection and Repair.
a. Clean pistons with cleaning solvent, Federal
Specification P-D-680, and dry them with clean, compressed air. After cleaning, the piston skirt, piston rings,
and ring grooves should be thoroughly inspected. Be sum
oil drain holes in the oil ring grooves are open and clean.
If the cleaning solution does not remove all carbon from
the bottom of the ring grooves, break the old rings in half
and use the butt ends as scrapers. Be careful to remove
only carbon or foreign material; do not scrape away any
metal from the side or bottom of the ring grooves.
b. The piston skirt should be examined for score
marks or other indications of improper piston clearance.
Inspect the inside of pistons for cracks; scored or cracked
pistons should be replaced. Check pistons for wear. The
skirt diameter of a new piston is 4.246-4.247 inches
(measured at right angles to piston pin and bottom of the
skirt); the inside diameter of a new cylinder sleeve is
4.2495-4.251 inches. giving a running clearance of
0.0025-0.005 inch.
c. Any deviation from these measurements will
indicate the amount of wear on the piston and/or the cylinder sleeve. If the piston assembly and piston rings are
removed from the cylinder sleeve, even after a short
period of operation, do not reinstall the same rings; in
most cases, used rings will not again seat properly. The
outer diameter of new piston rings have tool marks and
reasonably rough surfaces which allow for fast wear-in
and seating of the rings to the cylinder walls. After a
period of operation, the rings wear or lap themselves to fit
perfectly with the cylinder’ walls and ring seat.
d. If the wear the in piston compression ring
grooves does not create side clearance with new piston
rings greater than 0.011 inch, if piston pin bore does not
exceed 1.5026 inches, and if no cracks or scores are
detected in piston pin bosses, on the skirt or in the combustion chamber rues, the pistons may be reused with a
reasonable life expectancy of one-half to three-fourths that
of new pistons.
e. Inspect the bore of connecting rod with cap in
place and the socket head capscrews tightened to 80 to 85
foot-pounds or the 12 point capscrews tightened to 65 to
65.5 foot-pounds. Using an inside micrometer, measure
dimensions A and B as shown in figure 14-43. Record
dimensions A and B and arrive at an average dimension.
The average dimension must not exceed 2.9705 inches.
Subtract dimensions A and B and the remainder must not
exceed 0.0015 inch, which is the maximum allowable outof-roundness.
(1) Select a new connecting rod that has been
checked for correct nominal length of 8.500 inches. The
length of new connecting rod (center-to-center of bores)
is 8.498 to 8.502 inches.
(2) Lubricate threads of connecting rod bolts
with engine oil and assemble cap to connecting rod.
Tighten bolts alternately to torque of 80-85 foot-pounds.
(3) Install pin and crank mandrels in connecting
rod. Center crank mandrel in crankshaft end so the
expanding pin is located in bottom of bore near the center
of rod cap. Tighten expanding pin snugly.
(4) Place rod with mandrels in checking future.
Figure 14-43. Conneting Rod, Crankshaft End
(5) Adjust dial indicators until their hands move
approximately on revolution while resting on pin mandrel.
(6) Adjust indicator faces to zero.
Avoid causing nicks and other physical damage
to the I-beam section of the connecting rod.
Do not clamp I-beam section of rod in a vise.
Whenever connecting rod is clamped in a vise,
use lead jaw protectors and clamp rod on the
crankshaft end only.
f. Measure outside diameter of the piston pinto
determine amount of wear. Outer diameter of a new piston pin is 1.5011 to 1.5013 inches. The bore of the connecting rod bushing is 1.5027 to 1.5032 inches. These
dimensions of pin and bushings provide a running clearance of 0.0014 to 0.0021 inch. Replace the connecting rod
bushing if clearance exceeds 0.002 inch.
g. Inspect connecting rod for cracks by the magnetic particle wet fluorescent continuous method.
h. Magnetization must be performed longitudinally
(between the heads) using a minimum current of 2000
amperes and, transversely, (in the coil) using a minimum
current of 800 amperes. A minimum of two applications
of current of approximately one-half second duration in
each position should be made. Apply indicating solution
gently and uniformly to all portions of the part while the
magnetizing current is flowing.
i. Inspect the threads of connecting rod and lock
bolts. If damaged, they must be replaced.
j. Check the alignment, length and twist of connecting rod, using a checking future. The checking fixture
must fist be calibrated as follows:
(7) Remove connecting rod and mandrels as an
assembly from checking fixture, turn rod horizontal y
180° and carefully place back in future. Readjust indicator faces so the zero position is halfway between original
zero and reading and the new reading. The fixture is now
calibrated.
(8) Carefully remove connecting rod and mandrels as an assembly from checking future.
k. Check connecting rod alignment as follows:
(1) Lubricate threads of connecting rod bolts
with engine oil and assemble cap to connecting rod that is
to be checked. Tighten bolts alternately to specified
torque of 80 to 85 foot-pounds for socket head capscrews
or 65 to 65.5 foot-pounds for 12 point capscrews.
(2) Install pin and crank mandrels in connecting
rod. Center crank mandrel in large bore so the expanding
pin is located in bottom of bore near the center of rod cap.
Tighten expanding pin snugly.
(3) Carefully place rod with mandrels in checking fixture and record indicator readings.
(4) Remove connecting rod and mandrels as an
assembly from checking fixture; turn rod horizontally
180° and carefully replace in future. Record the new
indicator readings.
(5) The maximum allowable bend in the rod is
a combined total gauge reading of 0.004 inch. Calculate
the differences in the individual indicator gauge recorded
readings between step (3) and (4) above. Then add the
two to get the combined total gauge reading.
Change 12
14-89
NOTE
Straightening of used rods that are bent beyond
0.004 inch and up to a maximum of 0.030 inch is
acceptable. Bridge the rod to be straightened at
the pin and crank ends and bend rod in the center
of the I-beam section. Do not nick or indent the
rod surfaces during this operation. Always bend
beyond the straight position and then bend back
to the straight position. A hydraulic press or fixture can be satisfactorily used for this operation.
(6) The twist of the connecting rod can be
checked with a feeler gauge between the pin mandrel and
fixture face. A twist up to 0.010 inch maximum is acceptable.
l. Make certain oil hole in connecting rod is clean
and free of foreign matter. Blow dry compressed air
through hole.
m. Inspect connecting rod bearing shells for scoring,
chipping, corrosion, cracking, or signs of overheating;
discard bearing shells if any of these conditions are apparent. The backs of bearing shells should be inspected for
bright spots and discarded if any bright spots are found;
this condition indicates that bearing shells have been moving in their supports,
a. Inspect rod bearing shells for wear. The bore of
bearing shells is 2.7495 to 2.7510 inches installed and
with connecting rod bolts tightened to the specified torque
of 80 to 85 foot-pounds. This provides a running clearance of 0.001 to 0.0035 inch. New bearing shells must be
installed when this clearance exceeds 0.008 inch.
Q . Measure connecting rod bearing shells for wear
with a micrometer at several places away from the parting
line. Bearing shells, when in place, are 0.0004 to 0.001
inch larger in diameter for a distance of 3/8 inch each side
of the parting line than they are 90° from the parting line,
Connecting rod bearings have a thickness of 0,10975 to
0.11025 inch. Shells measuring less than 0.108 inch
should be discarded and new ones installed. In the event
that the crankshaft is worn or damaged and must be
ground, bearing shells 0.002 inch, 0.010 inch, 0.020 inch
and 0.040 inch undersize are available.
NOTE
Install new bearing shells if the fit is unsatisfactory. The crankshaft must turn freely after all the
connecting rod socket head cap bolts have been
tightened to torque of 80 to 85 foot-pounds or 12
point cap screws torque to 65-65.5.
p. Replace rod bearings if they have been removed
and have given 2000 hours or more service. Always
replace rod bearings when rebuilding engine at depot
maintenance level.
14-90 Change 12
g. If the connecting rod bushing is worn it must be
pressed out and a new bushing pressed into the connecting
rod. When new bushing are installed, be sure the bushing
oil hole lines up with the ccm.netting rod oil hole. The
outer diameter of a new piston pin is 1.5011 to 1.15013
inches and the bore of the bushing is 1.5027 to 1.5032
inches. These dimensions provide a running clearance of
0.0014 to 0.0021 inch between the pin and the bushing. It
is necessary to ream the connecting rod bushing to obtain
this clearance The bore in the piston for the piston pin is
1.5014 to 1.5016 inches. These dimensions provide a fit
of pin in piston at room temperature of 0.001 inch loose to
0.0005 inch loose.
14-83 Piston, Rod, and Rod Bearing Reassembly and
Installation.
When installing rings on pistons, do not spread
the rings more than necessary. Whenever a
connecting rod with the piston is secured in a
vise, be extremely careful that the bottom of
the piston skirt is not nicked. Use lead protective jaws to protect the bottom of the skirt
from nicks and also to prevent nicks in the rod
which will lead to piston and/or connecting rod
failure.
a. Install the three piece oil control ring as follows:
(1) Place stainless steel expander spacer of
three-piece ring in the bottom groove of the piston with
the ends butted.
(2) Install chrome-plated steel segment on the
bottom side of expander spacer, with gap of segment
approximately 90° beyond gap of expander spacer, making
certain expander spacer is still in a butted position.
(3) Install second segment on the top side of
expander spacer with segment gap approximately 90°
from expander spacer gap in opposite direction from
which the bottom segment has been installed.
b. Install the three compression rings. The gap of
all rings must be positioned 180° apart and in line with the
piston pin holes.
c. Recheck the three-piece ring assembly. Rings
should be free to move in the grooves; however, a slight
drag will be evident because of the side sealing action of
the ring assembly. Be sure the expander spacer remains in
butted position,
NOTE
Pistons must be fitted to their respective cylinder
sleeves before the piston rings are installed to
provide a running clearance of not less than
0.0025 inch. Insufficieint clearance will result in
premature failure of pistons and/or cylinder
sleeves. Measurements must be taken at room
temperature.
d. Using an inside micrometer, measure the bore
of the cylinder sleeve. Using an outside micrometer,
measure the outer diameter of the piston skirt at the
right angle to the piston pin and at the bottom of the
skirt. The difference between the two readings is the
running clearance.
e. The gap between ends of piston rings should be
measured before rings are installed on pistons. Insufficient end gap can cause scored rings and scored
cylinder sleeves. Check the ring gap by inserting
each ring into the cylinder sleeve in which it is to be
used. Use a piston to push ring squarely down in the
bore of the cylinder sleeve and far enough to be on the
ring travel area. Check ring gap with a feeler gauge.
The ring end gaps, using cylinder sleeves of 4. 2495 4.251 inches bore are:
Top compression ring
Center rings
Oil control ring (3 pc.)
0.013-0.027 inch
0.013-0.024 inch
0. 013-0, 024 inch
CAUTION
The piston rings should never be filed to
open the gap because the chrome plating
might be loosened by the file and later
distributed through the engine causing
damage or scoring of the piston and the
cylinder sleeve.
f. Measure ring-to-groove clearance (top of ring
to top of groove in piston). The ring to groove clearances, using a new piston and new rings, are as
follows:
Top compression ring
Center rings
Oil control ring (3 pc.)
0.0040-0.0060 inch
0.0020-0.0040 inch
0.0005-0.0030 inch
g. Install one of the piston pin retainers in one end
of the piston pin hole in the piston.
—h. Insert upper end of connecting rod into piston.
Install each piston, with rings and connecting rods, as
an assembly. The lower end of each connecting rod,
as well as the connecting rod bearing caps, are number 1, 2, 3, etc. for identification. They must be
installed in the corresponding numbered cylinder with
the numberedside of rod toward the camshaft side of
engine.
k. Stagger piston rings gaps 180° apart and in line
with piston pin holes, and apply clean engine oil to
pistons and rings. With a piston ring compressor
(piston inserted), install the piston and connecting
rod in the cylinder sleeve by pressing on top of piston with wooden hammer handle. If any difficulty is
encountered, however slight, the piston inserted must
be removed and ring set inspected for correct installation in piston grooves. Align lower end of connecting rod with crankshaft before inserting piston into
cylinder.
1. Lubricate and install a bearing shell in position
in connecting rod, with tang of bearing shell in the
corresponding slot in connecting rod, and position rod
on crankshaft journal.
CAUTION
Make certain the backs of the bearing shells
are free from dirt and grit particles,
m. Lubricate and install a bearing shell in position in the connecting rod bearing cap, with tang of
bearing shell in corresponding slot in bearing cap.
Install bearing cap and shell, making certain identification number stamped in the bearing cap is located
on the same side as corresponding number stamped
in the connecting rod.
n . Prior to installation, thoroughly clean and dry
with compressed air all of the connecting rod capscrews (lock bolts).
o. Install an 0i1 lubricated piston and connecting
assembly, minus bearing cap but with upper bearing
shell in place, in engine.
CAUTION
NOT E
When assembling piston to connecting rod,
make certain top of piston stamped CAM SHAFT SIDE is toward side of connecting
rod stamped with numbers identifying the
cap with upper portion of rod.
Do not allow the rod to scratch the cylinder
bore nor let it strike the crankshaft webs or
thrust faces when pushing rod into place on
the crankpin.
i. Lubricate piston pin with clean 0i1 and, with a
piston pin remover and installer tool tap piston pin
into piston and connecting rod.
p. Check rod anti cap index numbers for position
anti correctly assemble cap, with lower bearing shell
in place. to the rod.
j. Install the other piston pin retainer at the opposite end of the piston pin bore.
q. Generously coat the capscrew threads and their
underhead areas with engine lubricating oil.
NOT E
r. Install connecting rod capscrews and tighten to
8-12 foot -pounds torque, (the socket head capscrews
require a male 3 8 inch hex wrench).
After piston rings have been properly fitted,
lubricate piston and rings with engine oil.
Install second and third rings on piston (with
side marked "Top" or "T" toward top of piston)
using a piston ring remover and installer tool.
Top ring may be installed with either side
toward top.
s. Using a plastic head hammer and striking the
connecting rod cap on its balance pad only, align the
cap to the rod by driving it first against the crankpin
forward web and then against the crankpin rear web.
14-91
t. Tighten both the capscrews to approximately 1/2
torque and then to full torque.
u. Check connecting rod side clearance. Correct
clearance is 0.005 to 0.010 inch.
v. Install oil pump and oil pan. (para 14-67.)
w. Install cylinder head. (para 14-79.)
X.
Install engine assembly. (para 2-14.)
Section XVII. CRANKSHAFT AND CYLINDER BLOCK
14-84 G E N E R A L
a. The cylinder block is the main structural part of
the engine. It is cored to receive removable wet-type
cylinder sleeves. The cylinder sleeves are completely
surrounded by water jackets which extend the full length
of the cylinder walls for maximum cooling.
b. The seven-bearing, counterbalanced crankshaft
converts the vertical power strokes of the pistons to a rotational torque that can be applied to the generator through
the flywheel.
c. The six camshaft bearings which support the
camshsaft are mounted in the cylinder block. These bearings are easily accessible when the piston assemblies, connecting rods, cylinder sleeves and crankshaft are removed.
14-85 Crankshaft. Cylind er Sleeves and Camshaft
Bearings Removal.
a . C r a n k s h f t Removal.
(1) Refer to Operator and Organizational Maintenance Manual for removal of the housing, radiator, electric starter, winterization kits (if installed), turbocharger,
and manifolds.
(2) Remove oil pan and oil pump. (para
14-65.)
(3) Remove flywheel housing and flywheel. (para 14-69.)
(9) Remove upper main bearing shells from
cylinder block.
b.
Cylinder Sleeves Re moval,
(1) If the sleeves are to be reused, insure that
the ridge above the ring travel is removed with a hone or a
ridge removing tool. Insure that the glaze in ring travel
area is removed with a cylinder hone or a glaze breaker
tool. Hone the sleeve to a cross hatch pattern at angles of
22 to 32° to a place perpendicular to the bore axis. The
cross hatch should be nearly uniform in both diretions.
Do not over- hone; stop when glazed area is removed.
Thoroughly clean the sleeve with warm water and common laundry detergent and scrub the bore with a stiff
bristle brush. Dry the sleeve with compressed air and
inspect the bore to see that it is not oversize. After cleaning protect the bore of the sleeve with a thin coating of
engine lubricating oil.
If the cylinder sleeve was honed while installed
in the cylinder block, clean the block thoroughly to make certain that all abrasive material is removed.
(4) Remove crankshaft pulley and vibration
dampener. (para 14-61.)
(2) Refer to Operator and Organizational Maintenance Manual and remove housing, radiator, electric
starter winterization kits, (if installed), turbocharger, manifolds, and valve cover.
(5) Remove timing gear housing, crankshaft
gear and engine front plate. (para 14-72.)
(3) Remove cylinder head and valve operating
mechanism.
(para 14-77.)
(6) Remove connecting rod bearing
caps. (para 14-81.)
(4) Remove piston and connecting rod assemblies. (para 14-81.)
