User manual | TM-5-6115-593-34

DEPARTMENT OF THE ARMY TECHNICAL MANUAL
DEPARTMENT OF THE NAVY PUBLICATION
DEPARTMENT OF THE AIR FORCE TECHNICAL ORDER
*TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
TECHNICAL MANUAL
Intermediate (Field) (Direct and General Support)
and Depot Level Maintenance Manual
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL
SKID MTD., 500 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS
DOD MODEL
CLASS
HERTZ
MEP-029A
MEP-029B
UTILITY
UTILITY
50/60
50/60
NSN
6115-01-030-6085
6115-01-318-6302
INCLUDING OPTIONAL KITS
DOD MODELS
MEP-029AHK
MEP-029ACM
MEP-029ARC
MEP-029ACC
NOMENCLATURE
HOUSING KIT
AUTOMATIC CONTROL MODULE
REMOTE CONTROL MODULE
REMOTE CONTROL CABLE
NSN
6115-01-070-7550
6115-01-275-7912
6110-01-070-7553
6110-01-087-4127
Approved for public release; distribution is unlimited.
*This manual supersedes TM 5-6115-593-34/NAVFAC P-8-631-34/TO-35C2-3-463-2, dated 21
September 1981, including all changes.
HEADQUARTERS DEPARTMENTS OF THE ARMY, AIR FORCE AND
NAVY
23 JULY 1991
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
WARNING
WARNING
HIGH VOLTAGES PRESENT
DURING TEST.
DEATH
OR SEVERE BURNS MAY RESULT
IF PERSONNEL FAIL
TO OBSERVE SAFETY PRECAUTIONS.
BEFORE TURNING OFF
GENERATOR SET,
ENGAGE MAINTENANCE LOCKOUT SWITCH.
DISCONNECT AND ISOLATE
ELECTRICAL LEADS.
WARNING
WARNING
SECONDARY TERMINALS
SHOULD NOT
BE LEFT OPEN
WHEN AC CURRENT IS APPLIED.
THE USE OF ACID IS
EXTREMELY DANGEROUS TO WORKMEN
AND
INJURIOUS TO MACHINER.
ALWAYS PROVIDE A TANK OF STRONG SODA
WATER AS A NEUTRALIZING AGENT.
WARNING
SET MAINTENANCE LOCKOUT SWITCH
TO LOCKOUT.
DISCONNECT NEGATIVE CABLE
FROM BATTERIES.
REMOVE EXTERNAL POWER BY OPENING
CB101 (120V RECEPTACLE BREAKER).
WARNING
AVOID BREATHING FUMES
GENERATED BY SOLDERING.
REMOVE RINGS AND WATCHES.
EYE PROTECTION IS REQUIRED
TO AVOID INJURY TO PERSONNEL.
WARNING
WARNING
WHENEVER
GENERATOR SET
HAS JUST BEEN SHUT DOWN,
REMOVE RADIATOR CAP SLOWLY
TO ALLOW PRESSURE
TO ESCAPE
BEFORE REMOVING CAP.
USE EXTREME CARE WHEN REMOVING ROTOR
TO PREVENT INJURY TO HANDS
DUE TO MAGNETIC ATTRACTION BETWEEN
THE PERMANENT MAGNET GENERATOR ROTOR
AND THE PERMANENT MAGNET GENERATOR
STATOR OR GENERATOR SHAFT.
WARNING
WARNING
CLEAR AREA OF
PERSONNEL
AND
OTHER EQUIPMENT
WHEN ATTEMPTING
TO LIFT THE ENGINE
NEVER ATTEMPT TO "DRILL OUT"
HOLES IN DRIVE DISCS.
IF DRIVE DISCS DO NOT FIT PROPERLY,
REPLACE DRIVE DISCS.
a
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
WARNING
WARNING
OVERHEAD OPERATIONS
HAVE INHERENT HAZARDS THAT CANNOT
BE MECHANICALLY SAFEGUARDED.
HARD HATS AND SAFETY SHOES
ARE REQUIRED.
HIGH VOLTAGES PRESENT DURING TEST.
DEATH
OR
SEVERE BURNS
MAY RESULT IF PERSONNEL
FAIL PRECAUTIONS.
WARNING
WARNING
SILENCER FRAME ASSEMBLY
IS HEAVY.
BE SURE TO PROVIDE
ADEQUATE SUPPORT.
BEFORE STARTING
ANY MAINTENANCE PROCEDURE,
SET MAINTENANCE LOCKOUT SWITCH
TO LOCKOUT.
DISCONNECT NEGATIVE CABLE
FROM BATTERIES.
REMOVE EXTERNAL POWER BY
OPENING CB101 (EXTERNAL POWER
CIRCUIT BREAKER) AND
DISCONNECTING POWER CABLE
FROM RECEPTACLE J101
(120V RECEPTACLE).
WARNING
MAINTENANCE PERSONNEL
SHOULD EXERCISE EXTREME CARE
WHEN TESTING EQUIPMENT
WITH POWER ON.
WARNING
LIFTING DEVICES, CABLES,
AND/OR CHAINS SHOULD BE INSPECTED
FOR DETERIORATION OR DAMAGE
BEFORE USE.
A STABILIZING TETHER
SHOULD BE ATTACHED BETWEEN
THE ENGINE AND LIFTING HOOK FOR
ADDED SAFETY AND STABILIZTION
WHEN LIFTING THE UNIT.
WARNING
COMPRESSED AIR
USED FOR
CLEANING AND DRYING PURPOSES
CAN CREATE AIRBORNE PARTICLES
THAT MAY ENTER THE EYES.
PRESSURE
SHALL NOT EXCEED 30 PSIG
AND
USE ONLY WITH ADEQUATE CHIP
GUARDS AND CHIPPING GOGGLES.
b
DEPARTMENT OF THE ARMY TECHNICAL MANUAL
DEPARTMENT OF THE NAVY PUBLICATION
DEPARTMENT OF THE AIR FORCE TECHNICAL ORDER
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
HEADQUARTERS
DEPARTMENTS OF THE ARMY, NAVY AND AIR FORCE
WASHINGTON, D.C., 23 JULY 1991
Intermediate (Field) (Direct and General Support)
and Depot Level Maintenance Manual
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL
SKID MTD., 500 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS
DOD MODEL
CLASS
HERTZ
MEP-029A
MEP-029B
UTILITY
UTILITY
50/60
50/60
NSN
6115-01-030-6085
6115-01-318-6302
INCLUDING OPTIONAL KITS
DOD MODELS
MEP-029AHK
MEP-029ACM
MEP-029ARC
MEP-029ACC
NOMENCLATURE
NSN
HOUSING KIT
AUTOMATIC CONTROL MODULE
REMOTE CONTROL MODULE
REMOTE CONTROL CABLE
6115-01-070-7550
6115-01-275-7912
6110-01-070-7553
6110-01-087-4127
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If you find any mistakes or if you know of a way to improve
the procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to
Publications and Blank Forms), or DA Form 2028-2 located in the back of this manual directly to:
US Army Troop Support Command, ATTN: AMSTR-MMTS, 4300 Goodfellow Blvd. , St. Louis,
MO 63120-1798. A reply will be furnished directly to you.
Approved for public release; distribution Is unlimited.
TABLE OF CONTENTS
Paragraph
CHAPTER
Section
1.
I.
II.
INTRODUCTION
General
Description and Tabulated Data
1-6
* This manual supersedes TM 5-6115-593-34/NAVFAC P-8-631-34/TO-35C2-3-463-2, dated 21 September 1981.
i
Page
1-1
1-1
1-1
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
TABLE OF CONTENTS (Cont)
Paragraph
CHAPTER
Section
2.
GENERAL MAINTENANCE INSTRUCTIONS
Repair Parts, Special Tools, Test, Measurement,
and Diagnostic Equipment (TDME) and
Support Equipment
Troubleshooting
General Maintenance
Removal and Installation of Major Components
2-1
2-4
2-7
2-12
2-1
2-1
2-1
2-6
3.
MAINTENANCE OF EXTERNAL POWER ASSEMBLY
3-1
3-1
4.
MAINTENANCE OF AC-DC CONTROL BOX ASSEMBLY
Enclosure Components
Battery Charger
Governor Controller
Voltage Regulator
Panel Component Base Assembly
Capacitor, Diode, and Circuit Cards
4-1
4-5
4-11
4-17
4-21
4-27
4-1
4-1
4-2
4-9
4-14
4-16
4-30
I.
II.
III.
IV.
CHAPTER
CHAPTER
Section
Page
I.
II.
III.
IV.
V.
VI.
2-1
CHAPTER
5.
MAINTENANCE OF CONTROL CUBICLE
5-1
CHAPTER
6.
MAINTENANCE OF THE SUPPORT FRAME ASSEMBLY
6-1
CHAPTER
7.
MAINTENANCE OF RADIATOR ASSEMBLY
7-1
CHAPTER
8.
MAINTENANCE OF ENGINE PREHEAT ASSEMBLY
8-1
CHAPTER
9.
MAINTENANCE OF FUEL TRANSFER AND PUMP ASSEMBLY
9-1
CHAPTER
10. MAINTENANCE OF INTERCONNECTING ELECTRICAL
HARNESSES AND PARALLEL CABLE ASSEMBLIES
Maintenance of Interconnecting Electrical Harnesses
Maintenance of Parallel Cable Assemblies
Section
I.
II.
CHAPTER
CHAPTER
CHAPTER
Section
I.
II.
III.
10-1
10-3
10-1
10-1
10-1
11. MAINTENANCE OF GENERATOR AND
RECONNECTION ASSEMBLY
11-1
12. MAINTENANCE OF ELECTRIC HYDRAULICACTUATOR
12-1
13. MAINTENANCE OF ENGINE ASSEMBLY
General
Speed Switch, Starter and Tachometer Drive and Adapter
Oil Filter and Sensors
ii
13-1
13-3
13-11
13-1
13-1
13-1
13-25
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
TABLE OF CONTENTS-CONTINUED
Paragraph
IV.
V.
VI.
VII.
VIII.
IX.
Water Pump
Housing
Flywheel and Housing
Cylinder Head and Valve Operating Mechanism
Piston and Rings
Crankshaft and Block
13-17
13-18
13-22
13-24
13-33
13-34
Page
13-56
13-63
13-70
13-74
13-89
13-94
CHAPTER
14. MAINTENANCE OF BASE ASSEMBLY
CHAPTER
I.
II.
III.
IV.
15. MATERIEL USED IN CONJUNCTION
WITH THE GENERATOR SET
Maintenance of Remote Cable Assembly
Maintenance of Remote Control Module
Maintenance of Automatic Control Module
Housing Kit
15-2
15-6
15-15
15-24
15-1
15-1
15-1
15-12
15-21
I.
II.
III.
16. GENERATOR SET TEST AND INSPECTION
AFTER REPAIR AND OVERHAUL
General Requirements
Inspection
Operational Tests
16-1
16-2
16-7
16-1
16-1
16-1
16-4
17-1
17-13
17-17
17-24
17-1
17-1
17-2
17-2
17-7
17-26
17-38
17-60
17-71
17-79
17-7
17-11
17-19
17-24
17-26
Section
CHAPTER
Section
CHAPTER
Section
I.
II.
III.
IV.
V.
VI.
VII.
VIII.
IX.
17. GENERATOR SET INSTALLATION PRACTICES
Safety Precautions
Location
Mounting the Generator Set
Vibration
Air Requirements for Unhoused 500 KW Generator Sets
Installed within a Building
Cooling System
Fuel System
Exhaust System
Electrical Requirements
iii
14-1
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LIST OF ILLUSTRATIONS
Figure
2-1.
2-2.
2-3.
2-4.
2-5.
3-1.
3-2.
3-3.
3-4.
4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
4-9.
4-10.
4-11.
4-12.
4-13.
4-14.
4-15.
4-16.
4-17.
4-18.
5-1.
5-2.
5-3.
5-4.
5-5.
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.
6-1.
Title
Location of Major Components ............................. .....................................................
AC-DC Control Box Assembly, Remove and Installation ............... ............................
External Power Box Assembly, Removal and Installation .............. ............................
Radiator Assembly, Removal and Installation ............................................................
Engine, Removal and Installation ................................... ...........................................
External Power Box Assembly, Exploded View ..........................................................
Preheat System Contactor K107 and Heater Contactor K109, Exploded View ...........
Transfer Contactor K108, Exploded View ............................. .....................................
Contactor K120 Exploded View and Test Setup .........................................................
AC-CD Control Box Assembly, Exploded View ......................... .................................
Fuel Transfer Pump Relay K20, Test Setup ...............................................................
Battery Charger Schematic.........................................................................................
Battery Charger, Exploded View ................................................................................
Governor A106, Test Setup .......................................... .............................................
Governor Controller, Exploded View ..........................................................................
Voltage Regulator, Test Setup ...................................................................................
Voltage Regulator ......................................................................................................
Voltage Regulator Schematic ....................................... .............................................
Component Base Assembly, Exploded View ..............................................................
Component Assembly Panel, Relay K1 and K50, Test Setup .....................................
AC-DC Control Relay Assembly, Test Setup ........................... ..................................
Time Delay Module TD1 ............................................................................................
Time Delay Module TD3 ............................................................................................
Motor Operated Potentiometers, Exploded View ........................................................
Motor-Operated Potentiometer, Test Setup .................... ...........................................
Motor-Operated Potentiometers, Cam Adjustment .....................................................
Motor Operated Potentiometers, Clutch Adjustment Nut ............................................
Control Cubicle, Exploded View .................................................................................
Transducers A107 and A108, Test Setup ...................................................................
Transducer A103, Test Setup .................................. ..................................................
Transformers T101 and T102, Schematic...................................................................
Transformer T103, Schematic .............. .....................................................................
Relay K23, Test Setup................................................................................................
Overvoltage Relay K102, Test Setup .........................................................................
Phase Sequence Relay K103, Test Setup................................ ..................................
Sync Check Relay K106, Test Setup .................................. .......................................
Undervoltage Relay K111, Test Setup .......................................................................
Reverse Power Relay K112, Test Setup ................................ ....................................
Short Circuit Relay K113, Test Setup ............................... .........................................
Overload Relay K114, Test Setup .................................... .........................................
Time Delay TD2, Test Setup ......................................... ............................................
Control Relay Assembly TB10O, Test Setup ....................... ......................................
Annunciator Control Assembly, TB6 .................................. ........................................
Synchroscope, Test Setup .........................................................................................
Digital Clock, Mill .......................................................................................................
Control Cubicle, Relay Panel .....................................................................................
Under and Over frequency Devices, Test Setup ........................ ................................
Over/under Voltage Device, Test Setup ........................... .........................................
Relay Test Setup .......................................................................................................
Synchronizer, Test Setup ........................................... ...............................................
Support Frame Assembly ............................................. .............................................
iv
Page
2-8
2-9
2-10
2-13
2-15
3-2
3-4
3-5
3-6
4-3
4-4
4-7
4-8
4-11
4-12
4-14
4-17
4-19
4-20
4-21
4-22
4-24
4-25
4-27
4-28
4-29
4-29
5-2
5-5
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
5-21
5-23
5-24
5-25
5-26
5-27
5-28
6-2
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure
7-1.
7-2.
7-3.
7-4.
8-1.
8-2.
8-3.
8-4.
9-1.
9-2.
10-1.
11-1.
11-2.
11-3.
11-4.
11-5.
11-6.
11-7.
11-8.
11-9.
11-10.
11-11.
11-12.
11-13.
11-14.
11-15.
11-16.
11-17.
11-18.
11-19.
11-20.
12-1.
12-2.
12-3.
12-4.
12-5.
12-6.
12-7.
12-8.
12-9.
12-10.
12-11.
12-12.
12-13.
12-14.
12-15.
12-16.
12-17.
12-18.
12-19.
12-20.
LIST OF ILLUSTRATIONS-CONTINUED
Title
Radiator Assembly, Code A, Exploded View ..............................................................
Radiator Fan Motor, Code A ......................................................................................