NOTE
(5) Remove cylinder sleeves. (fig. 14-41.)
Identify connecting rod caps as to their original
location on the connecting rods, and in the cylinder block in the event inspection proves they can
be reused. Cylinder numbers is marked on the
camshaft side of each rod and rod cap.
(7) Remove two capscrews on each main bearing cap and remove main bearing caps and lower main
bearing shells. (fig. 14-41.)
(8) Remove crankshaft.
14-92 Change 12
(6) Remove all dirt, carbon. and oil from cylinder sleeves and from the machined recess and bore in cylinder block.
c. Camshaft Bearings Removal
(1) Refer to Operator and organizational Maintenance Manual and remove housing, radiator, electric
starter, winterization kits, (if installed). turbocharger, manifolds, and valve cover.
(2) Remove cylinder head and valve operating
mechanism. (para 14-77.)
* U.S. GOVERNMENT PRINTING OFFICE : 1994-655-026/00441
PIN 013550-012
blies.
(3) Remove piston and connecting rod assem(para 14-81.)
(4) Remove crankshaft and cylinder sleeves
(refer to paragraphs (a) and (b) above).
(5) Drive camshaft bearings from block. (fig.
14-41.)
14-86. Crankshaft, Cylinder Sleeves, Camshaft
Bearings and Cylinder Block Cleaning, Inspection
and Repair.
a. Crankshaft.
(1) Clean crankshaft thoroughly and inspect the
journals for scoring, chipping, cracking, or signs
of overheating. If crankshaft has been overheated
(usually indicated by discolored or blue bearing journal surfaces), or is scored or excessively worn, reconditioning or replacement will be required. Examine bearing journals for cracks if overheating has
occurred. (fig. 14-41.)
(2) Measure the crankshaft main bearing and
connecting rod journals at several places on their
diameter to check for roundness. The diameter of
main bearing journals is 3.2465 to 3.248 inches; connecting rod journals is 2.747 to 2.7485 inches. The
only recommended method of reconditioning the crankshaft is regrinding, as required, to accommodate
undersize bearing. Chrome plating or metallizing the
bearing journals is not acceptable.
(3) All main and connecting rod bearing journal
surfaces of the crankshaft are hardened to a minimum
depth of approximately 0.060 inch. If regrinding of
crankshaft journals becomes necessary, the work
should be done by a reputable machine shop that has
suitable equipment to handle precision work of this
type. Main bearing shells 0.002, 0.010, 0.020 and
0.040 inch undersize are available. If crankshaft is
ground, the diameter of main bearing journals should
be reduced in steps of 0.002, 0.010, 0.020, or 0.040
inch below 3.2465 to 3.248 inches to fit the undersize
main bearing shells.
(4) If out-of-round or taper of journals exceeds
0.002 inch, crankshaft must be reground to a standard
undersize or replaced.
(5) Blow out all oil passages in crankshaft with
dry compressed air.
(6) Any bearing shells that are scored, chipped,
pitted, or worn beyond the specified limits given below
must be replaced. Inspect backs of the shells for
bright spots. Bright spots on backs of the shells indicate shells have shifted in their supports and are unfit
for further use.
(7) The clearance between main bearing shells
and the crankshaft journals is 0. 0019 to 0. 0046 inch.
New bearing shells must be installed when this clearante exceeds 0. 008 inch.
(8) With crankshaft removed, measure inside
diameter of the bearing at a point 90° from the parting
line, with bearing cap installed and tightened to 170190 foot-pounds. Bearing shells when in place are
0. 002 to 0. 004 inch larger in diameter at the parting
line than they are 90° from the parting line, and do
not form a true circle. The two halves of the shells
have a crush fit in their bore in the block and must be
tight when the cap is secured in place. Do not measure
inside diameter at the parting line.
(9) The bore of new main bearings installed is
3.2499 to 3.2511 inches and any reading above 3.2511
inches indicates the amount of bearing wear. Measure
diameter of the crankshaft journal at the corresponding
bearing location and subtract this dimension from inside diameter measurement of the bearing (as determined above); the difference between these two measurements is the crankshaft-to-bearing clearance.
(10) Another method for determining amount of
wear on bearing shells is by measuring each shell with
a micrometer at a point of 90° from the parting line.
New (standard size) shells, should measure 0. 1549- to
0. 1554-inch thick. Bearing shells less than 0. 153inch thick are worn beyond the allowable limits and
must be replaced.
(11) The most accurate method of determining
main bearing clearance is by using micrometer, as
described i n the preceding paragraphs. However, if
the proper size micrometers are not available or the
crankshaft is installed in the engine, bearing clearance
must be measured by using a plastic strip manufactured for this purpose. The plastic strip must be used
in accordance with the manufacturer’s instructions.
b. Cylinder Block and Cylinder Sleeves.
(1) Thoroughly clean the bores in cylinder block
for the sleeve. Make certain bottom surface of flange
on cylinder sleeve and the counterbore in cylinder
block are clean and free from nicks or burrs.
(2) Before installing the new sleeves, use warm
water and common laundry detergent and scrub the bore
with a stiff bristled brush to insure cleanliness and removal of any possible hone dust from the pores. Dry
and protect with a thin coating of engine lubricating
oil.
(3) Before installing packing rings on sleeve, insert sleeve into bore of cylinder block to make sure
sleeve can be pushed down into place and turned in the
bore by hand pressure. If the sleeve cannot be inserted
and turned in the above manner, more cleaning is necessary.
(4) Rotate the sleeve with the contact point of the
dial indicator, contacting the bottom of the counterbore.
Total indicator reading should not exceed 0. 002 inch.
If the total dial indicator reading exceeds the specified
limit, reworking of the counterbore is necessary.
(5) The protrusion (standout) of the cylinder
sleeve flange above the top flat surface of the cylinder
14-93
block is very important. The allowable standout is
0.002 to 0.005 inch. Measure cylinder sleeve standout as follows:
(a) Using a depth micrometer, measure
depth of cylinder sleeve counterbore in the cylinder
block (measure at two more locations). The depth
should be 0. 315 to 0. 3165 inch.
a. Cylinder Sleeve Installation.
(1) Two packing rings are used on each cylinder sleeve: one black on water side, one red on oil
side.
CAUTION
Rubber packing rings are easily damaged.
Use extreme care in handling and installing them in order not to cut or shear them.
Rings swell and expand after short contact
with petroleum products and certain types
of permanent anti-freeze. This causes
them to drop out of their cylinder sleeve
grooves and their installation in the cylinder block becomes impossible. Do not
pre-soak or apply lubricant to a ring.
(b) Using a micrometer, measure width of
cylinder sleeve flange (measure at three or more
locations). The width should be 0.3185 to 0. 320 inch.
(c) Subtract counterbore depth from width
of cylinder sleeve flange. The result is the cylinder
sleeve standout. If the standout is not within 0. 002 to
0.005 inch, install a cylinder sleeve shim of the proper thickness in the sleeve counterbore to bring the
standout within the allowable limits. Cylinder sleeve
shims are available in 0.005-, 0. 010-, 0. 010-,
0.015- and 0. 020-inch thickness. If shimming will
not correct the cylinder sleeve standout, reworking
of the counterbore will be necessary.
(6) To double check the cylinder sleeve standout,
insert sleeve with shims into the cylinder block. To
hold flange of sleeve firmly against the counterbore
seat in the cylinder block, make up a bar similar to
the one illustrated in figure 14-44. Place bar across
top of sleeve and secure in position with 9/16-12 capscrews and flat washers. Tighten capscrews evenly to
60 foot-pounds torque. Using a depth micrometer,
measure the distance between the top of the block and
top of the sleeve flange at three or more locations.
Make certain the standout measurements are made
from the top of the cylinder block to the top of the
sleeve flange and not on the firewall.
(2) Thoroughly clean the packing ring grooves
in the cylinder sleeve. Stand sleeve on a clean work
bench with packing ring end up. Install black on
bottom groove; install red on top groove. The rings
must be installed dry without lubrication of any kind.
CAUTION
New cylinder sleeve packing rings must be
used at each installation of a new or used
sleeve. Make certain rings are not twisted.
(3) Brush a light coat of vegetable or mineral
oil in lower sleeve bore in cylinder block. Be extremely careful so packing rings are not cut on sharp
edges of bore in block when installing.
CAUTION
Do not use any other lubricant except vegetable or mineral oil; doing so prevents
proper installation and operation.
(7) Remove sleeve.
(4) Install cylinder sleeve as follows:
(a) Insert cylinder sleeve installer tool in
cylinder block. Brush bore of tool with a light coat
of vegetable or mineral oil.
(b) Position cylinder sleeve with packing
rings.
(c) Carefully force the cylinder sleeve into
the sleeve lower bore of the cylinder block.
ME 6115-545-34/14-44
Figure 14-44. Cylinder Sleeve Hold-Down Bar
c. Camshaft Bearings. Camshaft bearings must
be replaced by new bearings whenever removed. Camshaft bearings should always be replaced when rebuilding engine.
14-87. Crankshaft, Cylinder Sleeves, and Camshaft
Bearings Installation.
14-94 Change 3
b. Crankshaft Installation.
(1) Install the upper halves of main bearing
shells in position with tang of bearing shell in slot in
bearing seats of the cylinder block.
ME 6115-545-34/14-45
1. Front main bearing cap
2. Intermediate main bearing caps
3. Center main bearing cap
4. Rear main bearing cap
Figure 14-45. MainBearing Caps
CAUTION
Make certain the backs of bearing shells are
free from dirt and grit particles.
(2) Lubricate all crankshaft main bearing journals with engine oil; lower the crankshaft into position
in the cylinder block with flywheel flange end of crankshaft toward the rear.
CAUTION
Make certain that timing mark on crankshaft
gear is aligned with timing mark on camshaft
gear, when crankshaft is installed.
(3) Place the lower halves of the main bearing
shells in position in the main bearing caps.
CAUTION
Make certain the backs of the bearing shells
are free from dirt and grit particles.
(4) The bearing caps are numbered 1,2,3, etc.
indicating their respective positions. Before installing center main bearing cap, insert upper thrust
flanges (flanges without dowel pin holes) with oil
grooves of thrust flanges located next to cheeks of
the crankshaft. Position lower thrust flanges on
dowel pins, with the oil grooves in the thrust flanges
to the outside of the bearing cap.
(5) Install main bearing caps with numbers
facing camshaft side of the engine and corresponding
to number stamped on lower edge of cylinder block
as shown in figure 14-45. Install the main bearing
cap attaching lock bolts snugly. Force crankshaft
in both directions to align the bearing caps with the
upper portion of the main bearing bores.
(6) Using a torque-indicating wrench, tighten
the main bearing cap lock bolts to a torque of 170 to
190 foot-pounds.
CAUTION
Do not overtighten main bearing lock bolts.
If these lock bolts are overtightened, bearing caps may be distorted, causing bearing
to be drawn tight against the crankshaft and
premature failure will result. The crankshaft should turn freely after all capscrews
are properly torqued. Never file or shim
a bearing cap to make the bearings shell fit;
install new bearing shells if fit on the
crankshaft is unsatisfactory.
14-95
(7) Check end play of the crankshaft using a dial
indicator. Tap crankshaft with a soft-headed hammer
in one direction to take up slack or end play. After
dial indicator is set in place, force crankshaft with a
pry bar in opposite direction to obtain end play reading. The end play is 0.007 to 0.013 inch. The end
play is controlled by thrust flanges at the center main
bearing. If end play is not within the allowable range,
replace thrust flanges. Thrust flanges are available
in standard thickness (0. 126 to 0. 127 inch) and 0.005,
0.010, and 0. 015 inch oversize.
(8) Install piston and connecting rod assembly.
(para 14-83.)
(9) Install crankshaft gear and timing gear
housing. (para 14-75.)
(9) Install timing gears and housing. (para
14-75.)
(10) Install flywheel and housing. (para 14-70.)
(11) Install oil pump and oil pan. (para 14-65.)
(12) Refer to Operator and Organizational
Maintenance Manual and install valve cover, manifolds.
turbocharger, radiator, electric starter and housing.
d. Oil Pressure Regulating Valve Installation and
Adjustment.
(1) Thoroughly clean valve bore in cylinder
block, lubricate valve piston with clean oil and install
the regulating valve components in the reverse order
of removal.
(10) Install flywheel housing. (para 14-70.)
(11) Install oil pump and oil pan. (para 14-67.)
(12) Install crankshaft pulley and vibration
dampener. (para 14-63.)
(13) Refer to Operator and Organizational
Maintenance Manual and install electric starter,
winterization kits (if installed), manifolds, turbocharger, radiator and housing.
c. Camshaft beari ng installation.
(1) Position new bearing so that oil hole in
bearing lines up with oil hole in cylinder block.
(2) Front bearing must be installed so that bearing end is flush with or below front side of cylinder
block.
(3) The rear and intermediate bearings are alike.
The rear bearing should be installed with the bearing
end flush with the front side of the cylinder block bearing bore.
(2) Turn valve adjusting screw into cylinder
block the same number of turns required for removal.
(3) With the engine re-installed in the generator
set, start the engine and allow it to reach normal
operating temperature. Adjust oil pressure regulation screw to obtain oil pressure of 45 psi. No further
adjustment should be necessary.
e. Oil Pressure R egulating Valve Removal.
Remove oil pressure regulating valve in the order of
sequence numbers (items 31-36, figure 14-41,
sheet 3).
(1) Thoroughly clean the area around the cylinder block where the pressure regulating valve is located.
(2) Loosen jam nut.
(3) Remove regulating valve screw, noting number of turns required for removal.
(4) Withdraw the spacer, spring and piston.
NOTE
When a new camshaft rear bearing is installed
in place, the old rear bearing will remain partly
in the cylinder block. Use a punch and collapse
the old bearing, preferably at the seam, and
remove the old bearing with pliers.
(4) Install remaining bearings.
(5) Install cylinder sleeve. (Refer to step a.
above.)
(6) Install cylinder head and valve operating
mechanism. (para 14-79.)
(7) Install crankshaft. (Refer to step b. above.)
(8) Install piston and connecting rod assemblies.
(para 14-83.)
14-96 Change 8
f. Oil Pressure Regulating Valve Cleaning
Inspection and Repair.
(1) Wash valve parts in cleaning solvent and inspect carefully for wear or damage.
(2) Inspect the valve seat in the cylinder block
and clean if necessary.
(3) Replace any necessary parts.
CHAPTER 15
BASE GROUP REPAIR INSTRUCTIONS
15-1. General.
a. The base group consists of a rigid frame
skid base and a fuel tank. (fig. 15-1).
b. The main fuel tank is mounted in the skid base,
recessed so that the engine and generator may be
mounted above it without interference.
15-2.
Disassembly.
Refer to the Operator and Organizational Maintainance Manual and remove the main fuel tank.
15-3. Cleaning and Inspection.
a. Clean the skid base with cleaning solvent,
Federal Specification P -D -680.
b. Use a stiff bristled brush to remove heavily
concentrated grease and dirt.
c. Flush inside of the fuel tank with steam under
pressure. Rinse with hot water and detergent to
insure that rust flakes and other foreign material
have been removed.
d. Inspect the skid base, and fuel tank for
cranks and distortion.
e.
15-4.
Inspect tapped holes for damaged threads.
Repair.
a. Repair cracks in the skid base, and fuel
tank by welding or brazing.
b. File or sand the weld marks to an even
finish.
c. Repair the threads in the tapped holes by
retapping.
15-5.
Reassembly.
a. Install the fuel tank in the skid base. (Refer
to the Operator and Organizational Maintenance
Manual).
b. Install the engine and generator assembly.
(Para 2-16).
c. Refer to Operator and Organizational
Maintenance Manual, and install housing.
Key to Fig. 15-1
1.
Screw
2.
Panel
3.
Screw
Bracket
4.
5.
Screw
6.
Washer
Frame
7.
8.
Screw
9.
Bracket
9A. Screw
10. Bracket
11. Nut
12. Washer
12A. Nut
13. Ground Strap
14. Tank
15. Base
Change 1 15-1
Figure 15-1. Base Group
15-2 Change 7
CHAPTER 15A
PAINT AND WING REQUIREMENTS AFTER OVERHAUL
15A-1.
General.
(AF Only) Paint and markings on the generator set shall be in accordance
with AFR 35-1-3.
15A-2.
Noise Level Warning.
Assure that the noise level warning sign is stenciled on the top half of
both rear (generator end of set) side doors as shown in Figure 15A-1.
Figure 15A-1
Change 2 15 A-1
CHAPTER 16
GENERATOR SET TESTS AFTER OVERHAUL REPAIR INSTRUCTIONS
Section I. INSPECTION
16-1 General.
16-3. Engine Inspection.
a. A thorough inspection of the generator set
shall be conducted to insure that workmanship and
materials are satisfactory.
a. Check mounting bolts of all components and
accessories to insure that they are firmly secured.
b, The inspection shall be conducted each time
the-generator set is overhauled or rebuilt.