Radiator Assembly, Code B, Exploded View ..............................................................
Radiator Fan Motor, Code B ......................................................................................
Preheat Installation ....................................................................................................
Heater Assembly ............................................................ ...........................................
Heater Element Test Set-up ................................................. .....................................
Thermostat Test Set-up..............................................................................................
Fuel Transfer Pump Installation, Exploded View ........................................................
Fuel Transfer Pum, Exploded View ................................... ........................................
Parallel Cables, Diagram ...........................................................................................
Reconnection Box Assembly, Exploded View .......................... ..................................
Current Transformer Assembly, Exploded View .........................................................
Generator Assembly, Exploded View .........................................................................
Air Cleaner Assembly Removal ............................... ...............................................
Generator Mounting Bolts ........
............................................................................
Checking Flywheel Face Runout ...................................... .........................................
Check Flywheel Pilot Bore Eccentricity ......................................................................
Checking Flywheel Housing Runout ................................... ......................................
Obtaining Dimension Y...............................................................................................
Obtaining Dimension C...............................................................................................
Removing Exciter Armature and Rotating Rectifier Assembly.....................................
Installing Exciter Armature and Rotating Rectifier Assembly.......................................
Rotating Rectifier Assembly .......................................................................................
Testing Rotation Rectifiers with an Ohmmeter............................................................
Removing Bearing from Generator Shaft....................................................................
Install Bearing on Generator Shaft .............................................................................
Drive Plate Assembly .................................................................................................
Drive Plate Assembly and Engine Flywheel Housing ................... ..............................
Exciter Stator Winding Data ................ .....................................................................
Exciter Rotor Winding Date ................................................. ......................................
Speed Setting Adapter Plate.................... ..................................................................
Actuator Test Circuit ..................................................................................................
Governor Actuator, Exploded View ............................................................................
Governor/Actuator Mounting on Engine and Actuator Test Connections .....................
Pilot Valve Wrench P/N 370109 .................................... ...........................................
Ball Heat Disassembly ...............................................................................................
Check Valve Installation .............................................................................................
Speeder Spring Subassembly.....................................................................................
Governor Pilot Valve Assembly ..................................................................................
Actuator Pilot Valve Assembly....................................................................................
Clamp Bracket Subassembly......................................................................................
Buffer System Parts Layout........................................................................................
Needle Valve Assembly..............................................................................................
Power Piston Linkage Assembly.................................................................................
Power Piston Assembly ............................... ..............................................................
Power Piston and Linkage Installation .............................. .........................................
Piston Placement .................................. ....................................................................
Piston Link Assembly .................................................. ..............................................
Base and Parts ..........................................................................................................
Bushing Assemblies ................................................. .................................................
v
Page
7-3
7-6
7-8
7-13
8-2
8-3
8-4
8-4
9-3
9-5
10-2
11-2
11-6
11-12
11-14
11-15
11-16
11-16
11-17
11-18
11-19
11-22
11-23
11-24
11-25
11-26
11-27
11-28
11-28
11-36
11-37
12-2
12-3
12-4
12-7
12-8
12-10
12-10
12-11
12-12
12-13
12-13
12-14
12-14
12-14
12-15
12-15
12-16
12-17
12-17
12-17
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LIST OF ILLUSTRATIONS-CONTINUED
Figure
12-21.
12-22.
12-23.
12-24.
12-25.
12-26.
12-27.
12-28.
12-29.
12-30.
12-31.
12-32.
13-1.
13-2.
13-3.
13-4.
13-5.
13-6.
13-7.
13-8.
13-9.
13-10.
13-11.
13-12.
13-13.
13-14.
13-15.
13-16.
13-17.
13-18.
13-19.
13-20.
13-21.
13-22.
13-23.
13-24.
13-25.
13-26.
13-27.
13-28.
13-29.
13-30.
13-31.
13-32.
13-33.
13-34.
13-35.
13-35A
13-36.
13-37.
13-38.
13-39.
13-40.
13-41.
13-42.
13-43.
Title
Relief Valve and Piston Sleeve Assembly ........................... ......................................
Ball Head Assembly ..................................................................................................
Centering Pilot Valve Plunger.....................................................................................
Base Assembly...........................................................................................................
Transducer Parts Assembly........................................................................................
Terminal Shaft Installation..........................................................................................
Speed Droop Lever ................................ ...................................................................
Speed Droop Lever Assembly ....................................................................................
Dial Plate and Seal Assembly.....................................................................................
Speeder Spring Assembly ..........................................................................................
Speed Adjusting Shaft Assembly................................................................................
Governor Linkage Adjustment ........................................ ...........................................
Speed Switch, Exploded View (Mechanical Type Switch) (Code A) ..........................
Speed Switch Sensitivity Tests(Mechanical Type Switch) ..........................................
Speed Switch Test (Electronic Type) (Code B)....................... ...................................
Starter Assembly, Exploded View (Code A) .......................... .....................................
No Load Test Circuit (Code A)....................................................................................
Checking Solenoid Hold-In and Pull-In Windings (Code A) ............ ............................
Circuit for Checking Pinion Clearance (Code A) ........................ ................................
Checking Pinion Clearance (Code A) .........................................................................
Starter Assembly, Exploded View (Code B) .............................. .................................
No-Load Test Circuit (Code B) ...................................................................................
Adjusting Starter Pinion Clearance ................................. ..........................................
Mainshaft Cover and Tachometer Drive, Exploded View Code A................................
Mainshaft Cover and Tachometer Drive, Exploded View Code B................................
Lubricating Oil Cooler, Exploded View, Code A ...................... ...................................
Lubricating Oil Cooler, Exploded View, Code B ......................... ................................
Injector, Exploded View ..............................................................................................
Injector Leakage Tester ...... .......................................................................................
Spray Angle Tester.....................................................................................................
Injector Test Stand .....................................................................................................
Fuel Injection Pump, Exploded View, Code A.............................................................
Fuel Injection Pump, Exploded View, Code B.............................................................
Fuel Shut-off Valve, Exploded View ................................ ..........................................
Governor Spring Pack, Exploded View ................................ ......................................
Gear Pump, Exploded View .......................................................................................
Fuel Pump Damper, Exploded View ...................................... ....................................
Fuel Pump Test Stand................................................................................................
Turbocharger, Exploded View, Code A ................................. .....................................
Turbocharger, Exploded View, Code B .................................... ..................................
Water Pump, Exploded View ...................................................................................
Water Pump with Idler Assembly .............................................................................
Crankshaft Pulley Vibration Damper, Exploded View .................................................
Vibration Damper Wobble Check Points ....................................................................
Engine Front Support, Exploded View ................................ .......................................
Oil Pan Assembly, Exploded View .............................................................................
Oil Pump, Exploded View ..........................................................................................
Ring Gear, Flywheel, and Flywheel Housing, Exploded View .....................................
Gear Case, Exploded View.........................................................................................
Timing Gear, Exploded View .......................................... ...........................................
Rocker Arm Shaft and Rocker Arm Assembly, Exploded View ............ ......................
Pushrods and Tappets, Code A ....................................... ..........................................
Pushrods and Tappets, Code B ....................................... ..........................................
Cylinder Head, Exploded View ................................. .................................................
Head Capscrew Tightening Sequence ................................... ....................................
Crosshead Dimensions ..............................................................................................
vi
Page
12-17
12-18
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12-18
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13-2
13-3
13-5
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13-78
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13-80
13-82
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LIST OF ILLUSTRATIONS-CONTINUED
Figure
13-44.
13-45.
13-46.
13-47.
13-48.
13-49.
13-50.
13-51.
13-52.
13-53.
13-54.
14-1.
15-1.
15-2.
15-3.
15-4.
15-5.
15-6.
15-7.
15-8.
15-9.
15-10.
15-12.
15-13.
15-14.
15-15.
15-16.
15-17.
15-18.
15-19.
15-20.
15-21.
15-22.
15-23.
15-24.
16-1.
17-1.
17-2.
17-3.
17-4.
17-5.
17-6.
17-7.
17-8.
17-9.
17-10.
17-11.
17-12.