16-2. Housing and Frame Inspection.
b. Check designation and data plates for legibility.
c. Insure that fuel and hydraulic oil lines are
protected from damage due to vibration.
16-4. Generator Inspection.
a. Check-that lifting eyes are installed and firmly
secured.
a. Insure that generator leads are properly identified and protected from damage due to vibration.
b. Check that drain holes are open to prevent
moisture accumulation.
b. Insure that inspection openings are protected
by screening or protective plates.
c. Insure that exposed parts are properly treated
to resist corrosion.
c. Check that the engine generator screws are
firmly secured. See table 1-3 for proper torque
values.
d. Open and close panel doors, engine area doors,
and-generator area doors to insure proper installation
and freedom of motion.
16-5. Electrical Accessories Inspection.
e. Inspect movable door gasketing to insure that
it is weatherproof.
a. Check all cable and harness assemblies for
secure fastenings and protection against chafing
and vibration.
f. Check that all caps and covers are equipped
with ties, chains, or other ties to prevent loss.
b. Insure that all cable and harness connectors
are-firmly secured in their proper place.
Section II. OPERATING TESTS
16-6. General.
a. The tests described in this section require
generator set operation and provide verification of
generator set performance characteristics.
NOTE
All tests shall be conducted with the
240/416 volt connections, unless otherwise specified. All tests, that are applicable, will be conducted on both
Mode I and Mode II generator sets. Mode
I tests shall be conducted at 60 Hz only
unless otherwise specified.
b. Unless otherwise specified, all test instrumentation will be in accordance with Military Standardization Handbook MI L-HDBK- 705 and Military Standard
MIL-STD-705A.
c. Temperatures will be measured by means of
approximately located thermocouples and properly
calibrated read-out devices. Thermocouples will be
insulated from contact with other metals, as practical. Temperatures will be recorded in degrees
Fahrenheit or Centigrade, depending on the instrument scale, but will be converted to degrees Fahrenheit in all cases. Barometric pressures will be
measured by a mercurial barometer which will be
corrected for the temperature of the scale, the mercury, for vapor pressure and for the location of the
barometer with regard to altitude and latitude. Ameroid barometers will not be used.
d. Operational procedures required in support of
the individual tests specified herein shall be performed as in the Operator and Organizational Maintenance Manual.
e. All test results, for generator set overhaul,
shall be logged on the appropriate forms as required.
16-1
f. Perform the operating tests as indicated in
table 16-1.
16-7. Direction of Rotation Controls.
With the generator set running at a rated load, rotate
the following controls and verify their proper operation.
a. Frequency Adjust Control. On Class 1 sets
clockwise rotation of the frequency adjust control
rheostat must cause set frequency to increase as indicated on the frequency meter. On Class 2 sets
counterclockwise rotation of manual speed control
must increase frequency.
NOTE
On Class 1 sets, set manual control fuel
injection pump lever in the full fuel position with the manual speed control in the
IN position to assure mechanical governor
does not interfere with operation of electric governor.
On Class 2 sets, set manual control fuel
injection pump lever for 48 hertz operation with the manual speed control in the
IN position to assure set does not operate at low speeds.
b. Voltage Adjust Control. Clockwise rotation
of the voltage adjust control must cause set voltage
to increase as indicated on the voltmeter.
c. Governor Paralleling Control (Class 1 sets
only) . Counterclockw ise rotation of the governor
paralleling control must cause an increase in the signal appearing at the paralleling receptacles.
d. Voltage Regulator Paralleling Control. Clockwise rotation of the voltage regulator paralleling control must cause that set to increase its share of the
total reactive Kva.
16-8.
Reverse Power Protective Device Test.
(2) With rated (60 kw) load on the generator
set, measure the dc voltage across pins A and B of
one of the paralleling receptacles (J45, J46 or J47).
Adjust R28 (located in the precise relay box on Mode
I sets and in the special relay box on the Mode II
sets) until 7 volts dc is indicated on Mode I sets and
2.4 volts dc is indicated on Mode II sets. Insure that
pin A is positive.
b.
For Class 2 sets.
Adjust governor droop in accordance with paragraph
14-48 (17).
16-11. Parallel Operation Provision (Reactive
Power).
a.
Remove the shorting plug.
b. With rated load 60kw at .8 PF on the generator-set, and the unit parallel switch in the parallel
position, adjust R29 (located on the special relay box)
until 7.2 volts ac is indicated across pins C and D of
one of the paralleling receptacles (J45, J46 or J47).
c.
Install the shorting plug.
d. With 60kw 1.0 PF load applied the change in
voltage from no load should not exceed 1%. With
60kw .8 PF load applied the voltage change, from no
load should be approximately 3%.
16-12.
Malfunction Indicator Test.
a. The malfunction indicator system is electrically isolated and independent of the protection system. Testing of the indicators can be accomplished
at the same time that the protective devices are tested
in tests 6,9,10,11,12,14,15,16,17 and 18 of table 16-1,
b. In the event that one of the indicator circuits
does not work, verify that the lamp is functional by
operating the test and reset switch on the fault indicator panel,
a. Operate two generator sets in parallel at no
load, with contractors closed.
16-13.
b. Lower speed of set being tested until the main
contactor opens.
a. General. Polyphase electrical equipment may
not–operate properly or may be damaged if the phase
voltages of a polyphase generator differ greatly from
each other. Also, large differences between the
phase voltages of a polyphase generator may be an
indication that the generator set has been improperly
manufactured or damaged.
c. Record the value on the kilowatt meter of the
other set at the moment the contactor opens. The
load contactor of the set under test, must open when
power flow into the generator exceeds 20 percent of
the rated value.
16-9.
Low Fuel Protective Device.
a. Disconnect cable to the day tank fuel solenoid
value.
b. Operate generator set at full load.
c. The low fuel protective device must operate
when the fuel in the day tank falls to a point at which
there is only enough to operate the set at rated load
for one minute.
16-10. Parallel Operation Provisions (Real Power).
a. For Class 1 sets:
(1) Remove the shorting plug.
16-2
Change 4
Phase Balance Test Voltage.
b. Apparatus. A frequency meter (or tachometer)
as described and illustrated in MIL-HDBK-705,
Method 104.1 (or 109. 1) and an rms indicating ac
voltmeter having an accuracy of ± .1% of the reading
shall be required to perform both procedures. A
means of separately exciting the generator is required since procedure H is performed.
c. Generator with Separate Excitation.
(1) Preparation for test.
(a) Completely isolate the generator
windings (armature coils and field windings).
Table 16-1. Operating Tests
Test
MIL-STD-705
procedure
Test parameter
1. Regulator and governor stability and
transient response. (Short Term)
608. la
See tables l-4 and l-5.
2. Overspeed protection device.
505.2a
2400 rpm to 2450 rpm.
3. Phase balance.
508.lc
See tables l-4 and l-5.
4. Circuit’ interrupter (short circuit).
512.lc
Instantaneously at 425 + 25 percent
of rated current.
5. Circuit interrupter (overload trip).
512.2c
8 ± 2 minutes at 130 percent
of rated current.
6. Circuit interrupter (undervoltage)
(Class 1 sets only).
512.3c
Instantaneously below 48 volts. 6 ± 2
seconds at 99 ± 4 volts or less.
7. Circuit interrupter (overvoltage).
512.3c
Not more than 1 second after voltage
has risen to and remained at any
value greater than 153 + 3 volts
for not less than 200 milliseconds.
8. Circuit interrupter
(Under Frequency Trip).
514.1
60 Hz = 55 ± 1
50 Hz = 46 ± l
400 Hz = 370 ± 5
9. Low oil pressure protective device.
515. la
Trip pressure 20 ± 2 psi.
Refer to para 16-8.
10. Reverse power protective device.
11. High coolant temperature protective.
515.2a
Trip temperature +222 ± 3° F.
Refer to para 16-9.
12. Low fuel protective device.
13. Regulator range.
511.lc
Test at both 50 Hz and 60 Hz for Mode
I sets. See tables 1-4 and 1-5.
14. Phase sequence (rotation).
507.1c
Ll, L2, L3.
15. Frequency adjustment range.
511.2b
See tables 1-4 and 1-5.
16. Parallel operation provisions.
Refer to para 16-10.
17. Malfunction indicator system.
Refer to para 16-12.
18. Maximum power.
640.lb
125 percent of rated load
CAUTION
Prior to performing any of the operating tests listed in table 16-1, insure that
the generator set is serviced with the correct fuel, oil and coolant as listed on
the data plate.
Change 1 16-3
(b) Connect the frequency meter to one of
the armature coils of the generator.
(c) Provide separate excitation for the
exciter field.
(2) Test.
(a) Start and operate the generator at rated
frequency and at no load.
(b) Adjust the excitation so that any one of
the coil voltages is at rated value.
(c) Read and record the generator frequency
(speed) and the voltage of each armature coil.
d. Generator with separate excitation
(1) Determine from the data obtained in 16-13d.
(2) the maximum and minimum armature coil voltages.
(2) The voltage unbalance is the difference between the maximum and minimum armature coil
voltages. To express this in percent divide this
difference by rated armature coil voltage and multiply
by 100.
Voltage Unbalance (Coil), in percent =
(2) Test.
(a) Start and operate the generator set and
allow the set to stabilize at rated load, rated voltage
and rated frequency. During this period record all
instrument readings including thermal instrumentation at minimum intervals of 10 minutes. If necessary, adjustments to the load, voltage and frequency
may be made to maintain rated load at rated voltage
and frequency. Adjustments to the voltage and frequency shall be limited to those adjustments available to the operator, specifically adjustments to the
voltage or frequency adjust devices. On sets utilizing a droop-type speed control system as the prime
speed control, the speed and droop portions of the
control may be adjusted. No other adjustments to the
voltage and frequency control systems shall be made.
Adjustments to load, voltage or frequency controls
shall be recorded on the data sheet at the time of
adjustment. Stabilization shall be considered to have
occurred when four consecutive voltage and current
readings of the generator (or exciter) field either
remain unchanged or have only minor variations
about an equilibrium condition with no evident continued increase or decrease in value after the last adjustment to the load, voltage, or frequency has been
made.
(b) No further adjustments shall be made to
any set control for the remainder of this test except
the control panel voltage adjust device.
(c) Record all instrument readings.
(d) Remove load.
(3) Compare the results of step (2) above with
the requirements.
(e) Record all instrument readings (after
transients-have subsided).
16-14. Regulator Range Test.
a. General. The voltage adjust device associated
with the voltage regulator provided with the generator
set must have adjustment capable of varying the regulated voltage throughout the limits and under the
various load conditions and temperature ranges without causing the voltage droop of the set to exceed
specification limits. The voltage adjust device also
must be capable in some cases of providing an operating voltage other than rated voltage for special
types of equipment and to compensate for external
line drop.
b. Apparatus. Instrumentation for measuring
load conditions, ambient temperature, and the
generator field (or exciter field) voltage and current
shall be as described and illustrated in MIL-HDBK705.
c. Preparation for Test.
(f) Adjust the terminal voltage to the maximum specified value.
(g) Record all instrument readings.
NOTE
At voltages above rated values, the
generator will be supplying less than
rated current; and at voltages below
rated values, the generator will be
supplying greater than rated current.
Caution should be taken to avoid
damage to instrumentation and load
banks.
(h) Apply rated load (rated kw at rated power
factor).
(i) Record all instrument readings (after
transients–have subsided).
(1) Preparation for test.
(a) Connect the load and field instrumentation in, accordance with the applicable figure of MILHDBK-705, Method 205.1, Paragraph 205.1.10 for
one voltage and frequency.
16-4
(j) Remove load and adjust voltage to the
maximum attainable value or to a value just prior to
actuation of the overvoltage protection device.
NOTE
The output voltage may exceed the
rating of connected equipment.
(k) Record all instrument readings (after
ransients have subsided).
(l) Apply rated load.
(m) Record all instrument readings (after
ransients have subsided).
(n) Adjust voltage to the minimum specified
value at rated load.
(o) Record all instrument readings (after
transients have subsided).
(p) Remove load.
(q) Record all instrument readings (after
transients have subsided).
(r) Adjust voltage to the minimum attainable
value or a value just prior to activation of the undervoltage protection device.
(s) Record all instrument readings (after
transients have subsided).
(t) Repeat steps (a) through (s) above for
all other voltage connections).
Frequency stability describes the tendency of the
frequency to remain at a constant value. Generally,
the instantaneous value of frequency is not constant
but varies randomly above and below a mean value.
Stability may be described as either short-term or
long-term depending upon the length of time that the
frequency is observed. Another term, bandwidth,
describes the limits of these variations. Bandwidth
is expressed as a percentage of the rated frequency
of the generator set. Voltage stability is described
similarly.
Frequency transient response describes the reaction
of the frequency to a sudden change in some condition;
such as, a load change on a generator set. This response consists of the amount of excursion beyond the
mean of the new operating band, and the recovery
time. The recovery time is the interval beginning at
the point where the frequency leaves the original
prescribed operating band and ending at the point
where it enters and remains within the new prescribed
operating band. The amount of surge is expressed
as a percentage of the rated frequency of the generator set. The recovery time is expressed in seconds.
The voltage transient response is described similarly.
b. Apparatus. Instrumentation for measuring
load conditions, field voltage and current, and ambient
temperature shall be as described and illustrated in
MIL-HDBK-705. In addition, recording meter(s) for
recording voltage and frequency shall be required.
The recording meters shall be as described in
Table 2-1.
c. Procedure.
d. Sample Calculations. Regulation (droop) is
defined for the purposes of this method as the noload value minus the rated load value divided by the
rated load value the quantity expressed in percent.
% Regulation =
(No-Load Voltage) - (Rated-Load Voltage) x 100
(Rated -Load Voltage)
e. Results. The data sheets shall indicate the
voltage regulation as a percent of rated voltage within the specified limits at the minimum and maximum
specified voltages and the regulation as a percent of
rated voltage at the extremes, the maximum and
minimum voltages attainable and the actuation of the
protection devices (if applicable). Compare these
results with the requirements of Table 16-1.
16-15.
Frequency and Voltage Regulation, Stability
and Transient Response Test (Short-Term).
a. General. The frequency regulation (sometimes
referred to as droop) of a generator set is the maximum difference between the no load value of frequency
and the value at any load up to and including rated load.
This difference is expressed as a percentage of the
rated frequency of the generator set. The voltage
regulation is expressed similarly except that the rms
value of voltage is used.
(1) Preparation for test.
(a) Connect the load and field instrumentation in accordance with the applicable figure of
MIL-HDBK-705, Method 205.1, paragraphs 205.1.10,
for one voltage and frequency. Connect the signal
input of the recording meter(s) to the convenience
receptacle of the set or to the generator coil which is
used as the voltage sensing input to the voltage regulator. (Power the recording meter(s) from the
commercial utility.)
(b) Set the recording meter chart speed(s)
to a minimum of 6 inches per hour. The following
items shall be recorded on both the data sheets and
recording chart(s):
1. The date
2. The serial number(s) of the recording
meter(s)
3. Generator set identification
4. The recording chart speed(s)
5. The data reading number
(c) Place all instrumentation referred to in
paragraph 16-15b. in operation.
16-5
(2) Test.
(a) Start and operate the generator set and
allow the set to stabilize at rated load, rated voltage
and rated frequency. During this period operate the
recording meter(s) at a chart speed of not less than
6 inches per hour, and record all instrument readings
including thermal instrumentation at minimum intervals of 10 minutes. If necessary, adjustments to the
load, voltage and frequency may be made to maintain
rated load at rated voltage and frequency. Adjustments to the voltage and frequency shall be limited to
those adjustments available to the operator, specifitally adjustments to the voltage or frequency adjust
devices. On sets utilizing a droop-type speed control
system as the prime speed control, the speed and
droop portions of the control may be adjusted. No
other adjustments to the voltage and frequency control
systems shall be made. Adjustments to load, voltage
or frequency controls shall be recorded on both the
data sheet and the recording chart(s) at the time of a
adjustment. Stabilization shall be considered to have
occurred when four consecutive voltage and current
recorded readings of the generator (or exciter) field
either remain unchanged or have only minor variations about an equilibrium condition with no evident
continued increase or decrease in value after the last
adjustment to the load, voltage or frequency has been
made.
(b) After stabilization has occurred, drop
the load to no load and reapply rated load a number
of times (three should be sufficient) to assure that the
no load and rated load voltage and frequency values
are repeatable and that the frequency and voltage
regulation is within the limits specified in the procurement document. If any adjustments are necessary, paragraph (a) above must be repeated. Reapply
rated load.