17-13.
17-14.
17-15.
17-16.
17-17.
17-18.
Title
Valve Seat Insert, Cross Sections ..............................................................................
Minimum Valve Head Rim Thickness ................................... ....................................
Camshafts, Exploded View.........................................................................................
Piston and Connecting Rod, Exploded View ..............................................................
Piston Check Points ...................................................................................................
Cylinder Liner Check Points .......................................................................................
Cylinder Block, Exploded View ..................................................................................
Crankshaft, Exploded View.........................................................................................
Cylinder Block Height Checking Location ..................................................................
Sleeve and Block Boring Dimensions ........................................................................
Engine Injection Timing Procedure Diagram ..............................................................
Base Assembly, Exploded View .................................................................................
Remote Cable Assembly ...........................................................................................
Synchroscope, Test Setup .........................................................................................
Remote Control Module, Plate Assembly, Exploded View .........................................
Undervoltage Relay K115, Test Setup .......................................................................
Under frequency Relay K116, Test Setup ..................................................................
Transducer A103, Test Setup .....................................................................................
Transducer A107 and A108, Test Setup ....................................................................
Annunciator Control Assembly A20 ...........................................................................
Automatic Control Module .........................................................................................
Under/over Voltage Relay, Test Setup .......................................................................
Time Delay Relay, Test Setup ....................................................................................
Relay Test Setup .......................................................................................................
LR, LRDT. Test Setup ...............................................................................................
SDT Timer Test Setup ...............................................................................................
Housing Kit, Door and Shutter Assembly ...................................................................
Housing Kit, Right Side ..............................................................................................
Housing Kit Front .......................................................................................................
Housing Kit, Left Side ................................................................................................
Housing Kit, Rear ......................................................................................................
Housing Kit, Top ........................................................................................................
Housing Kit, Shutter Assembly ...................................................................................
Housing Kit Wiring......................................................................................................
Actuator Control Relay Assembly ..............................................................................
Overshoot and Undershoot Chart Recording .............................................................
Generator Set Operational Requirements ..................................................................
Mounting Bolt Layout in Concrete Pad .......................................................................
Cross Section View of Pad and Mounting Bolt Installation .........................................
Vibration Isolator (12 Required) .................................................................................
500 KW Generator Set Installation .............................................................................
Fixed Louvers for Air Inlet ..........................................................................................
Thermostatically Controlled Louvers ..........................................................................
Exhaust Fan Operated Louvers ..................................................................................
Exhaust Fan ..............................................................................................................
500 KW Deaerating Top Tank Design ........................................................................
500 KW DOD Deaerating Top Tank Piping ................................................................
Recommended Auxiliary Tank Piping ........................................................................
Remote Radiator Application "A" ...............................................................................
Remote Radiator Application "B" ................................................................................
Remote Radiator Application "C" ...............................................................................
Auxiliary Diesel Fuel System ......................................................................................
500 KW Generator Set Installation. ............................................................................
500 KW Generator Set Anti-Siphon Installation .........................................................
vii
Page
13-84
13-88
13-88
13-90
13-92
13-94
13-96
13-98
13-100
13-102
13-105
14-2
15-2
15-3
15-4
15-5
15-6
15-8
15-9
15-10
15-13
15-16
15-19
15-19
15-20
15-20
15-22
15-24
15-26
15-27
15-30
13-32
15-34
15-36
15-42
16-11
17-3
17-6
17-7
17-8
17-9
17-10
17-10
17-10
17-11
17-13
17-14
17-15
17-16
17-17
17-18
17-21
17-22
17-23
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LIST OF ILLUSTRATIONS-CONTINUED
Figure
17-19.
17-20.
17-21.
17-22.
17-23.
17-24.
17-25.
FO-1.
FO-2.
FO-3.
FO-4.
FO-5.
FO-6.
FO-7.
FO-8.
FO-9.
FO-10.
FO-11.
FO-12.
FO-13.
FO-14.
FO-15.
FO-16.
FO-17.
FO-18.
FO-19.
FO-20.
FO-21.
FO-22.
FO-23.
FO-24.
FO-25.
FO-26.
FO-27.
FO-28.
FO-29.
FO-30.
FO-31.
FO-32.
FO-33.
FO-34.
FO-35.
FO-36.
FO-37.
FO-38.
FO-39.
FO-40.
FO-41.
FO-42.
FO-43.
FO-44.
Title
500 KW Levelometer System Installation ...................................................................
Double Thimble-Wall Outlet Details ...........................................................................
500 KW Exhaust System ...........................................................................................
Installation of Mufflers on Generator Set ...................................................................
Muffler Provided with Generator Set ..........................................................................
Generator Voltages and Schematic ...........................................................................
Service Points on 500 KW Generator Set ..................................................................
Generator Set, Electrical Layout ................................................................................
Main Control Harness (Sheet 1 of 2) ..........................................................................
Main Control Harness (Sheet 2 of 2) ..........................................................................
AC Power Wiring Harness .........................................................................................
External Power Box Harness Assembly (Sheet 1 of 2)................................................
External Power Box Harness Assembly (Sheet 2 of 2)................................................
AC-DC Control Box Harness Assembly (Sheet 1 of 5) ...............................................
AC-DC Control Box Harness Assembly (Sheet 2 of 5) ...............................................
AC-DC Control Box Harness Assembly (Sheet 3 of 5) ................................................
AC-DC Control Box Harness Assembly (Sheet 4 of 5) ................................................
AC-DC Control Box Harness Assembly (Sheet 5 of 5) ...............................................
Control Box Harness Assembly (Sheet 1 of 8) ...........................................................
Control Box Harness Assembly (Sheet 2 of 8) ...........................................................
Control Box Harness Assembly (Sheet 3 of 8) ...........................................................
Control Box Harness Assembly (Sheet 4 of 8) ...........................................................
Control Box Harness Assembly (Sheet 5 of 8) ...........................................................
Control Box Harness Assembly (Sheet 6 of 8) ...........................................................
Control Box Harness Assembly (Sheet 7 of 8) ...........................................................
Control Box Harness Assembly (Sheet 8 of 8) ...........................................................
Reconnection Box Harness Assembly .......................................................................
Reconnection Harness ...............................................................................................
Engine Accessory Harness (Sheet 1 of 3) ..................................................................
Engine Accessory Harness (Sheet 2 of 3) ..................................................................
Engine Accessory Harness (Sheet 3 of 3) ..................................................................
Remote Control Cable Assembly (Sheet 1 of 2) .........................................................
Remote Control Cable Assembly (Sheet 2 of 2) .........................................................
Remote Control Box Harness Assembly (Sheet 1 of 4) ..............................................
Remote Control Box Harness Assembly (Sheet 2 of 4) ..............................................
Remote Control Box Harness Assembly (Sheet 3 of 4) ..............................................
Remote Control Box Harness Assembly (Sheet 4 of 4) ..............................................
Paralleling Cables, Governor Control ........................................................................
Paralleling Cables, Voltage Regulator .......................................................................
Louver Harness Assembly (Sheet 1 of 2) ...................................................................
Louver Harness Assembly (Sheet 2 of 2) ...................................................................
Louver Control Harness (External Power Box) ...........................................................
Auxiliary Power Harness ............................................................................................
Electrical Cable Assembly .........................................................................................
AC Neutral Power Cable ............................................................................................
AC-DC Control Cable Assembly ................................................................................
Battery Cables ...........................................................................................................
Cables 25- and 37-Conductor ....................................................................................
ACM Wiring Harness (Sheet 1 of 3) ...........................................................................
ACM Wiring Harness (Sheet 2 of 3) ...........................................................................
ACM Wiring Harness (Sheet 3 of 3) ............................................................................
viii
Page
17-25
17-27
17-28
17-30
17-31
17-32
17-33
FP-1
FP-3
FP-5
FP-7
FP-9
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FP-35
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FP-39
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FP-55
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FP-61
FP-63
FP-65
FP-67
FP-69
FP-71
FP-73
FP-75
FP-77
FP-79
FP-81
FP-83
FP-85
FP-87
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LIST OF TABLES
Number
1-1.
1-2.
1-3.
1-4.
2-1.
2-2.
11-1.
12-1.
16-1.
17-1.
17-2.
17-3.
17-4.
17-5.
17-6.
17-7.
17-8.
17-9.
17-10.
Title
Special Torque Data ...................................................................................................
Repair and Replacement Standards ................................... ........................................
Parameters AC-0% Droop ............................................. .............................................
Electrical Performance Characteristic Parameters AC-3% Droop ...............................
Special Tools, Test, and Support Equipment ......................... .....................................
Generator Set, Troubleshooting ..................................................................................
Repair of Generator Components ............................. ..................................................
Recommended Tools, Electric Hydraulic Actuator .......................................................
Operational Tests ........................................................................................................
Weight and Dimensions ..............................................................................................
Air Requirements Cubic Foot Per Minute (Cubic Liters Per Sec) .................................
Generator Set Heat Rejection, Radiator Connections ................. ................................
Radiator and Crankcase Capacities ...........................................................................
500 KW DOD Generator Set Radiator Data ................................................................
Fuel Consumption for 500 KW DOD Generator Set ....................................................
Date on Engine Used in 500 KW DOD Generator Set .................................................
Exhaust Line Recommendations .................................................................................
Typical. Full Load AC Generator Amps ......................................................................
Installation Check List..................................................................................................
ix/(x blank)
Page
1-5
1-7
1-15
1-16
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2-4
11-20
12-1
16-2
17-5
17-9
17-11
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17-19
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17-26
17-27
17-34
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
CHAPTER 1
INTRODUCTION
Section I. GENERAL
1-4. REPORTING OF ERRORS. Report of errors,
omissions, and recommendations for improvement of
this publication by the individual user is encouraged.
Reports should be submitted as follows:
a.
(A) Army DA Form 2028 directly to:
Commander, U. S. Army Troop Support
Command, ATTN: AMSTR-MCTS, 4300
Goodfellow Boulevard, St.
Louis, MO
63120-1798.
1-1. SCOPE. This manual contains instructions for
intermediate (field) (direct support and general support)
and depot maintenance personnel maintaining the 500
KW Diesel Engine Driven Generator Set. The unit is a
50/60 Hertz, (Mode I) Tactical Utility (Type I, Class 2A)
Set and maintained as authorized by the Maintenance
Allocation Chart (MAC). 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/crew and
organizational levels. Where the contents of referenced
documents conflict with the contents of this manual, the
contents of this manual will be followed.
1-2. LIMITED APPLICABILITY. Some portions of this
publication are not applicable to all services. These
portions are prefixed to indicate the services to which
they pertain: (A) for Army, (F) for Air Force, and (N) for
Navy.
Portions not prefixed are applicable to all
services.
(A) Maintenance forms and records used by
Army personnel are prescribed by DA PAM
738-750.
b.
(F) Maintenance forms and records used by
Air Force personnel are prescribed in AFM66-1 and the applicable 00-20 Series
Technical Orders.
c.
(F) Air force AFTO Form 22 directly to:
Commander, Sacramento Air Logistics
Center,
ATTN:
SM-ALC-MMEDTA,
McClellan Air Force Base, CA 95652-5609,
in accordance with tO-00-5-1.
c.
(N) Navy by letter directly to: Commanding
Officer, Naval Construction Battalion
Center, ATTN:
Code 15741, Port
Hueneme, CA 93043-5000.
1-5. LEVELS OF MAINTENANCE ACCOMPLISHMENT.
The authorized maintenance and repair functions will be
accomplished as follows:
1-3. MAINTENANCE FORMS AND RECORDS.
The forms and records used for maintenance purposes
by the various services are specified as follows:
a.
b.
(N) Navy users should refer to their service
peculiar directives to determine applicable
maintenance forms and records to be used.
a.
(A, MC) Army and Marine Corps users shall
refer to the maintenance Allocation Chart
(MAC) for tasks and levels of maintenance
to be performed.
b.
(F) Air Force users shall accomplish
maintenance at the user level consistent
with their capability in accordance with
policies established in AFM-66-1.
c.
(N) Navy users shall determine their
maintenance levels in accordance with their
service directives.
Section II. DESCRIPTION AND TABULATED DATA
1-6. DESCRIPTION. A general description of the
generator set and the auxiliary equipment used in
conjunction with 'it is contained in the Operator/ Crew
and Organizational Maintenance manual.
descriptions of the
1-1
Detailed
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
components of the generator set are provided in the
applicable maintenance paragraphs of this manual.
1-7. TABULATED DATA. This paragraph contains all
maintenance data pertinent to intermediate (field) (direct
and general support) and depot maintenance personnel.
The generator set has identification and instructional
plates located throughout the set. The information
pertaining to these plates is contained in the
Operator/Crew and Organizational Maintenance manual.
a. Generator Set.
Manufacturer .................................. Fermont Division,
Dynamics Corporation of
America
DOD Drawing Number... ................. 76-029
Model ............................................. MEP-029B
Mode .............................................. 50/60 Hertz
3 phase, 4 wire
Class .............................................. Utility
b. External Power Box Assembly.
Starter Motor Contactor
DOD Drawing Number .............. 76-11254
Contact Rating
Volt .................................... hp
200 ............... ..................... 10
230 ................ .................... 15
380-575 ........... .................. 25
Overload trip ...... ............................ 35.5 to 38.2 amps
Nominal operating........................... .120V AC, 50/60 Hz
Required operating.......................... 50 Hz nominal from
ranges
110 to 123V AC
and from 47.5
to 52.5 Hz
60 Hz nominal from
114 to 144V AC
and from 57.5
to 62.5 Hz
c. AC-DC Control Box Assembly.
Battery Charger
DOD Drawing Number.. ............ 76-11207
AC Input ............. ..................... 120V AC, 50/60 Hz
DC Output ................................ 24V DC, 20 amps
Fuse protection ..... ................... AC input and DC
output
Diodes, zener (measured with
associated resistor)
CR1 (TD1) ........ ....................... .6.8 volts
CR4 (TD3) ......... ...................... 15 volts
Resistors
R116 ........................................ 5 ohms, 14 watts,
+5 percent
R4 (TD1) .................................. 820 ohms, 25 watts
+5 percent
R1
(TD1) 2 k, 1 watt,
+5 percent
R2 (TD1) .................................. 2.7 megohms, 25
watts,
+5 percent
R1 (TD3) .................................. 2 k, 1 watt,
+5 percent
R2 (TD3) .................................. 2 k, 1 watt,
+5 percent
R4 (TD3) .................................. 2 k, 0.25 watt,
+5 percent
R7 (TD3) .................................. 20 k, 0.25 watt,
+5 percent
R6 (TD3)................................... 200 ohms, 1 watt,
+5 percent
R5 (TD3) .................................. 68 k, 0.25 watt,
+5 percent
R3 (TD3) .................................. .6 k, 0.25 watt,
+5 percent
Capacitors
C1 (TD1) .................................. 10 microfarads,
25 volts,
+5 per-cent
C2 (TD1) ........... ............................. 47 microfarads,
50 volts,
+5 per-cent
C1 (TD3) ........... ............................. 300 microfarads,
30 volts,
±5 per-cent
Governor Controller
DOD Drawing Number... ........... 76-11208
Inputs ....................................... 90 to 240V AC,
3 phase load
sensing
24V DC supply,
10 watts consumption
900 to 2700
rpm speed
range
Output ............................................ Voltage to actuator 0 to 8V DC
Operating range .............................. 40 to 160°F (-40
to 71°C)
Voltage Regulator
DOD Drawing Number .............. 76-11209
Power input............................... 120V AC, 50/60 Hz
840VA
Output rating............................. 62.5V DC, 7 amps
mas
continuous;
90V DC, 10
amps
1 minute
forcing
Sensing..................................... 208V AC, 3 phase,
50/60 Hz
Voltage regulation..................... +1/2 percent
Response time ......................... T6 milliseconds
d. Control Cubicle Assembly.