(c) The recording meter chart speed(s)
shall be 12 inches per minute throughout the remainder of this test. At each of the following load conditions (one step) operate the set for a minimum of 40
seconds (or the short-term stability period plus the
allowable recovery time as specified in the procurement document). During each load condition read and
record all instrument readings except thermal instrumentation (for three-phase sets it is not necessary to
record line-to-line voltages). Each load condition
shall be applied to the generator set in one step at the
end of the short -term stability period for the previous
load condition. The load conditions are:
1. Rated load
2. No load
3. Rated load
No load
Rated load
No load
Rated load
No load
3/4 rated load
No load
3/4 rated load
16-6
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
No load
3/4 rated load
No load
1/2 rated load
No load
1/2 rated load
No load
1/2 rated load
No load
1/4 rated load
No load
1/4 rated load
No load
1/4 rated load
No load
Rated load
No load
Rated load
No load
Rated load
No load
(d) Repeat (a) through (c) for all voltage
connections) and frequency(ies).
d. Results.
(1) Prepare a chart giving for each load change
the momentary overshoot or undershoot and the recovery time. For each constant load, give the maximum voltage variation,
(2) Referring to figure 16-1, begin by determining the observed (B) and steady -state (D) voltage
bandwidths.
(a) Mark numerically the stabilizations
occurring after each load change, starting with the
stabilization obtained before the first load change.
(b) Determine the observed voltage bandwidth (B) by marking the maximum trace excursion
and minimum trace excursion in the stabilized
portion. Draw two lines parallel to the axis of chart
movement, one each passing through these maximum
and minimum trace excursions respectively.
(c) Draw a line (C) parallel to and equidistant from the edges of the observed voltage bandwidth. Determined in (b) above,
(d) Using the rated voltage of the generator
and given requirements of table 16-1, calculate the
steady -state voltage bandwidth (D). Draw this
steady -state voltage bandwidth as two parallel lines,
parallel to and equidistant from the median (C) at
the observed voltage bandwidth.
(3) To determine the maximum voltage variation at constant load
(a) One-half the observed voltage bandwidth
(B) is the plus or minus value of voltage deviation
at constant load.
(b) Divide each of the values obtained in (a)
Trace and definitions apply to either voltage or
frequency.
NOTE
Point at which trace initially leaves
prescribed no load band.
Point at which trace enters and remains
within prescribed load band.
Chart marked at start of test.
Actual instrument trace of function.
Observed steady-state band (two lines
parallel to the axis of chart movement,
one each passing through the center points
of maximum and minimum trace excursion
respectively during the short-term stability
sample period, [email protected],
Regulation between any two loads.
Surge after a load change.
Overshoot
Undershoot
Observed recovery time, no load to load.
Mean of observed band.
Observed recovery time, load to no load.
Mean value at selected load.
Mean value at no load.
Maximum allowable recovery time.
Prescribed steady-state band.
Maximum allowable recovery time, no
load to load.
Point at which trace initially leaves prescribed load band under condition of
decrease in load.
Maximum allowable recovery time, load
to no load
Point at which trace enters and remains
within prescribed no load band.
Prescribed short-term sample time for
determining stability.
ME 6115-545-34/16-1
Figure 16-1. Overshoot and Undershoot Chart Recording
16-7
by the rated voltage of the generator and multiply by
100 to convert to percentage.
16-16. Frequency Adjustment Range Test.
(4) To determine the maximum overshoot and
undershoot at each load step, and express this as a
percentage of its rated voltage, proceed as follows:
(a) From the meter recording charts, determine the maximum amount that the voltage trace goes
beyond the line (3) of the observed voltage band following the load change. See figure 16-1 for illustration
of overshoot and undershoot.
a. General. It is necessary that the frequency of
a generator set be adjustable to provide rated frequency at various load conditions as required in
certain applications and to synchronize two or more
generator sets for parallel operation.
(b) Divide the result obtained in (a) by
rated voltage (as given on the generator nameplate),
then multiply by 100 to convert to percentage.
CAUTION
Do not use the constant operating voltage
at each load as the divisor in the computation. Use only the rated voltage of the
generator.
(5) To determine the time required to restore
stable voltage conditions after each load change
(recovery time):
(a) The prescribed steady state voltage
bandwidth, extended to the point at which the voltage
trace leaves the prescribed steady state band, shall
be considered as the time at which the transient conditions begin. The point at which the voltage trace
enters and remains within the prescribed band after
a load change shall be considered as the point at which
stabilization begins.
(b) Measure the distance (in inches) on the
chart from the point where the voltage trace leaves
the prescribed steady state band to the point where
it re-enters and remains within the prescribed voltage
band for the next load condition.
(c) Divide this distance by the chart speed
(in inches-per second). This will give the voltage
recovery time, in seconds.
(6) Determine the voltage regulation for all
load changes (e. g. rated load to no load, 1/2 rated
load to no load to 1/4 load, etc. ) as follows:
(a) Using the indicating voltmeter readings
subtract the load value of voltage from the no load
value for each load change (e. g. step (a) to step (b)).
(For voltage regulators utilizing single-phase voltage
sensing, the value of voltage in the sensed phase only
shall be used in the above calculations. For voltage
regulators utilizing multi-phase voltage sensing the
average value of the sensed voltage shall be used. )
(b) Convert each of the values obtained in (a)
above to a percentage of rated voltage by dividing by
the rated voltage and multiplying by 100. This is the
voltage regulation expressed in percent.
(c) Repeat paragraph 16-15d. (1) above substituting frequency for voltage.
(d) Compare the results tabulated in paragraphs 16-15d. (1) and 16-15d. (6)(c) with the requirements of Table 16-1.
16-8
b. Apparatus. Instrumental ion for measuring
load conditions, field voltage and current, and
ambient temperature shall be as described and
illustrated in MIL-HDBK-705.
c. Procedure.
(1) Preparation for test. Connect the load and
field instrumentation in accordance with the applicable
figure of MIL-HDBK-705, Method 205.1, paragraph
205.1.10.
(2) Test.
(a) Start and operate the generator set
and allow it to stabilize at rated load, rated
voltage and rated frequency.
During this period, readings of the load and field
instrumentation shall be recorded at minimum intervals of 10 minutes. If necessary, adjustments to
the load, voltage and frequency may be made to
maintain rated load at rated voltage and rated frequency. However, adjustments available to the
operator, specifically adjustments to voltage and
frequency adjust devices. Adjustments to the load,
voltage or frequency shall be noted on the stabilization data sheet. Stabilization will be considered to
have occurred when four consecutive voltage and
current readings of the exciter field either remain
unchanged or have only minor variations about an
equilibrium condition with no evident continued increase or decrease in value after the last load,
voltage or frequency adjustment has been made.
(b) No further adjustments shall be made to
any set control for the remainder of this test except
for the control panel frequency adjust device.
(c) For each of the conditions in the following steps allow approximately 2 minutes between each
adjustment and the subsequent instrument readings.
(d) Adjust the generator set frequency for
the specified maximum frequency at rated load.
Read and record all instrument readings.
(e) Adjust the generator set frequency for
the specified minimum frequency at rated load.
Read and record all instrument readings.
(f) Reduce the load to zero.
(g) Adjust the generator set frequency for
the maximum attainable frequency. Read and record
all instrument readings. If the overfrequency or
over speed protection device actuates, read and record
all instrument readings just prior to the point of
actuation and note on the data sheet that the protection
device actuated.
CAUTION
Do not operate the set in excess of 125
percent of rated speed or as otherwise
limited in the procurement document.
NOTE
This step is not applicable to generator
sets having governors that utilize a
threaded shaft and lock nut(s) or other
mechanical means as a method of
operator speed adjustment.
(h) Adjust the generator set frequency for
the minimum attainable frequency. Read and record
all instrument readings.
(c) Attempt to start the set. Record if
starting is achieved. If the set did not start, reset
the overspeed protective device.
(d) Repeat steps (a) through (c) above two
additional times.
d. Compare the test results with requirement of
Table 16-1.
16-18. Circuit Interrupter Test (Short Circuit).
NOTE
This step is not applicable to generator
sets having governors that utilize a
threaded shaft and lock nut(s) or other
mechanical means as a method of
operator speed adjustment.
(i) Repeat 16-16c. (1) and 16-16c. (2)(a)
through (f) for each frequency.
d. Results. The data sheet shall show the maximum and minimum frequencies attained at rated load,
the maximum and minimum attainable frequencies at
no load and actuation of the protection devices (if
applicable). Compare these results with the requirements of Table 16-1.
a. General. A circuit interrupter is connected
between the generator voltage reconnection system
and the generator set output terminals to disconnect
the generator output from the load and also to protect
the generator from a short circuit. The circuit interrupter is operated from a current sensor external
to the interrupter.
b. Apparatus. Instrumentation for measuring
load conditions shall be as described and illustrated
in MIL-HDBK-705. In addition, a non-inductive
shunt, as short-circuiting switch, galvanometers
mat thing net works, an oscillograph as described and
illustrated in MIL-HDBK-705, Method 106.1, paragraph 106. 1.3 and galvanometers having a flat
frequency response (flat within plus or minus five
percent) from DC to 3,000 hertz will be required.
16-17. Overspeed Protective Device Test.
c. Procedure.
a. General. To assure that adequate protection
is afforded the generator set against overspending,
the overspeed protective device must operate properly.
b. Apparatus. A frequency meter or tachometer
as described and illustrated in MIL-HDBK-705,
Methods 104.1 or 109.1 shall be required.
c. Procedure.
(1) Preparation for test. Connect the frequency
meter in accordance with the applicable figure of
MIL-HDBK-705, Method 205. l, Paragraph 205. 1.9,
or utilize the tachometer in accordance with the manufacturer’s instructions. Electronic governor and
throttle stops must be deactivated.
(2) Test.
(a) Start and operate the generator set at
rated speed (frequency), rated voltage and no load.
(b) Slowly increase the engine speed until
the overspeed protective device actuates. Record
the speed of the generator set at this point, and the
malfunction indicator light indication.
(1) Preparation for test.
(a) Connect the load and instrumentation in
accordance with the applicable figure of MIL-HDBK705, Method 205. 1, paragraph 205. 1. 10 for one
voltage and frequency.
(b) Connect the shunt, galvanometers
matching net work, oscillograph, and short-circuiting
switch as illustrated in figure 512. 1.I.
(2) Test.
(a) Start and operate the generator set at
rated voltage, rated frequency and rated load.
(b) Set the oscillograph time marker to a
minimum of 0. 01 seconds or use a 60 hertz timing
trace set the chart speed such that the individual
peaks of the current waveform are clearly visible
and adjust the peak -to-peak rated current amplitude
to a minimum of 0.5 inch (or approximately 12
millimeters).
16-9
(c) Prior to closing the short-circuiting
switch, record a portion of the steady state load for
calibration. With the same load conditions record
all instrument readings.
(d) With oscillograph still recording the
steady state current, close the short-circuiting
switch.
CAUTION
If the circuit interrupter fails to operate
within the specified time, remove the
short circuit to prevent damage. Note
the failure to operate on the data sheet.
(e) The generator set contains a shortcircuit malfunction indicator, check and record its
indication,
(f) Repeat steps (a) thru (e) above for each
possible short circuit condition
(g) Repeat steps (a) thru (f) above for both
voltage confections if applicable.
d. Results.
(1) From the oscillograms taken in 16-18c
(2)(d), determine the time between the indicated
closure of the short-circuiting switch and the opening
of the circuit interrupter. See figure 512.1-110
(2) Calculate the short-circuit current using
the peak-to-peak amplitudes of the current trace and
the steady state ammeter reading prior to application of the short circuit. See figure 512. l-II.
(3) Tabulate the above results and the m alfunction indicator indication for each line connection
at each voltage connection and compare the results
with the requirement in table 16-1.
c. Procedure.
(1) Preparation for test. Connect the load and
field instrumentation in accordance with the applicable figure of MIL-HDBK-705, Method 205.1, paragraph 205.1.10 for one voltage and frequency,
CAUTION
If the circuit interrupter fails to operate
within the time specified in table 16-1
at any time during the performance of
this method, manually open the circuit
interrupter and reduce the load impenance to rated value before reclosing
the circuit interrupter. Record on the
data sheet the failure of the interrupter
to operate and the total elapsed time
the overload was on the set.
(a) Start and operate the generator set at rated
voltage; rated frequency and rated load.
(b) Allow the generator set to stabilize at rated
load, voltage and frequency, During this period,
readings of the load and field instrumentation shall
be recorded at minimum intervals of 10 minutes.
If necessary, adjustments to the load, voltage and
frequency may be made to maintain rated load at
rated voltage and frequency. Adjustment to the load,
voltage or frequency shall be noted on the data sheet.
Stabilization will be considered to have occured when
four consecutive voltage and current readings of the
exciter field either remain unchanged or have only
minor variations about an equilibrium condition with
no evident continued increase or decrease in value
after the last load, voltage or frequency adjustment
has been made.
(c) In one step, increase the load current to
the overload current value specified in table 16-1
(the increase in current may be accomplished by
any practical means, e. g. reactively or using reduced voltage levels).
16-19. Circuit Interrupter Test (overload Current)
NOTE
a. General. A circuit interrupter is connected
bettween the generator voltage reconnection system
and the generator output terminals to disconnect the
generator output from the load and to protect the
generator from a sustained overload current. The
circuit interrupter is operated from a current sensor
external to the interrupter.
b. Apparatus. Instrumentation for measuring
load condition field voltage and current shall
be as described and illustrated in MIL-HDBK-705.
In addition a stopwatch or an oscillograph with galvanometer matching network and a non-inductive
shunt as described and illustrated in MIL-HDBK-705,
Method 106.1, paragraph 106. 1.3 and galvanometers
having a flat frequency respond (within plus or minus
5% from dc to 3000 Hz.
16-10
The frequency shall be maintained at rated
conditions, the load current shall be kept
constant and the load current shall be balanced equally among the phases. Simultaneously with the load current increase,
start the stopwatch.
(d) Record all load instrumentation and the
time, m seconds, required for the circuit interrupter to operate.
(e) The generator set contains an overload
malfunction indicator, check and record its indication,
(f) Allow the generator set to cool at rated load
for a minimum of 15 minutes.
(g) Repeat steps (c) thru (f) except that the
load current is increased to the overload current value
in Phase A only, Phases Band C remain at the rated
load current value.
(h) Repeat step (g) except that the load is
increased to the overload current value in phase B
rely. Phases A and C remain at the rated load value
of current.
condition, it will be necessary to temporarily deactivate this provision to permit adjustment of
the overvoltage value. This may be done by activation of the "protective bypass" (Battle Short)
switch. Do not deactivate the circuit interrupter
trip circuitry.
(c) Open the switch, reset the overvoltage
circuit and adjust the resistance, R2, until Voltmeter
Number 2 reads rated voltage.
(i) Repeat step (g) except that the load is
increased to the overload current value in phase C
only. Phases A and B remain at the rated load value
of current.
(d) Repeat (b) and (c) to assure that the
specified overvoltage and rated voltage settings are
correct.
d. Results. The data sheets shall show, as a
minimum, whether or not the circuit interrupter operated, the time(s) required for the interrupter to operate, the indication of the malfunction indicator, the
overload load condition(s) and the stabilization data.
Compare the time(s) requirements of table 16-1.
(e) Set the oscillograph chart speed such that
the individual waveform peaks are clearly visible.
Set the timing lines to a minimum of 0.01 seconds per
line or use a 60 Hertz time trace. Adjust the trace
peak-to-peak amplitude to a minimum of one inch (or
25 millimeters).
(f) Read and record both voltmeter readings.
16-20. Circuit Interrupter Test (Overvoltage and
Undervoltage)
a. General. To protect the load from generator
malfunction (e.g. overvoltage or undervoltage) a
circuit interrupter is connected between the generator
voltage reconnection system and the generator output
terminals. A voltage sensing circuit operates the
circuit interrupter if an overvoltage or undervoltage
condition occurs and thus protects the load from a
generator malfunction.
b. Apparatus. Instrumentation for measuring
voltage and frequency shall be as described and illustrated in MIL-HDBK-705. Resistor(s), galvanometers
matching networks, an oscillogram (as described
and illustrated in MIL-HDBK-705, Method 106.1,
paragraph 106.1. 3) and galvanometers having a minimum flat frequency response (flat within plus or
minus 5 percent) from DC to 3,000 Hertz and the
voltage divider transformer network will be required.
c. Procedure I. (Overvoltage)
(1) Preparation for test.
(a) Locate and disconnect the input circuit
to the input terminals of the overvoltage protective
sensing circuit and connect the apparatus as illustrated in figure 512, 3- I for one voltage connection.
(b) Connect the frequency meter to the output terminals of the generator set.
(2) Test.
(g) With the oscillograph recording and the
circuit interrupter closed, close the switch. (See
figure 512. 3-I).
(h) Reactivate the shutdown provision if
used.
(i) The generator set contains an overvoltage malfunction indicator, check and record its indication.
(j) Record whether or not the set shuts
down.
(k) Open the switch, reset the overvoltage
circuit if necessary, restart the set if required, and
close the circuit interrupter.
(1) Repeat steps (e) thru (k) above two additional times.
d. Procedure II. (Undervoltage)
(1) Preparation for test.