Alarm Horn
DOD Drawing Number... ........... 76-11225
Input .................. ...................... 24V DC
Output ...................................... 370 cycles per
second, audible
1-2
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Annunciator Control Assembly
DOD Drawing Number. ............. 76-11272
Diodes (20) ........... ................... JANIN4383
1 amp, 200 volt
Relays (13) ............................... M5757/23-003
10 amp, DPDT,
MIL-R-5757
Diodes, Silicone
DOD Drawing Number. ............. 76-11244
Five diodes ........... ................... 400 prv, 3 amps
Resistor
Type .................. ................... RWR74S3920RFR,
39,000 ohms,
+5 percent,
MIL-R-22
Resistor Assembly TB107
DOD Drawing Number.. ............ 70-1131
Two resistors ............................ 7.5 ohms, +5
percent
Resistors
R4 (TD2) .................................. 820 ohms, 25
watts
+5 percent
R1 (TD2) .................................. 2 k, 1 watt,
+5 percent
R2 (TD2)................................... 2.7 megohms,
25 watts,
+5 percent
R3 (TD2)................................... 390 k, 0.25 watt,
+5 percent
Capacitors
C1 (TD2) .................................. 10 microfarads,
25 volts,
+5 per-cent
C2 (TD2)................................... 47 microfarads,
50 volts,
+5 per-cent
Flashing Circuit (FC1)
Flasher
DOD Drawing Number... ........... 76-11396
24V DC, No.
313 lamp
Terminal
DOD Drawing Number... ........... 76-11241
Digital Clock
DOD Drawing Number... ........... 76-11221
Input ............... ......................... 120V AC, 50/60 Hz
Features .............. .................... 50 to 60 Hz
select; fast
and slow set,
and hold
Synchroscope Meter
DOD Drawing Number.. ............ .76-11219
Voltage ........................................... 120V AC, 50/60 Hz
Accuracy ......................................... .2 degrees
Pull-in frequency ............................. 48 Hz
Dropout frequency........................... 47 Hz
Underfrequency Relay
DOD Drawing Number .............. 77-11002
Input .................. ...................... 1 20V AC 50 or
60 Hz
Trip Characteristic..................... .50 or 60 Hz - 3%
(adjustable)
Overfrequency Relay
DOD Drawing Number... ........... 77-11001
Input ................. ....................... 120V AC 50
or 60 Hz
Trip Characteristic..................... 50 or 60 Hz - 3%
(adjustable)
Over/Under Voltage Relay
DOD Drawing Number .............. 77-11003
Input ................ ..................... 120V AC 50
or 60 Hz
Trip Characteristic.. .................. 50 or 60 Hz - 3%
120V AC +10%
(adjustable)
Synchronizer Relay
DOD Drawing Number .............. 77-11006
Input ............. ........................... 120V AC 50 or
60 Hz
Output ...................................... Will allow breaker
closing when
buss and
generator
voltages are
matched to
within
+.5%
frequency,
+10% voltage.
e. Fuel Transfer Pump.
Solenoid Valve
DOD Drawing Number... ........... 69-787-1
24V DC, 2-way
normally closed
Rated ....................................... 25 psi
f. Generator and Reconnection
Assembly.
Limit Switch
DOD Drawing Number.. ............ 76-11295
Type ................. ....................... .Roller Plunger
Contacts ......... ......................... DPST - 1 NO - 1
NC
600 volts max
6 amps at 600V
AC, 15 amps at
-30V AC
Current Transformer
DOD Drawing Number... ........... 76-11259
Ratio ........................................ 1155/1 - 12.5VA
Max current through ... .................... .1.5 amp
winding
Continuous at 68°F ......................... 1.5 amp
(20 C)
Insulation class ............................... .600V AC
1-3
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
g. Engine and Controls.
Oil Pre-Alarm Pressure Switch
DOD Drawing Number .............. .76-11310
Switch code ........... .................. 1 NO contact,
1 NC contact
Contact rating ....... ................... NO contact: 10
amp, 280V DC
resistive.
NC contact:
10 amp,
125V DC
resistive
Pressure range ............................... 500 psi (35.2
2
kg/cm ) max
Pressure setting ..... ........................ NO circuit trip:
19 to 23 psi
(1.33 to 1.6
2
kg/cm ) decreasing;
NC circuit trip:
19 to 23 psi
(1.33 to 1.6
2
kg/cm )
decreasing
Temperature range.... ............... -65 to 160°F
(-54 to 71°C)
Connector ............. ................... MS3102R-14S-2P
Oil Shut Down Pressure.Switch
DOD Drawing Number.. . ......... 76-11311
Switch code ........... .................. 1 NO contact;
1 NC contact
Contact rating ...... .................... 10 amp, 28V DC
resistive; 10
amp, 125V AC
Pressure range ........ ................ 500 psi (35.2
2
kg/cm ) max
Pressure setting ..... .................. NC circuit trip:
11 to 15 psi
(0.8 to 1
2
kg/cm )
decreasing;
NC circuit trip:
11 to 15 psi
(0.8 to 1
2
kg/cm )
decreasing
Temperature range ... ............... .65 to 160°F
(-54 to 71°C)
Connector ............. ................... MS3102R-14S-2P
Lubricant Temperature Switch
DOD Drawing Number... ........... 76-11309
Rating .............. ........................ .10 amp, 28V DC
Connector ............ .................... MS3102E-14S-2P
Circuit .............. ........................ Two independent
double-break
circuits, one NO
and one NC
Operation ............ ........................... The NC circuit
opens at 265
+3°F (129
+1°C) and the
circuit closes
at 255 +3°F
(124 +1°C)
Overspeed Switch
DOD Drawing Number... ........... 70-1105-5
Type .................. ...................... Centrifugal or
electronic
element; 2 auto
reset, 1 manual
reset
Operating temper-........................... -65 to 150°F
ature range ............................... (-54 to 66°C)
Element No. 1 ......................... Transfer at 290 to
310 rpm rising
speed, auto
reset
100 rpm max
below
trip speed
Element No. 2 ................................ Transfer at 590 to
610 rpm rising
speed, auto
reset 100 rpm
max below
trip speed
Element No. 3 ................................ Transfer at 1100 to
to 1150 rpm
rising speed,
manual reset
Oil Temperature Sender
DOD Drawing Number .............. 76-11249-2
Maximum operating.... .............. 325°F (163°C)
temperature
Temperature .......... .................. 230°F (110°C)
341.3 ohms,
+31 ohms
Magnetic Pickup
DOD Drawing Number... ........... 76-11250
Coil resistance ...... ................... 170-210 ohms
Output ...................................... 70V P-P min
h. Remote Control Module.
Alarm Horn
DOD Drawing Number... ........... 76-11225
Input ................. ....................... 24V DC
Output ...................................... 370 cycles per
second, audible
Annunciator Control Assembly
DOD Drawing Number... ........... 76-11272
Diodes (20) ........... ................... JANIN4383
1 amp, 200 volt
Relays (13) ......... ..................... .M5757/23-003
10 amp, DPDT
MIL-R-5757
1-4
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Flashing Circuit (FCI)
Flasher
DOD Drawing Number.. ............ 76-11396 24V DC,
No. 313 lamp
Terminal
DOD Drawing Number.. ............ 76-11241
Synchroscope Meter
DOD Drawing Number..7 .......... 6-11219
Voltage ............. ....................... 120V AC, 50/60 Hz
Accuracy .................................. 2 degrees
Pull-in frequency....................... 48 Hz
Dropout frequency... ................. 47 Hz
i. Parallel Cable Assemblies.
DOD Drawing Number.. ............ 76-11320 and
76-11321
76-11320
1200 ft (365 m)
76-11253 cable
76-11321
1200 ft (365 m)
76-11253 cable
j. Housing Kit.
Actuator
DOD Drawing Number.. ............ 76-11475
Voltage ............. ....................... 24V DC
Load ................ ........................ 250 pounds (113.5
kilograms)
Speed ............... ....................... 1.0 in/sec
(25.4 mm/sec)
Current .............. ...................... 7 amps
26.5V DC Relay
DOD Drawing Number.. ............ 76-11444
Coil resistance ..... .................... 300 ohms
.............................................. +10 percent
Contact type ........ .................... DPDT with arc
chamfer
Contact rating ..... ..................... .10 amp resistance
at 26.5V DC/
115V AC 400
Hz with
enclosure
grounded
Max pull-in volts........................ 18V DC
Min holding volts....................... .10V DC
Min dropout volt .... ................... 1V DC
Operating time at... ................... 15MS max
26.5V DC
Release time at ........................ 15MS max
26.5V DC
NOTE
Throughout this technical manual MEP-029A is
referrd to as code A and MEP-029B is referred to as
code B.
1-8.
INSTRUCTION PLATES.
Refer to the
Operator/Crew and Organizational .Maintenance manual
for location of instruction plates in the generator set.
1-9. TORQUE DATA. Table 1-1 lists components that
require special torques.
1-10. SCHEMATICS AND WIRING DIAGRAMS. FO-1
through FO-16 of the Operator/Crew and Organizational
Maintenance manual are the schematic and wiring
diagrams for the generator set and auxiliary equipment.
1-11. SERIAL NUMBER EFFECTIVITY.
Refer to TM5-6115-593-24P, Usable on Code data.
Table 1-1. Special Torque Data
COMPONENTS
GENERATOR
Generator mount to skid base screws
Flexible coupling to flywheel screws
ENGINE
Front trunnion mounting bolts
Bell housing mounting bolts
Main bearing capscrew
Tighten to
Advance to
Loosen
Tighten to
Advance
* Applicable to Generator Set serial numbers FZ00001-FZ00064 only
* Cap screw should be coated with 30 weight oil
1-5
TORQUE VALUE
FT/LBS
JOULES
202
112
274
152
202
296
274
401
200 min/210 max
410 min/420 max
all
200 min/210 max
420 min/460 max
271min/285 max
555 min/570 max
271 min/285 max
570 min/624 max
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Table 1-1. Special Torque Data - Continued
COMPONENT
Main bearing side capscrew
All right side
All left side
All right side
All left side
Connecting rods nut
Tighten to
Advance to
Loosen
Tighten to
Advance to
Rear cover capscrews
Tappet guide screws *
FT/LBS
TORQUE VALUE
JOULES
70 min/75 max
70 min/75 max
135 min/145 max
135 min/145 max
95 min/102 max
95 min/102 max
145 min/197 max
145 min/197 max
70 min/80 max
140 min/150 max
95 min/108 max
190 min/203 max
all completely
95 min/108 max
190 min/203 max
39 to 42
11 to 13
70 min/80 max
140 min/150 max
29 to 31
95 to 115
(in/lbs)
Cylinder head capscrews
Tighten to
Advance to
Continue to advance
Breakaway
Injector hold down capscrews
25 to 40
34 to 54
150 to 200
203 to 270
275 to 305
373 to 414
275 to 340
373 to 461
11 to 12
15 to 16
increments alternately of
4 ft/lbs (5 joules)
300 to 320
408 to 435 **
Damper flange capscrews
Damper capscrews
Conical head
Hexagon head
Flywheel capscrews
Breakaway
STARTER MOTOR
Nose housing bolts
TURBOCHARGER
V-Band clamp tension
Rotor assembly locknut tension
Lubricating oil drain fitting
Diffuser plate capscrew
PIPE PLUG SIZE WITH TEFLON TAPE
1/8
1/4
3/8
1/2
3/4
1
1-1/4
1-1/2
* In-lbs.
1-6
70 to 80
100 to 120
350 to 390
350 to 420
95 to 108
136 to 163
475 to 529
475 to 570
11 min/15 max
15 min/20 max
32 to 36 *
20 to 24
5 to 7
3.6 to 4.1
27 to 33
50 68
7 to 10
10 min/12 max
20 min/25 max
30 min/40 max
30 min/35 max
40 min/50 max
60 min/70 max
75 min/85 max
90 min/100 max
14 min/16 max
27 min/34 max
41 min/54 max
41 min/47 max
54 min/63 max
81 min/95 max
102 min/115 max
122 min/136 max
TM5-61 15-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Table 1-2. Repair and Replacement Standards
PART OR LOCATION
CYLINDER BLOCK
Camshaft bushing
Inside diameter
Camshaft bushing bore
Inside diameter
WORN LIMIT
2.1245
(53.962)
2.1283
(54.059)
2.2555
(57.290)
2.2535
(57.239)
2.2545
(57.264)
0.411
(10.44)
6.5616
(166.662)
0.350
(8.89)
6.5635
(166.713)
0.351
(8.91)
0.000
(0.00)
6.124
(155.55)
0.008
(0.20)
6.126
(155.60)
6.0965
(154.851)
6.095
(154.813)
6.096
(154.838)
1.627
(41.33)
1.190
(30.213)
1.997
(50.72)
1.6245
(41.262)
1.187
(30.150)
1.9975
(50.737)
0.6255
(41.288)
1.188
(30.175)
1.998
(50.75)
18.994
(482.45)
15.9457
(405.02)
19.004
(482.70)
15.9565
(405.27)
19.006
(482.75)
15.958
(405.33)
5.505
(139.83)
5.4995
(139.687)
0.004
(0.10)
5.501
(139.73)
0.006
(0.15)
Liner-to-block clearance
Lower bore
Lower liner bore
Main bearing bore
Inside diameter
Tappet bore
Injector
Valve
Idler gearshaft
NEW MAXIMUM
INCH (mm)
2.1295
(54.089)
Cylinder liner counterbore
Inside diameter
Depth
NEW MINIMUM
INCH (mm)
Block
Height from main bearing
centerline
Height from installed
alignment bar
Cylinder liner
Inside diameter
Protrusion (Installed)
NOTE
New cylinder liner dimensions at 60 to 70°F (16 to 21°C); may be
0.0002 to 0.0006 inch (0.005 to 0.015 mm) smaller than indicated due
to lubrite coating.
1-7
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Table 1-2. Repair and Replacement Standards - Continued
PART OR LOCATION
WORN LIMIT
Cylinder liner counterbore
Shim part number
143938
0.007
(0.196)
0.0088
(0.224)
0.0099
(0.251)
0.022
(0.56)
0.034
(0.86)
0.068
(1.73)
0.002
(0.05)
0.004
(0.10)
2.002
(50.85)
1.9965
(50.711)
0.090
(2.29)
2.000
(50.80)
1.9975
(50.77)
0.093
(2.36)
2.001
(50.83)
1.998
(50.75)
0.098
(2.49)
3.747
(95.17)
5.7465
(145.961)
0.002
(0.05)
3.7485
(95.212)
5.7485
(146.011)
3.750
(95.25)
5.750
(146.500)
0.1692
(4.298)
0.010
(0.254)
0.1705
(4.331)
0.0026
(0.066)
0.1712
(4.348)
0.0065
(0.165)
0.1232
(3.129)
0.0085
(0.216)
0.1245
(3.162)
0.0018
(0.046)
0.1250
(2.175)
0.0053
(0.135)
143946
143947
143948
143949
Main bearing cap interference
Fit in block
Idler gear hub
Thrust washer
Crankshaft
Connecting rod journal
Outside diameter
Main bearing journal
Outside diameter
Main and rod journals
Out-of-round
(total indicated runout)
Bearings
Main bearings
Shell thickness
Journal oil clearance (main
Rod bearings
Shell thickness
Journal oil clearance
(connecting rod)
NEW MAXIMUM
INCH (mm)
0.0063
(0.160)
0.0072
(0.183)
0.0081
(0.206)
0.018
(0.457)
0.028
(0.71)
0.056
(1.42)
143939
Idler Gear
Bushing inside diameter
NEW MINIMUM
INCH (mm)
1-8
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Table 1-2. Repair and Replacement Standards - Continued
PART OR LOCATION
Crankshaft thrust ring
Thickness
Crankshaft end clearance
(Installed)
Connecting Rod
Crankpin bore
Inside diameter
Out-of-round
WORN LIMIT
*
0.026
(0.66)
Center-to-center-length
NEW MINIMUM
INCH (mm)
NEW MAXIMUM
INCH (mm)
0.307
(7.80)
0.006
(0.15)
0.317
(8.05)
0.013
(0.33)
4.0018
)101.646)
4.0028
(101.671)
0.001
(0.02)
12.050
(304.80)
11.998
(304.75)
NOTE
*Add 0.003 inch (0.08 mm) ring gap to new maximum
limit for 0.001 inch (0.03 mm) wear in cylinder liner
wall.