(a) Locate the input terminals of the undervoltage sensing circuit and connect the apparatus as
illustrated in figure 512. 3-I.
(b) Repeat step (b) of para. 16-20c. (1)(b).
(2) Test.
(a) Start and operate the set at rated frequency and nO load.
(a) Start and operate the set at rated frequency and no load.
(b) Close the switch (see figure 512. 3-I)
and use resistance, R1 to adjust the voltage to the
overvoltage value specified in table 16-1. The
set has provisions for shutdown upon an overvoltage
(b) Close the switch (see figure 512. 3-I) and
use the resistance, R1, to adjust the voltage to the
rated value.
16-11
(c) Open the switch and adjust the resistance, R2 until Voltmeter Number 2 reads the undervoltage value specified in Table 16-1. This test shall
be repeated for each undervoltage value.
(d) Repeat steps (b) and (c) above to assure
that the specified undervoltage and rated voltage settings are correct.
(e) Set the oscillograph chart speed such
that the individual waveform peaks are clearly visible.
Set the timing lines to a minimum of 0. 01 seconds per
line or usc a 60 Hertz timing trace. With the switch
open, adjust the trace peak-to-peak amplitude to a
minimum of one inch (or 25 millimeters).
(f) With the set operating and the circuit
interrupter and the switch open, read and record
both voltmeter readings.
(g) Close the switch and circuit interrupter,
c.
Procedure.
(1) Preparation for test. With the set not operating remove the protective device tap from the engine-block and reconnect as shown in figure 515. 1-I
with the protective device and oil pressure gage in
approximately the same horizontal plane as the protective device tap located on the engine.
(2) Test.
(a) With the bleeder valve closed and the
shut-off valve in the oil pressure line open, start and
operate the set at rated speed (use the set instrumentation) and at no load.
(b) Open the bleeder valve slightly to purge
air from the system.
(c) Close the bleeder valve and record the
oil pressure as indicated on the external gage.
(h) With the oscillograph recording, open
(d) Almost completely close the shut-off
the switch,
valve.
(i) After allowing sufficient time for the
circuit interrupter to operate, check and record the
indication of the undervoltage malfunction indicator.
(e) Slowly open the bleeder valve until the
low oil pressure protective device shuts down the
engine. Record the reading of the oil pressure gage
at the point of set shutdown (see figure 515. l-II).
(j) Close the switch, and close the circuit
interrupter.
(k) Repeat steps (e) thru (j) above two additional times.
(l) Repeat (a) thru (k) for the other undervoltage value specified in para. 16-1.
e.
Results.
(1) From the oscillograms made in 16-20c
determine and tabulate the time between the application of the overvoltage and operation of the circuit
interrupter for each application of overvoltage.
(2) From the oscillograms made in 16-20d
determine and tabulate the time between the application
of the undervoltage and the operation of the circuit
interrupter for each application of undervoltage.
(f) Record operation of the malfunction indicator light.
d . Results. Compare the value of shutdown pressure with the requirement of Table 16-1.
16-22. Overtemperature Protective Device Test.
a . General. The overtemperature device must
be capable protecting the engine in the set against
overheating for any reason.
b . Apparatus. Instrumentation for measuring load
conditions and set and ambient temperatures shall be
as described and illustrated in MIL-HDBK-705,
Method 205.1, Paragraph 205.1.10.
c.
Procedure.
(1) Preparation for test.
(3) Compare these results with the requirements of table 16-1.
16-21. Low Oil Pressure Protective Device Test.
(a) Connect the load instrumentation in accordance with the applicable figure of MIL-HDBK-705,
Method 205.1, Paragraph 205.1.10.
a. General. Since generator sets frequently operate–unattended for long periods, the engine is
equipped with a low oil pressure protective device.
This device shuts down the engine when the oil pressure drops below the safe limit.
(b) Install a thermocouple to measure the
same temperature as seen by the protective device
sensor.
b. Apparatus. The following equipment shall be
required to perform this test.
Oil pressure gage (± 1%)
Flexible oil line (or copper tubing)
Regulating valves
Brass fittings.
16-12
(a) Start and operate the generator set at
rated voltage, rated frequency (speed), and rated load.
(2) Test.
(b) Block the cooling air to the generator set
by any suitable means.
(c) Continuously monitor the temperature
seen by the thermocouple installed in paragraph 1622 c(l)(b) above. Record the temperature at which
the–overtemperature protective device actuates. Record the temperature at which the coolant temperature indicator illuminates.
CAUTION
If the engine fails to shutdown when the
temperature exceeds the maximum
trip value specified in Table 16-1, the
test shall be immediately discontinued.
d. Results. Compare the results with the requirement of Table 16-1.
16-23. Phase Sequence Test (Rotation)
a. General. Unless the phase sequence (rotation)
of the load terminals of a three-phase generator set
is correct, serious damage or injury could be done
to connected equipment and to personnel as a result
of reversed motor rotation or excessive current
surges.
b. Apparatus. A phase sequence (rotation) indicator as described and illustrated in MIL-HDBK-705,
Method 116.1 or a three-phase motor whose direction of operation in relation to phase sequence is
known shall be required.
c.
Procedure.
(1) Connect the generator set load terminals
to the applicable test applicable test apparatus for
one of the set three-phase voltage connections. Recheck the connections to insure that
of the generator set are connected to Ll, L2 and L3
of the test apparatus respectively.
(2) Start and operate the generator set at rated voltage and frequency. The set indicating instruments shall be sufficient indication of output voltage
and frequency.
(3) Close the circuit interrupter and determine
the direction of phase sequence (rotation) by observing
the indicator, or by noting the direction of rotation if
a three-phase motor is used. Record results.
(4) Check the phase sequence (rotation) of the
power output of each power receptacle on the generator set by connecting the applicable test apparatus to
the receptacle and repeating steps (1) thru (3) above.
(5) Repeat steps (a) thru (d) above for all
other three-phase voltage-output connections of the
generator set.
d, Results. The phase sequence (rotation) as indicated by the test shall be checked against the requirements of Table 16-1.
16-24. Maximum Power Test.
a. General. The maximum power of a generator
set–is a function of the ambient conditions (temperature and altitude) and the mechanical condition of the
engine at any particular time.
b. Apparatus. Instrumentation for measuring
load conditions, field voltage and current, pressures
and temperatures shall be as described and illustrated in MIL-HDBK-705.
c. Procedure.
CAUTION
This procedure subjects the generator set
to a severe overload which may be damaging if maintained for too long a period of
time.
(1) Preparation for test.
(a) Connect the load and instrumentation in
accordance with the applicable figure of MIL-HDBK705, Method 205.1, paragraph 205.1.10 for one voltage and frequency.
(b) Install appropriate thermocouples to
measure the following temperatures:
1. Engine coolant (engine outlet and inlet)
2. Exhaust gas(es) (the exhaust manifolds
shall be drilled and tapped as close as
possible to the combustion chamber(s).
3. Lubricating oil sump,
4. Engine combustion air in (located at
the inlet of the intake manifold).
(c) Install appropriate pressure instrumentation to measure the following items:
1. Exhaust pressure (combined exhaust
gases in exhaust manifold).
2, Intake air manifold pressure (between
air filters and manifold).
(d) Obtain and record the barometric and
water vapor pressures (see MIL-HDBK-705, Method
220. 2).
(e) Bypass the set circuit interrupter.
(f) Connect the set to a source of fuel containing a specified fuel required by the procurement
document.
(2) Test.
(a) Start and operate the generator set and
allow it to stabilize at rated load, rated voltage and
rated frequency (speed). During this period, readings
of all instruments including thermal instrumentation
shall be recorded at minimum intervals of 10 minutes.
If necessary, adjustments to the load, voltage and
rated frequency. However, adjustments to the voltage and frequency shall be limited to those adjustments
16-13
available to the operator, specifically adjustments
to the voltage or frequency adjust devices. On generator sets utilizing a droop-type speed control
system as the prime speed control, the speed and
droop portions of the control may be adjusted. No
other adjustments to the voltage and frequency control systems shall be made. Adjustments to the
load, voltage or frequency controls shall be recorded on both the data sheet and recording chart(s).
Stabilization will be considered to have occurred when
four consecutive voltage and current recordings of
the exciter field either remain unchanged or have only
minor variations about an equilibrium condition with
no evident continued increase or decrease in value
after the last adjustment to the load, voltage or frequency has been made.
(b) Perform this test using resistive load
only. Remove reactive load after stabilization.
critical frequency value, the generators are equipped with an underfrequency protective device. The
device on this generator operates electrically. Although the under frequency protective device must be
capable of functioning at any voltage throughout the
specified voltage operating range, it is necessary
only to perform the test at the specified maximum, at
rated, and at minimum voltage limits.
b. Apparatus. Instrumentation for measuring load
conditions shall be as described and illustrated in
method 205.1, paragraph 205.1.10 of MIL-HDBK-705.
c.
Procedure.
(1) Preparation For Test. Connect a voltmeter
and frequency meter to the generator set terminals,
ahead of the circuit interrupter, and the remainder of
the apparatus as shown in the applicable figure of
paragraph 205.1.10 of MIL-HDBK-705.
(2) Test.
(c) For sets with droop-type governors:
1. Load the set to 125% of rated load.
Adjust the frequency to the rated value and maintain
the load for 5 minutes.
(d) For generator sets with isochronoustype governors, repeat step (c) above but do not adjust the frequency.
(e) Results. Compare these results with
the requirement of Table 16-1.
16-25. Under Frequency Protective Device Test.
a. General. For generators that power certain
types of equipment, it is extremely important that
the circuit interrupter open when the frequency fails
appreciably below rated value. Severe damage may
otherwise result to the powered equipment. To insure
that the circuit interrupter will open at or before the
(a) Operate the generator at rated speed and
voltage, and at no load since the generator is equipped
with an electrical-type underfrequency protective device, this test shall be repeated with the voltage adjusted to maximum and minimum voltage for the specified voltage operating range.
(b) With the circuit interrupter closed,
decrease the operating speed until the protective
vice causes the circuit interrupter to open. The
tric governor must be deactivated to sufficiently
crease the speed on Class 1, precise sets.
slowly
deelecde-
(c) Record the speed.
(d) Repeat the test while rapidly decreasing
the operating speed. Again record the speed.
(e) Operate the generator at rated speed and
voltage, and at rated load.
(f) Repeat steps (b), (c) and (d).
d. Results. Compare the test value of frequency
with that given Table 16-1.
16-14
CHAPTER 17
KIT AND OPTIONAL EQUIPMENT REPAIR INSTRUCTIONS
Section I. FUEL BURNING WINTERIZATION KIT
17-1. Introduction.
This chapter contains intermediate (field) (direct and
general support) and depot repair instructions for the
kits and optional equipment of the generator sets.
17-2. General.
The fuel burning winterization kit is available as an
aid in starting the generator set in temperatures from
-25° F to -65° F. The kit consists of a heater, which
burns fuel from the engine fuel supply, a control
panel, and the necessary plumbing which will route
coolant through the heater and to the oil pan heat exchanger and engine water jacket through an outlet at
the front of the cylinder block and back to the heater.
A thermostat on the engine cylinder head starts and
stops the heater according to coolant temperature
when the system is operating.
17-3. Troubleshooting.
Troubleshoot the fuel-burning winterization kit using
table 17-1. Typical malfunctions, the possible causes
and the necessary corrective actions are tabulated.
b. Test of Power Switch.
(1) Disconnect connector.
(2) Using an ohmmeter set scale to RI. Check
for continuity between terminals 4 to 6 and 1 to 3 in
the ON position. If defective, replace.
c. Replacement of Light Assembly.
(1) Disconnect connector J26.
(2) Disconnect and tag leads sequentially.
(3) Remove lens cap and locking bolt. Remove
light assembly from rear of panel.
(4) Replace in reverse order.
d. Replacement of Circuit Breaker.
(1) Disconnect connector J26.
(2) Disconnect and tag leads.
17-4. Removal and Disassembly.
(3) Unscrew holding nut and lock washer. Remove circuit breaker from rear of panel.
a. Removal. Refer to Operator and Organizational
Maintenance Manual and remove fuel-burning winterization kit.
(4) Replace in reverse order noting the proper
placement of locating lug.
b. Disassembly.
(1) See figure 17-1 and disassemble the fuel burning heater. Disconnect and tag leads sequentially
during disassembly procedure.
(2) See figure 17-2 and disassemble the fuelburning heater control box. Disconnect and tag leads
sequentially during disassembly procedure.
17-5. Fuel Burning Heater Control Box Testing,
Repair and Replacement.
a. Test of Circuit Breaker.
(1) Disconnect connector.
(2) Using an ohmmeter with the R x 1 scale
selected, read across the circuit breaker. With the
circuit breaker in the closed position (ON) the reading
should be zero (0) ohm.
(3) Open the circuit breaker (OFF), select the
x 100 scale, the meter should indicate infinity ohms.
(4) Connect the circuit breaker between a
28 Vdc source and a resistive load such that the current draw from the source is 16.73 amperes. The
circuit breaker should not trip. If the circuit breaker
trips, replace the circuit breaker.
e. Replacement of Power Switch.
(1) Disconnect connector J26.
(2) Disconnect and tag leads sequentially.
(3) Remove mounting hardware and extract the
switch through the rear of the panel.
(4) Replace in reverse order noting that ON is
to be in the up position.
17-6. Cleaning.
a. Clean all metal parts with cleaning solvent
Federal Spec P-D-680 and dry thoroughly.
b. Clean electric motor, micro-switch, limit switch,
thermostat, preheater elements and all electrical connectors and wiring with a cloth moistened with cleaning
solvent Federal Spec P-D-680. Do not submerge electrical components in cleaning solvent.
c. Clean all orifices, sintered filter and screen to
make sure they are free from any obstruction.
17-1
Table 17-1.
Malfunction
Fuel-Burning Winterization Kit Troubleshooting Chart
Probable cause
Corrective action
a. Faulty circuit breaker.
a. Replace circuit breaker.
(para 17-5.)
b. Open circuit.
b. Isolate and repair.
a. Faulty circuit
breaker open.
a. Replace circuit breaker.
(para 17-5.)
b. Open circuit.
b. Isolate and repair.
a. Burned out igniter.
Orifice clogged.
a. Visually inspect and test.
Clean orifice (para (17-7.)
b. Pressure regulator
solenoid closed.
b. Check regulator valve.
(para 17-70)
c. Fuel pump.
c. Check pump separately.
a. Broken quartz rod.
a. Replace rod.
b. Flame switch out of
adjustment.
b. Readjust.
c. Wiring connections
incorrect.
c. Correct connections.
a. Faulty micro-switch.
a. Replace switch. (para 17-5.)
b. Overheats, trips
limit switch.
b. Check fuel rate (too high).
Check for closed ducts or
restrictions. Check
blower speed.
6. Circuit breaker
pops open.
Short circuit.
Disconnect basic components, one at a time,
to isolate short - then check wiring. Replace
shorted/defective components or wire.
7. Failure to shut off.
a. Fuel regulator valve
stuck open.
a. Replace valve.
b. Flame switch stuck
open.
b. Adjust or replace.
a. Fuel regulator operating
erratically.
a. Check fuel rate and replace valve
if necessary.
b. Fuel pump operating
erratically.
b. Replace pump.
Faulty coolant pump. (See
malfunction no. 4 of
table 17-3)
Repair or replace pump. (See malfunction no.
of table 17-3.)
10. Coolant pump turns
over but fails to
deliver fluid.
Pump passages or blade slots
plugged with foreign
matter.
Remove pump from motor; disassemble and
clean. Clean filter.
11. Erratic or reduced
output.
a. Air leak.
a. Check tubing connections for leaks.
b. Reduced voltage.
b. Check voltage input to motor.
1. Press-to-test lamp
does not go on.
2. Turn switch on,
nothing happens.
3. Switch on, will not
ignite, Blower
operates.
4. Fan runs all the
time with switch
off.
5. Heater starts, then
goes out.
8. Surging combustion.
9. Coolant pump fails
to recirculate
liquid.
17-2
Table 17-1. Fuel-Burning Winterization Kit Troubleshooting Chart (Cont)
Malfunction
11. (Continued)
12. Leakage.
13. Motor failure.
Corrective action
Probable cause
c. Motor lag, low rpm
c. Check motor brushes for excessive wear.
d. Scored cam ring bore.
d. Replace the cam ring.
e. Foreign matter in pump
blade slots.
e. Remove pump from motor: disassemble
and clean pump and filter.
a. Face of seal cage scored,
or damaged seal “O”
ring.
a. Disassemble and inspect seal cage face
and “O” ring. Refinish or replace as
required.
b. Seal face of adapter
scored.
b. Disassemble and inspect seal surface,
Refinish or replace the adapter.
a. Worn brushes.
a. Remove and replace.
b. Worn bearings.
b. Replace motor.
c. Burned armature.
c. Replace motor.
17-7. Heater Assembly and Component Inspection.
a. Inspect regulator valve leaks or damaged
threads. Check resistance of solenoid coil. Resistante must be 150 ohms.
(1) Inspect nozzle orifice for damaged threads
and obstruct ion at pin holes. Pin hole diameter is
0.012 inch.
(2) Inspect sintered filter for clogged or damaged
condition.
b.
— Flame Switch and Quartz Rod Inspection.
(c) Inspect seal cage for scored or damaged
face. Remove all imperfections by lapping, or replace
seal cage.
(d) Inspect cam ring and port plate for
damaged, scored, or warped position.
(2) Motor assembly inspection.
(a) Inspect fan for damaged blades, cracks,
and breaks.
(b) Inspect motor for damaged receptacle
and worn brushes.
(1) Inspect flame switch for distorted or broken
springs, loose flame pivot points or stripped threads
and cracked or damaged insulation. Check flame
switch for continuity.
d. Inspect burner chamber for defective threads,
or burned or damaged condition.
(2) Inspect quartz rod for damage or burned
condition.
17-8. Repair.
c. Inspect pump and motor assembly for damaged
threads and other damage.
(1) Pump inspection.
(a) Inspect adapter for damaged or scored
face, warped condition, damaged seal face and for
motor shaft bore wear. Face of adapter must be
parallel within 0.001 inch. Adapter bore diameter
must be 0.315 to 0.318 inch. Adapter face must be
parallel with rotor side of adapter within 0.001 inch
per inch.
(b) Inspect rotor and rotor blades for excessive wear. See table 17-2 and inspect rotor and
blades for proper dimensions.
e. Inspect heat exchanger for damage or warpage.
a. Replace all gaskets, seal rings, motor brushes
and-ceramic vaporizer at each overhaul.
b. Seal faces of adapter and seal cage can be
dressed to remove minor nicks, scratches or scoring.
Remove only material necessary to clean seal face.
c. Replace all parts that do not pass inspections
in paragraph 17-7 above and all electrical components
that do not pass electrical tests as outlined in test
procedure, paragraph 17-11 which follows.
(1) Replacement of terminal board and limit
switch.
17-3
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17-4
Cover
Strap
Screw
Connector
Screw
Terminal
Screw
Switch
Switch assy
Nut
Screw
Washer
Spring
Screw
Switch
Spring
17.
18.
19.
20.
21.
22.
23.
24.
25,
26.
27.
28,
29.
30.
31.
32.
Retainer
Rod
Frame
Tube assy
Nut
Sleeve
Tube
Screw
Screw
Bracket
Valve assy
Plug
Orifice
Body
Filter
Gasket
33. Screw
49. Igniter
Plug
80. Motor
34. Setscrew
50. Gasket
Spring
81, Cap
35. Setscrew
51. Screw
Ball
82. Brush
36. Pre-heater
52. Burner
Packing
83. Plate
37. Valve
53. Setscrew
Ring
84. Screw
38. Elbow
54. Fan
Blade
85. Plug
39. Screw
55. Screw
Setscrew
86, Heat
40. Cover
56. Plate
Rot or
exchanger
41. Grommet
57. Screw
Packing
42. Screw
58. Inlet
Adapter
43. Housing
59. Elbow
Seal assy
44. Clamp
60. Motor-pump
Packing
45. Hose
assy
Retainer
46. Screw
61. Pump assy
Washer
47. Retainer
62. Screw
Spring
48. Vaporizer
63. Plate
79. Decal ME 6115-545-34/17-1
Figure 17-1. Fuel Burning Engine Coolant Heater
10.
11.
12.
13.
14.
15.
16.
17.
Screw
Frame
Nut
Screw
Screw
Connector
Connector
Cover
Lens
Figure 17-2.
Indicator
Terminal
Terminal
Circuit breaker
Terminal
Terminal
Switch
Plate
ME 6115-545-34/17-2
Fuel Burning Heater Control Box
17-5
Table 17-2. Fuel Burning Winterization Coolant Pump Wear Limits
Item
Dimensional limits (inches)
Rotor head diameter . . . . . . . . . . . . . . . . . . . . . .
0.904 - 0.906
Rotor head length . . . . . . . . . . . . . . . . . . . . . .
0.246 - 0.248
Rot or bore diameter . . . . . . . . . . . . . . . . . . . . . .
0.3033 - 0.3038
Rotor blade slot width . . . . . . . . . . . . . . . . . . . . . .
0.0935 - 0.0945
Rot or blade slot depth . . . . . . . . . . . . . . . . . . . . . .
0.263 - 0.268
Blade height . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.247 - 0.249
Blade thickness . . . . . . . . . . . . . . . . . . . . . . . . . .
0.091 - 0.093
Blade width . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.247 - 0.249
Adapter bore diameter . . . . . . . . . . . . . . . . . . . . .
0.315 - 0.318
17-9. Reassembly.
Reassemble control box, heater, and kit as
illustrated in figures 17-1 and 17-2.
b. Exercise care in replacing quartz rod as it is
easily broken if dropped. After installation, gently
move rod up and down to make sure it moves freely
in its stainless steel tube. Also make sure at least
1/32 inch extends out of tube when rod is resting on
bottom.
c. Assemble motor assembly, combustion air
inlet, inlet plate and combustion fan, before installing burner assembly.
d. Make sure lead wire from motor assembly is
on side of blower opposite name plate before drawing it through casing grommet.
e. Make sure all wire leads are connected to
their respective terminals as tagged during disassembly.
I
in position aligning scribe mark. With motor shaft
end play taken up in direction of pump, make certain
there is at least 0. 002-inch clearance between outer
face of rotor. Move rotor back and forth as necessary to produce this clearance, then tighten set
screw.
NOTE
Make sure that adapter and cam ring
are tightly compressed together when
determining 0. 002 inch clearance,
otherwise, a false reading will be
obtained.
i. Install rotor blades in rotor slots making
sure that grooves in blades face away from direction of rotation. Pump rotates counterclockwise
when viewing end of port plate.
j. Place preformed packing in groove of port
plate, then position plate against cam ring. Align
scribe marks and secure with four hex socket head
screws.
NOTE
NOTE
Coolant pump cannot be assembled
completely and installed as a separate unit. It must be assembled
as it is installed on short shaft end
of motor.
f. Install seal spring and seal washer over end
of motor shaft. Place performed packing in seal
cage, then install seal cage over end of motor shaft
with seal face facing forward.
g. Install pump adapter over motor shaft and
align holes with tapped holes in motor.
h. Install pump rotor on motor shaft and temporaily tighten rotor set screw. Place preformed
packing in groove of pump adapter. Place cam ring
17-6
Plug threaded ports with caps if pump
is not to be assembled in heater immediately.
k. Replace all defective wiring in control box
ant-heater assembly. Remove wire tags.
l. Wiring harness repair and rebuild. Refer to
Chapter 5.
17-10. Adjustments.
a. Coolant Pump Relief Valve. The coolant pump
relief valve is a non-adjustable relief valve. The
valve is set to relieve pressure at 30 to 35 psi. To
assure proper functioning of this valve, spring must
measure 1.164 inches free length and have a 0.750inch working length with a load of 1 pound, plus or
minus 0. 1 pound, applied. If spring fails to meet
these requirements, replace spring.
b. Fuel Regulator Valve. Remove cover plate and
disconnect fuel tube assembly at orifice assembly.
(2) Mount motor and pump assembly on a test
stand and install proper fittings in inlet and outlet ports.
Attach hose line from supply tank to port marked IN.
(3) Attach discharge line with pressure gauge and
needle valve to port marked OUT and return ,0 supply
tank.
(4) Attach electrical plug to motor receptacle and
plug in to dc power supply.
17-11. Testing.
a. Regulator Valve. Connect a fuel supply (3 to
15 psi) and 24 Vdc to regulator. Regulator valve
should operate and produce a steady stream of 21 to 23
cubic centimeters of fuel per minute (at 70° F). If
fuel rate is not within these tolerances, adjust regulator valve by turning the adjusting screw clockwise to
increase flow rate or counterclockwise to decrease
flow rate. This test can be made using a graduated
container and stop watch.
b. Igniter. With igniter removed from heater,
ground igniter and supply 24 Vdc power to igniter terminal. Igniter should draw approximately 10.5 amperes
and heat to a bright red color in a few seconds.
c. Flame Switch.
(1) Test flame switch using an ohmmeter to check
continuity of microswitch. Depress microswitch button.
This will be the ignition or start position of switch.
(2) Continuity should be made between two NO
(normally open) terminals and also between each of
NO terminals and common terminals. There should
e an open circuit between two NC (normally closed)
erminals and also between common terminals and two
NC terminals.
(3) Release microswitch button. This will be
run position of microswitch. Continuity should be made
between two NC terminals and common terminals. There
should be no continuity made between the NO ignition or
start terminals, or NO terminals and common terminals. Replace microswitch if it does not check out correctly.
NOTE
The common terminal is connected to
blower motor which operates at all
times when heater is in operation.
d. Coolant Pump and Motor Assembly.
(1) After coolant pump has been overhauled, it
must be tested before being reinstalled on heater.
(5) Turn power switch on and run unit for approximately 15 minutes on 24 Vdc.
(6) Close valve in outlet line. (make sure discharge pressure does not exceed a maximum of 30 to
50 psi when closing this valve). Open and close valve
a few times to check consistency of valve performance.
(7) To check pump for rated flow and pressure,
adjust valve in discharge line until a reading of 2 psi
is obtained on pressure gauge. Using a suitable timer,
check for rated coolant flow of 80 gph (gallons per hour)
minimum at 2 psi discharge pressure (at 70° F.) Amperage draw must not exceed 6 amperes during this
test. Observe smoothness of operation of both pump
and motor. Seal leakage of 1 cc per hour is maximum
when pump is operating at 2 psi discharge.
(8) Turn power supply off, then remove discharge
line and fitting from OUT port. Plug this port and apply 40 psi hydrostatic pressure for 20 minutes to inlet
port. No leakage shall be evident during this test.
e. Motor.
(1) The blower motor, (without coolant pump attached) can be tested when installed in heater.
(2) Check end play on motor shaft, grasp short
end and rotate in either direction at the same time
moving in and out. The end play should not exceed
0.010 to 0.025 inch, and fan should rotate freely.
(3) Use a strobe light to check motor rpm’s
(blower installed on heater). The fan speed should be
approximately 8500 rpm when 24 Vdc is applied.
(4) The blower motor should not draw more than
6 amperes (at 70° F). Higher amperage will indicate
a defective motor. Replace defective motor.
17-12. Installation.
Refer to Operator and Organizational Maintenance
Manual and install fuel-burning heater kit.
Section IL ELECTRIC WINTERIZATION KIT
17-13. General.
The electric winterization kit is available as an aid
in starting the generator set in temperatures from
25° F to -65° F. The electrical winterization kit
consists of a heat exchanger, control box, coolant
pump, thermostat and accessories. The primary
purpose of the kit is to maintain the set in a heated
condition, at any ambient temperature from 1250 F
to -65° F to enable it to accept 75% of rated load in
one step within 20 seconds after starting action is
initiated. The coolant temperature is thermostattally controlled at 130° F to 150° F.
Change 1 17-7
The kit can also be used to warm the Generator
Set for initial starting within 5 hours at any ambient
temperature down to -65° F.
Power for operation of the kit may be obtained from
any power source that supplies 205 to 240 volts at
50, 60 or 400 Hz single phase. For electrical winterization kit operating instructions refer to Fig.
2-11.
17-14. Troubleshooting.
Troubleshoot the electric winterization kit using table
17-3. Typical malfunctions, the possible causes,
and the necessary corrective action are tabulated.
17-15. Removal and Disassembly.
a. Removal. Refer to Operator and Organizational
Maintenance Manual and remove electric winterization
kit.
b. Disassembly.
(1) Refer to Operator and Organizational Maintenance Manual and disassemble the electric winterization kit.
(2) See figure 17-3 and disassemble the coolant pump.
(3) See figure 17-4 and disassemble the electric
winterization control box as follows:
Remove screws (1) and cover (2).
(b) Tag all leads attached to heat sink (14)
and (15).
leads.
(c) Remove nut (5) and screw (6) and remove
(d) Remove (7) thru (15) in sequential order.
(e) Tag and unsolder leads from semiconductors (12) and (13). bracket (16) and grommet (17)
can then be removed.
(f) Remove items (18) thru (39) in sequential order.
17-16. Inspection and Repair.
a. Replace all gaskets, seal rings and motor
brushes at each overhaul.
b. Replace all electrical and mechanical parts
that do not meet the requirements specified herein
and in table 17-4.
17-17. Reassembly.
Reassemble control box and coolant pump and motor
assembly in the reverse order of the numerical sequence in figure 17-4 and figure 17-3.
17-18. Testing.
a. Coolant Pump and Motor Assembly Test.
(1) After coolant pump has been reassembled,
it must be tested before being reinstalled.
17-8
(2) Mount motor and pump assembly on a test
stand and install proper fittings in inlet and outlet
ports. Attach hose line from supply tank to port
marked IN.
(3) Attach discharge line with pressure gauge
and needle valve to port marked OUT and return to
supply tank.
(4) Attach electrical plug to motor receptacle
and plug in to dc power supply.
(5) Turn power switch on and run unit for approximately 15 minutes on 24 Vdc.
(6) Close valve in outlet line. (Make sure discharge pressure does not exceed a maximum of 30 to
40 psi when closing this valve). Open and close valve
a few times to check consistency of relief valve performance.
(7) To check pump for rated flow and pressure,
adjust valve in discharge line until a reading of 2 psi
is obtained on pressure gauge. Using a suitable
timer, check for rated coolant flow of 80 gph (gallons per hour) minimum at 2 psi discharge pressure
(at 68°F. ) Amperage draw must not exceed 3.3
amperes during this test. The drive motor speed
should be approximately 7500 rpm. Observe smoothness of operation of both pump and motor. Seal leakage of 1 cc per hour is maximum when pump is operating at 2 psi discharge.
(8) Turn power supply off, then remove discharge line and fitting from OUT port. Plug this
port and apply 40 psi hydrostatic pressure for 20
minutes to inlet port. No leakage shall be evident
during this test.
b. Electric Winterization Control Box Components.
(1) Transformer. Inspect the transformer for
visual damage to lugs, windings, etc. If visual damage is obvious, replace transformer. Open transformer primary and secondary windings and check
the winding resistances. The primary resistance
(terminals 1 and 2) shall be 6.77 ohms ± 10 percent.
The secondary (termimls 3 and 5) shall be 0. 108 ohm
± 10 percent. Apply 230 Vac at 60 Hz winding 1-2
with the secondary open circuit. The exciting current
shall be less than 0. 04 amperes, rms. Apply 253 Vac
to 1-2. The exciting current shall be less than 0. 065
amperes, rms. With the secondary open circuit, apply 230 Vac to winding 1-2. The voltage across 3 to 4
and 4 to 5 shall be 14.8 volts rms, ± 1 percent. If any
of the above tests are failed, replace the transformer.
(2) Inspect the control relay for visual damage.
If visual damage is obvious, replace relay. Check
relay coil with an ohmmeter. The coil resistance
should be 300 ohms ± 10 percent at, or corrected to,
250 C. Apply 24 Vdc to the coil with a dc power supply. The two normally open contacts shall close.
Remove the 24 Vdc; the two contacts shall open. If
defective, replace per paragraph 17-15.
(3) Test the four control box diodes per paragraph 14-10. Replace a defective diode,
(4) Replace defective connectors.
.
Table 17-3. Electric Winterization Kit Troubleshooting Chart
Malfunction
Corrective action
Probable cause
With S301 closed
a. Defective wiring.
a. Repair or replace broken wiring.
b. Defective switch S301.
b. Check switch for continuity across contacts.
c. Defective circuit
breaker CB301.
c. Check circuit breaker for correct operation
with an ohmmeter.
d. Defective indicator.
d. Check indicator for continuity; it should
have some resistance.
e. Defective diodes CR301
to CR304.
e. Check diodes with ohmmeter.
f. Defective transformer.
f. Refer to transformer test, paragraph 17-18.
2. DS301 does not
illuminate.
Same as a. to f. above.
Same as a. to f. above.
3. HTR1 and HTR2
do not heat up.
a.
a. Test relay.
1. DS302 does not
illuminate.
Relay K301 does not
energize.
Refer to paragraph 17-18.
b. Defective wiring.
b. Repair or replace wiring.
c. Heating element defective.
c. Replace.
a. Same as a, b, c, e, and
f in step 1 above.
d. Same as a, b, c, e, and f in step 1 above.
b. Defective pump.
b. Replace pump.
5. Coolant pump fails
to recirculate
liquid.
Faulty coolant pump. (See
malfunction no. 4)
Repair or replace pump. (See malfunction
no. 4)
6. Coolant pump turns
over but fails to
deliver fluid.
Pump passages or blade
slots plugged with
foreign matter.
Remove pump from motor; disassemble and
clean. Clean filter.
7. Erratic or reduced
output.
a.
a. Check tubing connections for leaks.
4. Coolant pump does
not operate.
8. Leakage.
9. Motor failure.
Air leak.
b. Reduced voltage.
b. Check voltage input to motor.
c. Motor lag, low rpm
c. Check motor brushes for excessive wear.
d. Scored cam ring bore.
d. Replace the cam ring.
e. Foreign matter in
pump blade slots.
e. Remove pump from motor; disassemble and
clean pump and filter.
a. Face of seal cage
scored, or damaged
seal “O” ring.
a. Disassemble and inspect seal cage face and
“O” ring. Refinish or replace as required.
b. Seal face of adapter
scored.
b. Disassemble and inspect seal surface.
Refinish or replace the adapter.
a. Worn bearings.
a. Replace motor.
b. Burned armature.
b. Replace motor.
17-9
1.
2.
3.
4.
5.
6.
Screw
Plug
Spring
Ball
Nameplate
Decal
7.
8.
9.
10.
11.
12.
Plate
Packing
Set screw
Blade
Rotor
Ring
13.
14.
15.
16.
17.
18.
Adapter
Seal
Packing
Washer
Spring
Motor assy
19.
20.
21.
22.
Connector
Screw
Spring brush
Brush cap
ME 6115-545-34/17-3
Figure 17-3. Electric Winterization Pump
KEY to fig. 17-4.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
17-10
Screw
Cover
Screw
Screw
Nut
Screw
Nut
Washer
Screw
Washer
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Washer
Semiconductor
Semiconductor
Heatsink
Heatsink
Bracket
Grommet
Nut
Screw
Nut
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Screw
Screw
Washer
Nut
Washer shoulder
Relay
Insulator pad
Nut
Screw
Transformer
31.
32.
33.
34.
35.
36.
37.
38.
39.
Wiring harness assy
Chassis
Light assy
Light assy
Fuse
Fuseholder
Circuit breaker
Switch
Panel
Figure 17-4. Electric Heater Control Box Assembly
17-11
17-12
Figure 17-5.
Electric Winterization Kit Heater Control Box Test Set-Up
Table 17-4. Electric Winterization Coolant Pump Wear Limits
1
Dimensional Limits (inches)
Item
Rotor diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.904 - 0.906
Rotor width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.246 - 0.248
Rotor bore diameter . . . . . . . . . . . . . . . . . . . . . . . .
0.3033 - 0.3038
Rotor blade slot width . . . . . . . . . . . . . . . . . . . . . . . .
0.0935 - 0.0945
Rotor blade slot depth . . . . . . . . . . . . . . . . . . . . . . . . 0.262 - 0.268
Cam ring width . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.249 - 0.250
Camping bore diameter . . . . . . . . . . . . . . . . . . . . . .
1.000 - 1.002
Blade thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.091 - 0.093
Blade width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.247 - 0.249
Blade height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.247 - 0.249
Adapter bore diameter . . . . . . . . . . . . . . . . . . . . . . .
(5) Wiring harness inspection replacement,
repair and fabrication (Refer to Chapter 5).
0.315 - 0.318
replace per paragraph 17-5.
(8) Fuse holder and light assembly replacement. Replace per paragraph 17-5.
(6) Circuit breaker test.
(a) Disconnect connector.
(b) Using an ohmmeter, set scale to Rl
and read across the circuit breaker. With the circuit breaker in the closed position (ON), the reading
should be zero(0) ohm.
(9) Test the control box as shown in figure
17-5 and table 17-5. If control box fails test check
wiring. (Problem must be in wiring since the components have been qualified in paragraph 17-18b(l)
thru (8)).
c. Heater Test.
(c) Open the circuit breaker (OFF), set
the scale to R100, the reading should be infinity.
(d) Connect to a circuit which will drive
23.0 amps at 28 Vdc. Circuit breaker should not
trip. If it trips, replace per paragraph 17-5.
(?) Power switch set.
(a) Disconnect connector.
(b) Using an ohmmeter set the scale to
RI. Check for continuity between terminals, 1-2,
5-6, 3-4 and 7-8 in the ON position. If defective,
(1) With the control box energized, check for
230 Vac across the terminals on heaters number 1
and 2.
(2) With the control box deenergized, check
for continuity in each of the heating elements. Replace if defective.
17-19. Installation.
Refer to Operator and Organizational Maintenance
Manual and install the electric winterization kit in
the generator set.
Section III. WHEEL MOUNTING KIT
17-20. General.
17-21. Removal.
This wheel mounting kit, when installed, provides
mobility for the engine generator set. The kit consists of front and rear running gear, a manual control brake lever, mounted on the skid base, and a
towing bar with safety chains.
a. Using a lifting device, with 10.000 pound
capacity, hoist the engine generator set until the
running gear wheels clear the ground.
17-13
Table 17-5. Electric Winterization Heater Control Box Testing
Step
1.
2.
17-14
Test condition
Position heater
control box
switch to ON
and apply 230
Vat. Open
switch S2; see
figure 17-5.
Close switch S2.
Required result
Heater control box
indicators DS301
should illuminate.
Voltmeters V2
and V3 should
indicate 230
Vac and voltmeter V1
should indicate approximately 30
Vdc, and DS302
should illuminate.
Probable cause
for improper result
Check out procedure
Defective fuse F301.
Check continuity of fuse.
There should be continuity.
Defective switch 301.
Check continuity of switch
when positioned to ON.
There should be continuity.
Defective circuit breaker CB301.
With ohmmeter, check
circuit breaker for
correct operation.
Defective indicator 301.
Check indicator for continuity. There should
be some continuity.
Defective diodes CR301, CR302,
CR303 or CR304.
Check diodes with
ohmmeter.
Defective transformer T301.
See transformer test,
paragraph 17-18.
Defective relay K301.
Check relay per
paragraph 17-18.
1. Screw
2. Bracket
3. Washer
4. Nut
5. Screw
6. Washer
7. Washer
8. Nut
9. Screw
10. Washer
11. Bracket
12. Washer
13. Nut
14. Screw
15. Washer
16. Nut
17. Screw
18. Safety chain assy
19. Washer
20. Nut
21. Running gear assembly
17-15
Figure 17-6. Wheel Mounting Kit
b. Remove the wheel mounting kit and associated–hardware in reverse order as-illustrate in
figure 17-6.
capacity, hoist engine generator set until bottom
of skid base clears ground by approximately two
feet.
17-22. Inspection and Repair.
b. Position front and rear running gear and
lower engine generator set until it just rests on
running gear axles.
Refer to Operator and Organizational Maintenance
Manual for wheel-mounting kit inspection and repair instructions.
c. Install kit with attaching hardware as illustrated in figure 17-6.
17-23. Installation.
a.
Using a lifting device, with 10, 000 pound
Section IV.
17-24. General.
a. The load bank is a balanced, three phase,
four-wire device that can be used to apply a resistive load to the generator. The purpose of the
resistive load is to provide a partial load for the
set if the normal utility load is too low to keep the
engine generator set operating without carbonization of the engine.
b. When the load bank is used in conjunction
with the engine-generator set, the generator is
protected against overloads by the load reject relay
A41, incurred as a result of increases in utility
load. The selected kw load of the bank is continually present. The load reject relay, utilized when
the load bank mode selector switch is in the auto
position, receives the output of the load measuring
unit.
c. The load measuring unit senses the generator
output (utility load plus load bank), should the combined load exceed 50% of the rated generator capacity 60 kw (i. e. 30 kw). The LMU output voltage
applied to the load reject relay causes contacts
within the load reject relay to close, resulting in
the energizing of the trip coil of the Over Temperature Reset switch.
d. This action removes the selected load from
the–generator output allowing continued supply of
the utility load without the risk of generator overload.
e. When the generators utility load diminishes
the load bank may be reapplied by manually resetting the Over Temperature Reset switch.
f. Positioning the load bank select switch to the
manual mode disables the trip feature previously
described. Protection of the generator against
overloads produced by combined load bank and utility loads is then the responsibility of the operator.
The total load is displayed on the panel mounted
kw meter. Should the displayed reading exceed the
sets rated capacity, the operator must reduce or
remove the load bank setting with the load bank
selector switch.
17-16
LOAD BANK
g. The load bank incorporates a thermostatic
switch which will operate the trip end of the Over
Temperature Reset switch to remove the selected
load from the generator when the ambient temperature reaches 450 ± 15° F. The thermostatic switch
is fully operable in both manual and automatic
modes of operation.
17-25. Removal and Disassembly.
a. Removal. Refer to Operator and Organizational Maintenance Manual and remove the load
bank.
b. Disassembly.
ble the load bank.
See figure 17-7 and disassem-
17-26. Repair, Overhaul and Rebuild.
a. Test diodes per paragraph 14-10. Replace
a defective diode.
b. Repair or rebuild wiring harness as required.
Refer to Chapter 5, and to wiring schematic in
Chapter 1 for wiring instructions.
c. Refer to figure 17-8 and perform load reject
relay test.
d. Rotary Switches. Refer to Operator and
Organizational Maintenance Manual.
e. Fan and Motor Assembly. Refer to Operator
and-Organizational Maintenance Manual.
(1) Removal. Refer to Operator and Organizational Maintenance Manual to remove the fan and
motor assembly.
(2) Disassembly. See figure 17-9 and disassemble in the numerical sequence illustrated.
(3) Cleaning and inspection.
(a) Cleaning.
1. Blow out all dirt from inside field
frame and wipe interior with a clean cloth.
CAUTION
Do not submerge armature, or
field coils in solvent.
2. Clean field coils and frame thoroughly
with a cloth dampened with cleaning solvent Federal
Specification P-D-680. Dry thoroughly with compressed air.
3. Remove loose particles from armature with compressed air and wipe with a clean cloth
dampened with cleaning solvent. Clean commutator
lightly with number 00 sandpaper and remove all
traces of dust with low-pressure compressed air.
4. Clean brush holders with a brush and
cleaning solvent, Federal Specification P-D-680, and
dry them thoroughly with compressed air.
5. Clean brushes with a clean, dry cloth
only. Do not permit cleaning solvent to come in contact with the brushes.
3. After the mica has been undercut,
remove all copper and mica particles with compressed
air. Polish the commutator in a lathe with number
2/0 sandpaper while the armature is rotating at 1500
rpm. After polishing the armature, check that commutator diameter is not less than 0. 925 inches. Replace if diameter is less.
4. After repair work has been completed,
repeat steps 2 and 3 of e(3)(a) above.
(c) Field coil assembly.
1. Smooth minor scratches, burrs, and
nicks on machined surfaces of frame using fine mill
file.
2. Repair damaged threads in frame.
3. Replace motor assembly if field coil
insulation resistance is less than one megohm.
(5) Reassembly. Reassemble fan and mot or
assembly in reverse order of disassembly.
(b) Inspection.
(6) Bench tests.
1. Test field coils for insulation breakdown with megger connected between frame and one
coil terminal. Minimum resistance reading permissible is one megohm. Replace motor assembly if coil
is defective.
2. Test armature for grounds with a test
light. Touch a test light probe to the armature core
and the other probe to a commutator bar riser. If
test light glows, armature is grounded. Repeat test
for all commutator bars.
3. Test armature for short circuits using
a growler fixture.
(a) Energize the fan motor with 115 Vdc.
(b) Check the speed of the armature on the
tachometer. Minimum speed should be 3600 rpm.
(c) Check the current draw on the ammeter.
Maximum current draw should be 1.8 amperes.
(7) Installation. Refer to Operator and Organizational Maintenance Manual and install the fan and
motor assembly.
f. Circuit Breaker. Refer to Operator and Organimational Maintenance Manual.
(4) Repair.
(a) Housing and commutator end head.
1. Smooth minor scratches burrs, and
dents on machined surfaces using a fine mill file.
2. Repair damaged threads.
g. Indicator Light. Refer to Operator and Organizational Maintenance Manual.
h. Load Reject Switch. Refer to Operator and
Organizational Maintenance Manual.
i. Terminal Board. Refer to Operator and Organizational Maintenance Manual.
(b) Armature.
1. Resurface commutator by removing no
more than 0.005 inch during any one cut and no more
than 0.002 inch on final cut. Check that the final diameter of commutator is not less than 0. 925 inches.
2. If commutator diameter is satisfactory,
undercut mica to a depth of 0. 025 to 0. 032 inch below
commutator surface.
NOTE
Use care in undercutting. Do not widen
commutator slots by removing metal from
segments, and do not leave thin edge of
mica next to segment.
j. Thermostat. Refer to Operator and Organizational Maintenance Manual.
k. Heater Elements. Refer to Operator and
Organizational Maintenance Manual.
l. Replace all Defective Components.
17-27. Reassembly and Installation.
a. Reassembly. See figure 17-7 and the Operator
and Organizational Maintenance Manual and reassemble the load bank.
b. Installation. Refer to the Operator and Organizational Maintenance Manual and install the load
bank on the generator set.
17-17
1.
2.
3.
4.
5.
Screw
Relay
Nut
Screw
Fan guard
6.
7.
8.
9.
10.
Nut
Screw
Fan motor
Nut
Washer
11.
12.
13.
14.
15.
Diode
Nut
Washer
Diode
Nut
16.
17.
18.
19.
Screw
Screw
Heatsink
Heatsink
ME 6115-545-34/17-7
Figure 17-7. Load Bank
17-18
1. CONNECT AC AND DC POWER AS SHOWN.
2. RECOMMEND USE OF ISOIATION TRANSFORMER INCONJUNCTION WITH AN AUTO
TRANSFORMER FOR AC VOLTAGE.
3. INCREASE DC VOLTAGE FROM O TO 10 VDC, CONTACTS AT TERMINAL #5 AND
#6 WILL CLOSE NORMALLY AT 5 VDC.
Figure 17-8. Load Reject Relay Test Circuit.
Change 6
17-19
Figure 17-9. Load Bank Fan and Motor Assembly
17-20
APPENDIX A
REFERENCES
A-1.
Fire Protection.
TB 5-4200-200-10
A-2.
Lubrication.
C9100-IL
A-3.
A-4.
A-5.
Hand Portable Fire Extinguishers Approved for Army
Users.
Identification List for Fuels, Lubricants,
Oils and Waxes.
Painting.
T.O. 35-1-3
Painting and Marking of USAF Aerospace Ground
Equipment.
TM 9-213
Painting Instructions for Field Use.
Radio Suppression.
MIL-STD-461
Radio Interference Suppression.
TM 11-483
Radio Interference Suppression.
Maintenance.
T.O. 00-25-225
Repair of External Power Cables, Aeorspace Ground
Equipment.
T.O. 00-25-234
General Shop Practice Requirements for the Repair,
Maintenance and Test of Electric Equipment.
T.O. 1-1-1
Cleaning of Aerospace Equipment.
T.O. 1-1-2
Corrosion Control and Treatment for Aerospace
Equipment.
T.O. 1-1A-14
Installation Practices for Aircraft Electric and
Electronic Wiring.
T.O. 31-1-75
General Maintenance Practices.
T.O. 35-1-11
Organization, Intermediate and Depot Level
Maintenance for FSC 6115 Non-Airborne Equipment.
T.O. 35-1-12
Components and Procedures for Cleaning Aerospace
Ground Equipment.
T.O. 35-1-26
Repair/Replacement Criteria for FSC 6115
Aerospace Ground Equipment.
T.O. 35-1-524
USAF Equipment Registration Number System
Applicable to FSC 6115 Equipment.
TM9-1870-1
Care and Maintenance of Pneumatic Tires.
MIL HDBK-705A
Military Standardization Handbook Generator Sets,
Electrical, Measurements and Istrumentations.
A-1
A-6.
A-7.
TB 750-651
Use of Antifreeze Solutions and Cleaning Compounds
in Engine Cooling Systems.
TM 38-750
The Army Maintenance Management Systems.
TM 5-6115-545-12
TO-35C2-3-444-1
NAVFAC P-8-626-12
TM-000386-12
Operator and Organizational Maintenance Manual.
TM5-6115-545-24P
TO-35C2-3-444-4
NAVFAC P-8-626-24P
SL-4-00038G
Organizational, DS, GS and Depot Maintenance
Repair Parts and Special Tools List.
TM 9-6140-200-15
Operation and Organizational, Field, and Depot
Maintenance Storage Batteries, Lead Acid Type.
TM 5-764
Electric Motor and Generator Repair.
TM 5-6115-588-14
T.O. 35CA-1-111
NAFAC P-8-601
TM-6115-15/4
Operator, Organizational, Intermediate (Field)(Direct
and General Support) and Depot Maintenance Manual
Including Repair Parts and Special Tools List for
Auxiliary Equipment 15 Through 200 KW, DOD
Family Generator Sets.
Shipment and Storage.
T.O. 35-1-4
Processing and Inspection of Aerosapce Ground
Equipment for Storage and Shipment.
T.O. 38-1-5
Processing and Inspection of Non-Mounted, NonAircraft Gasoline and Diesel Engines for Storage
and Shipment.
TB 740-97-2
Preservation of USAMEC Mechanical Equipment
for Shipment and Storage.
TM 740-90-1
Administrative Storage of Equipment.
Destruction of Material.
TM 750-244-3
A-8.
Radioactive Material.
TB 750-248
A-2
Procedures for Destruction of Equipment to
Prevent Enemy Use.
Instructions for Safe Handling, Maintenance, Storage,
and Disposal of Radioactive Commodities
Managed by U.S. Army Mobility Equipment
Command.
ALPHABETICAL INDEX
Paragraph,
Figure, Table,
Number
Subject
B
Battery Charging Alternator
Alternator Assembly.
Disassembly, Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General
On Equipment Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly, Test and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulator Excitation Test Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair
Two Terminal Brush Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Regulator and Alternator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .
. .
. .
. .
. .
. .
F14-2
14-10
14-8
14-9
14-12
F14-3
14-11
F14-4
F14-1
C
Control Cubicle
3 - 8
AC Ammeter Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . 3-6
AC Wattmeter Convertor Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1 0
Control Box Relay Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Converter Testing....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 3 - 4
Converter, Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9
Frequency Meter andTransducer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1 2
Reassembly, Testing and Installation . . . . . . . . . . . . . . . . . . . . . . . F 3 - 3
Relay Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .3-5
Removal, Disassembly and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Relay Assemblies
F8-7
Dc Relay Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Inspection and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-11
Overload Relay Test Set-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-9
Overvoltage Relay Test Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-14
Permissive Parallel Relay Test Set-up . . . . . . . . . . . . . . . . . . . . . . F8-4
Precise Relay Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F8-1
Relay Table and Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .8-8
Repair, Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F8-5
Resistor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-10
Reverse Power Relay Test Set-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 4
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-8
Short Circuit Relay est et-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 8 - 6
Special Relay ox Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . F8-2
Tactical Relay Box Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . .F8-3
Tactical Relay Resistor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . F8-12
Underfrequency Relay Test Set-up . . . . . . . . . . . . . . . . . . . . . . . . . F8-13
Undervoltage Relay Test Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Group Repair Instructions
F12-1
Control Assembly . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . 1 2 - 1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 - 4
Radiator Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 - 2
Radiator Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator and Shutter Repair and Test . . . . . . . . . . . . . . . . . . . . . .F12-2
Shutter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Pulley and Vibration Dampener, and Engine Front Support
F14-28
Crankshaft Pulley and Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F14-29
Engine Front Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 - 6 2
Engine Front Support Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 - 6 0
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 - 6 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 - 6 1
Removal and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-61
Change 1 I-1
ALPHABETICAL INDEX (Cont)
Current Transformer
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-4
Assembly and Load Connecting Group Mounting Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-3
Cleaning, Inspection and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
On Equipment Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Reassembly and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Routing Main Generator Leads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-2
Cylinder Head and VAlve Operating Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-36
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-78
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-38
Cylinder Head Capscrew Locations and Torquing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-42
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-76
Installation of Wooden Dowels in Valve Lifters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-40
Piston, Crankshaft and Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-41
Reassembly and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-79
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-77
Rocker Arm Shaft Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-37
Valve Seat Insert WeldingDetails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-39
D
Day Tank Assembly Repair Instructions
Cleaning, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Description and Data
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Electrical Peformmce Charactetistic Parameter AC Precise (Class) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T1-5
Electrical Performance Charactitistic Parameter AC Utility(Class2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T1-6
Engine Generator Set Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T1-4
Time Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4, T1-11
Destruction of Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Destructoin of Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
E
Electric Starter
Brushes Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-26
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28
Drive Assembly Pinion Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-15
Electric Stater Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-11
Electric Starter Brush and Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-10
Electric Starter Test Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-16
Frame and Field Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-12
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-24
Reassembly and Adjustment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F14-9
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-25
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-29
Starter Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-27
Solenoid Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. F14-14
Test and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-31
Electric Winterization Kit
Electric Heater Control Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F17-4
Electric Wintertization Coolant Pump Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T17-4
Electric Winterization Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F17-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-13
Heater Control Box Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F17-5
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-19
I-2
Change 10
ALPHABETICAL INDEX (Cont)
Electric Winterization Kit (Cont)
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electro-Hydraulic Governing System (Class 1, Precise Sets Only)
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Governor Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Governor Control Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frequency Sensing Check (50/60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frequency Sensing Check (400 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location of Adjustments and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnetic Amplifier Bias Test (50/60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnetic Amplifier Bias Test (400 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parallel Winding Test (50/60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parallel Winding Test (400 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectifier Bridge and Feedback Winding Test (50/60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . .
Rectifier Bridge and Feedback Winding Test (400 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistance Test (50/60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistance Test (400 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Position for Unpotted Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tests and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Excitation System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Component Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair, Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistor Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Regulator Printed Circuit Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 17-17
. 17-15
. 17-18
. 17-14
. T17-3
. 7-8
. 7-7
. 7-5
. T7-2
. 7-4
. F7-2
. F7-1
. 7-9
. F7-4
. F7-8
. 7-1
.F7-13
.F7-3
F7-7
. 7-2
.F7-6
.F7-10
.F7-5
.F7-9
. 7-3
.T7-1
.T7-3
.
F7-11
.
7-6
.
F
. 7-12
. 14-3
. 14-1
. 14-4
. 14-7
. 14-5
. 14-2
. 14-6
.F8-15
. 8-14
. 8-11
.F8-18
. 8-12
. 8-10
. 8-13
.T8-2
. 8-9
.F8-19
.F8-16
.F8-17
F
Fault Indicator Panel
Assembly, Fault Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Locating Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly, Testing and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal, Disassembly and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fire Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Burning Winterization Kit
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.F 3 - 2
.F3-1
. 3-4
. 3-3
. A-1
. . . . 17-10
. . . . 17-6
Change 7 I-3
ALPHABETICAL INDEX (Cont)
Fuel Burning Winterization Kit (Cont)
Fuel Burning Engine Coolant Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F17-1
Fuel Burning Heater Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fl7-2
Fuel Burning Winterization Coolant Pump Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . T17-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2
Heater Assembly and Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 17-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-12
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-9
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-4
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-8
Repair and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 17-5
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . .T17-1
Fuel Injection Pump and Related Parts
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-21
Equipment Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-50
Fuel Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T14-2
Fuel Injection Pump Bench Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-48
Fuel Injection Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-49
Fuel Pump and Engine Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-25
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-42
Injection Pump and Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-20
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-44
Reassembly and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-45
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-43
Solenoid Armature Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-23
Solenoid inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-46
Throttle Linkage Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-22
Troubleshooting Chart.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T14-1
Variable Speed Droop Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-24
Variable Speed Droop Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-47
Flywheel and Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-33
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-68
Reassembly and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-70
Removal, Inspection and Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-69
G
General
Forms and Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Generator Assembly Repair Instructions
AC Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-1
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Exciter Repair and Rebuild. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Exciter Rotor Winding and Coil Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-8
Exciter Rotor Winding Data(50/60 and 400 Hz) . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . T9-6
Exciter Stator Winding and Coil Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-7
Exciter Stator Winding Data (50/60 and 400 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-5
Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-2
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Repair and Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Rotor Winding and Coil Connection (50/60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-4
Rotor Winding and Coil Connection (400 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-6
Rotor Winding Data (50/60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-2
Rotor Winding Data (400 Hz). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-4
Stator Winding and Coil Connection (50/60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-3
Stator Winding and Coil Connection (400 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-5
Stator Winding Data (50/60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-1
Stator Winding Data (400 Hz). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-3
Tests After Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
I-4
ALPHABETICAL INDEX (Cont)
Generator Set Controls Repair Instruction
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . 3. - 1
H
Housing Group Repair Instructions
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Housing Inspection, Servicing, and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Housing Removal and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 4-2
Hydraulic Actuator (Class 1, Precise Sets Only)
Actuator Valve and Piston Test
13-6
13-1
Cleaning, Inspection and RePair
General
F13-2
Hydraulic Actuator
F13-2
Hydraulic Actuator and Related Parts
F13-3
Hydraulic Actuator Tests
13-8
Installation
13-2
Malfunction
13-5
Reassembly and Installation
13-3
Removal and Disassembly
13-3
Throttle Linkage Adjustment
13-7
Throttle Position Transducer Test
Hydraulic Pump Assembly (Class 1, Precise Sets only)
14-1
Cleaning, Inspection and Repair
14-15
General
14-13
Malfunction, Removal and Disassembly
14-16
Reassembly, Installation and Adjustment
F14-5
Related Parts
Hydraulic Sump and Filter (Class 1, Precise Sets Only)
13-13
Equipment Test
13-10
General
13-11
Removal, Cleaning and Inspection
13-12
Repair
L
Lifting Frame Repair Instructions
Cleaning and Inspection
General
Lifting Frame Assembly
Reassembly and Installation
Removal and Disassembly
Repair
Load Bank
Fan and Motor Assembly
General
Load Reject Relay Test Circuit
Reassembly and Istallation
Removal and Dissembly
Repair, Overhaul and Rebuild
Load Connection Group Repair Instructions
Description
Scope
Load Measururing Unit
Disassembly
Removal
Repair, Reassembly and Installation
scope
Testing
Voltage Relationship Test Graph
Lube Oil Cooler and Filter Bypass Valve
General
11-3
11-1
F11-1
11-5
11-2
11-4
F17-7
F17-9
17-24
F17-8
17-27
17-25
17-26
6-2
6-1
8-17, F8-20
8-16
8-19
8-15
8-18,F8-21
F8-22
14-32
I-5
ALPHABETICAL INDEX (Cont)
Lube Oil Cooler and Filter Bypass Valve (Cont)
Lube Oil Bypass Valve
Inspection and Repair
Lube Oil Cooler
Removal. Disassemblv and Cleaning of Oil Cooler
Lubrication
F14-18
14-34
F14-17
14-33
A-2
M
F6-1
6-4
6-6, F6-l A
F6-lB, F6-lC
6-3
6-5
A-5
Main Load Contractor
Cleaning, Inspection and Testing
Reassembly and Installation
Removal and Disassembly
Repair
Maintenance
N
Nozzle Holder Assemblies
Assemblies
Assembly Installation
Dissassembly, Cleaning
General
Removal
Test Adjustments
F14-19
14-41
14-39
14-37
14-38
14-40
O
Oil Pump and Oil Pan Assembly
Cleaning, Inspection and Repair
General . . . . . . . . . . . . . . . .
Oil Pan and Heater . . . . . . . . .
Oil Pump Assembly . . . . . . . .
Oil Pump and Related Parts . . .
Reassembly and Installation . . .
Removal and Disassembly
14-66
14-64
F14-30
F14-32
F14-31
14-67
14-65
Painting
A-3
R
Radio Interference Suppression
General] Methods Used to Attain Proper Suppression
Interference Suppression Components
Testing of Radio Interferencce Suppression Components
Radioactive Material
Radio Suppression
Relay Table Group Instructions
Description
EquipmentTests
Related Parts
Scope
Symptoms and Isolation of Malfunction
Removal and Installation of Major Components
Component Locations (Right and Left Side)
Engine Generator Assembly Installation
Engine Generator Assembly Removal
Engine Installation
Engine Removal
General.
Generator Installation
Generator R e m o v a l
I-6 Change 1
2-7
2-9
2-8
A-8
A-4
8-2
T8-l
F8-1
8-1
8-3
F2-1
2-16
2-15, F2-4
2-14
2-13. F2-3
2-10
2-12
2-11, F2-2
ALPHABETICAL INDEX (Cont)
Repair Parts, Special Tools and Equipment
Direct Support, General Support and Depot Maintenance Repair Parts. . . . . . . . . . . . . . . . . 2-2
Repair and Replacement Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T1-2
Specially Designed (Fabricated) Tools and Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Special Tools and Repair Puts, Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Special Tools and Support Equipment, Test, Repair Calibration and Handling. . . . . . . . . . . . T2-1
S
Schematic Diagrams
Control Panel Relay, A4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-1
Electric Governor Control Unit, (Mode I, Class 1) Sets . . . . . . . . . . . . . . . . . . . . . . . . . . F1-4
Electric Governor Control Unit, (Mode II, Class 1) Sets. . . . . . . . . . . . . . . . . . . . . . . . . . F1-5
Excitation System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-8
Fault Indicator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F1-2
Fuel Burning Winterization Kit.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-13
Hydraulic Actuator Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F13-3
Load Measuring Unit Test..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-21
Shipment and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Speed Switch, Tachometer Drive and Adapter
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17
Speed Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-7
Speed Switch Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-20
Speed Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-18
Speed Switch Sensitivity Tests.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-6
Speed Switch Tests, Adjustment, Repair and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 14-19
Tachometer Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-8
Tachometer Drive and Adapter Inspection and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-22
Tachometer Drive and Adapter Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . 14-23
Tachometer Drive and Adapter Removal and Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . 14-21
T
Timing System
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-73
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-71
Gear and Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-72
Idler Gear Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. F14-35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-75
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-74
Timing Gear and Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-34
Troubleshooting
Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Generator Set Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-2
Troubleshooting Chart.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-26
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-53
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-51
Reassembly and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-55
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-52
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-54
W
Water Pump and Fan
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-56
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-58
Reassembly and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-59
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-57
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-27
Wheel Mounting Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F17-6
Electric Winterization Heater Control Box Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T17-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-20
I-7
ALPHABETICAL INDEX (Cont)
Wheel Mounting Kit (Cont)
Inspect ion and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-21
Wiring Diagrams
Exaltation System Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-9
Fault Indicator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-3
Fuel Burning Winterization Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-14
Tactical Relay Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-6
Wiring Harness Repair Instructions
AC Power Control 50/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-1
AC Power Control (50/60Hz). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-3
AC Power Contro1 400 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-2
Control Cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-10
Control Cubicle Interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-9
Convenience and Paralleling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-6
Current Transformer Assembly Model Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-12
Current Transformer Assembly Mode In sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-13
DC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-4
DC Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-5
Electric Governor Control (Class 1, Mode In sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-14
Electric Governor Control (Class l, Mode II) Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-15
Electric Governor Contralto Actuator Feedback Cables . . . . . . . . . . . . . . . . . . . . . . . . . . F5-17
Electric Governor Control to Actuator (Class I) Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-16
Electric Heater Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-35
Electric Winterization Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-34
Engine Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-30
Excitation System Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-24
Excitation System Assembly Interconnecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-25
Fault Indicator Panel.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-7
Fault Indicator Panel Interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-8
Fuel Buring Winterization Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-33
Fuel Burning Winterization Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-32
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-36
Load Bank Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-37
Load Bank Control Panel.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-38
Load Bank Interconnect Tactical Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-21
Load Measuring Unit..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-18
Load Measuring Unit Interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-29
Parallel Cable Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-31
Precise Relay Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-22
Precise Relay Assembly (Class l, Mode In sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-23
Removal and Ispection.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Repair and Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
RFI Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-40
Set Special Relay Assembly (Class l, Mode I) Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-27
Set Special Relay Assembly (Class l, Mode II) Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-28
Special AC Power Cables.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-11
Special Purpose Cable Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-39
Tactical Relay Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-19
Tactical Relay Assembly Interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-20
Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5-26
Wiring Schematic Diagrams
Electric Winterization Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-15
Precise Relay Assembly (Class l, Mode In sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-7
Special Relay Assembly, (Mode I) Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-11
Special Relay Assembly (Mode II) Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-12
Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-10
I-8
By Order of the Secretaries of the Army, the Navy, and the Air-Force:
Official:
VERNE L. BOWERS
Major General, United States Army
The Adjutant General
CREIGHTON W. ABRAMS
General, United States Army
Chief of Staff
A. R. MARSCHALL
Rear Admiral, CEC, USN
Commander, Naval Facilities
Engineering Command
Official:
DWIGHT W. COVELL, Colonel, USAF
Director of Administration
JOHN D. RYAN, General, USAF
Chief of Staff
Distribution:
Army:
To be distributed in accordance with DA Form 12-25D, Direct and General Support maintenance
requirements for Generator Sets, 60 KW, 60 Hz, Precise Power, 60 KW, 400 HZ Precise Power, 60 KW, 60 HZ
Utility.
MARCORPS CODE:
AGC
* U.S. GOVERNMENT PRINTING OFFICE : 1994 O - 300-421 (00112)
PIN: 013550-000
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available information, slap “watermarks” and other junk on it, and sell it.
Those masters of search engine manipulation make sure that their sites that
sell free information, come up first in search engines. They did not create it...
They did not even scan it... Why should they get your money? Why are not
letting you give those free manuals to your friends?
I am setting this document FREE. This document was made by the US
Government and is NOT protected by Copyright. Feel free to share,
republish, sell and so on.
I am not asking you for donations, fees or handouts. If you can, please
provide a link to liberatedmanuals.com, so that free manuals come up first in
search engines:
<A HREF=http://www.liberatedmanuals.com/>Free Military and Government Manuals</A>
– Sincerely
Igor Chudov
http://igor.chudov.com/
– Chicago Machinery Movers
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