Piston pin bushing
Inside diameter
Connecting rod
Alignment
without bushing
Alignment
with bushing
Twist
without bushing
Twist
with bushing
Bolt pilot
Rod bolt hole
Connecting rod bolt
Outside diameter
Piston and Piston Rings
Skirt diameter at 70xF
(21xC)
2.0025
(50.863)
2.001
(50.82)
2.0015
(50.838)
0.6242
(15.855)
0.6249
(15.872)
0.6245
(15.862)
0.6243
(15.857)
0.008
(0.20)
0.004
(0.10)
0.020
(0.51)
0.010
(0.25)
0.625
(15.87)
0.6248
(15.867)
0.540
(13.72)
0.541
(13.74)
0.545
(13.84)
5.483
139.27)
5.487
(139.37)
5.488
(139.39)
1-9
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Table 1-2. Repair and Replacement Standards - Continued
PART OR LOCATION
Piston pin bore
Inside diameter at 70xF
(21xC)
Piston pin
Outside diameter
Piston ring gap
147670
WORN LIMIT
1.9985
(50.762)
1.9989
(50.772)
1.9978
(50.744)
1.9988
(50.770)
1.990
(50.775)
0.017
(0.43)
0.013
(0.33)
0.019
(0.483)
0.010
(0.254)
0.027
(0.69)
0.023
(0.58)
0.029
(0.736)
0.025
(0.635)
*
214730
0.029
(0.736)
0.025
(0.635)
218732
NEW MAXIMUM
INCH (mm)
2.000
(50.80)
*
132880
NEW MINIMUM
INCH (mm)
NOTE
*Add 0.003 inch (0.08 mm) ring gap to new maximum limit for
0.001 inch (0.03 mm) wear in cylinder liner wall.
Vibration Damper
Misalignment of index marker
Wobble
Eccentricity
Journal Camshaft
Outside diameter
1/16
(1.59)
0.055
(1.40)
0.030
(0.76)
2.120
(58.85)
1/16
(1.59)
0.055
(1.40)
0.030
(0.76)
2.122
(53.90)
Lobe lift
Valve
0.2835
(7.201)
0.117
(2.97)
Injector
Thrust washer
Thickness
Valve Crossheads
Inside diameter
Guide outside
diameter
Guide assembled
height (protrusion)
Bore depth
2.123
(53.92)
0.440
(11.18)
0.432
(10.97)
1-10
0.093
(2.36)
0.098
(2.49)
0.434
(11.02)
0.433
(11.00)
1.860
(47.24)
1.000
(25.40)
0.436
(11.07)
0.4335
11.011)
1.880
(47.75)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Table 1-2. Repair and Replacement Standards - Continued
PART OR LOCATION
WORN LIMIT
Valve Crossheads (Cont.)
Crosshead to spring
retainer clearance
Valves, Guides and Springs
Valve stem outside
diameter
Valve guide inside
diameter
Valve guide height
NEW MINIMUM
INCH (mm)
NEW MAXIMUM
INCH (mm)
0.025
(0.64)
0.449
11.40)
0.4545
11.544)
Head height
5.460
(138.68)
0.450
(11.43)
0.4525
(11.494)
1.315
(33.40)
5.490
(139.45)
0.451
(11.46)
0.4532
(11.511)
1.325
(33.65)
5.510
(139.95)
0.002
(0.05)
1.565
(39.75)
1.316
(33.43)
1.751
(44.48)
1.569
(39.85)
1.319
(33.50)
1.754
(44.55)
8.500
(215.90)
8.502
(215.95)
Runout
Gear Cover
Fuel pump drive bushing
1.5705
(39.891)
1.3205
(33.541)
1.757
(44.63)
Generator drive bushing
Camshaft support
Rear Cover
Piston ring type
8.504
(216.00)
VALVE SEAT INSERT SPECIFICATION - INCH (mm)
INSERT
PART NO.
127930
CUTTER
DIAMETER
ST-662
Std.
OVERSIZE
DEPTH
2.0025/2.0035
(50.864/50.889)
2.0075/2.0085
Std.
(50.991/51.016)
2.0125/2.0135
Std.
(51.118/51.143)
0.005
2.0225/2.0235
(0.1270)
(51.372/51.397)
0.010
2.0325/2.0335
(0.2540)
(51.626/51.651)
0.015
2.0425/2.0435
(0.3810)
(51.880/51.905)
CAUTION
Std.
127935
ST-662
127931
ST-662-1
127932
ST-662-2
127933
ST-662-3
127934
ST-662-4
0.005
(0.13)
0.010
(0.25)
0.020
(0.51)
0.030
(0.76)
0.040
(1.02)
INSERT
OD
CYLINDER HEAD
ID
INSERT
THICKNESS
1.9995/2.005
(50.787/50.813)
2.0045/2.0055
(50.914/50.940)
2.0095/2.0105
(51.041/51.067)
2.0195/2.0205
(51.295/51.321)
2.0295/2.0305
(51.549/51.575)
2.0395/2.0405
(51.803/51.829)
0.278/0.282
(7.06/7.16)
0.278/0.282
(7.06/7.16)
0.278/0.282
(7.06/7.16)
0.283/0.287
(7.06/7.29)
0.288/0.292
(7.32/7.42)
0.293/0.297
(7.44/7.54)
Be sure to measure insert before machining head or installing insert in head.
1-11
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Table 1-2. Repair and Replacement Standards - Continued
PART OR LOCATION
CYLINDER HEAD
Head Height
WORN LIMIT
ROCKER LEVERS
Bushing Inside
Diameter
Shaft Outside
Diameter
Push Tubes
Valve (ball end radius)
5.490
(139.45)
5.510
(139.95)
0.065
(1.65)
1.145
(29.08)
0.045
(1.14)
1.155
(29.34)
0.055
(1.40)
1.1285
(28.664)
1.122
(28.50)
1.1245
(28.562)
1.123
(28.52)
1.1275
(28.639)
1.124
(28.55)
0.623
(15.82)
0.505
(12.83)
0.623
(15.82)
0.505
(12.83)
0.625
(15.88)
0.520
(13.21)
0.625
(15.88)
0.520
(13.21)
1.6215
(41.186)
0.998
(25.36)
1.6225
(41.212)
1.007
(25.58)
1.6235
(41.237)
1.196
(30.38)
0.630
(16.00)
0.6233
(15.832)
0.025
(0.64)
1.198
(30.43)
0.628
(15.95)
0.6243
(15.857)
0.008
(0.20)
1.200
(30.48)
0.629
(15.98)
0.6247
(15.867)
0.020
(0.51)
.001
(0.03)
0.004
(0.10)
1.184
(30.08)
1.059
(26.90)
0.968
(24.59)
1.185
(30.10)
1.061
(26.95)
0.978
(24.84)
1.186
(30.12)
1.063
(27.00)
Socket (spherical
inside diameter)
Injector (ball end
radius)
Socket (spherical:
inside diameter)
TAPPETS
Injector
Body inside diameter
Body outside diameter
Injector
Roller outside diameter
Roller inside diameter
Roller pin outside
diameter
Roller side diameter
NEW MAXIMUM
INCH (mm)
5.460
(138.68)
Injector Sleeve
Top inside diameter
Injector cup protrusion
NEW MINIMUM
INCH (mm)
Roller concentrating
Roller squareness
Valve
Body inside diameter
Body outside diameter
Roller outside diameter
1-12
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Table 1-2. Repair and Replacement Standards - Continued
PART OR LOCATION
TAPPETS (Cont'd)
Roller inside diameter
Roller pin outside
diameter
Roller side clearance
WORN LIMIT
0.505
(12.83)
0.4985
(12.662)
0.027
(0.69)
NEW MINIMUM
INCH (mm)
0.503
(12.78)
0.4995
(12.69)
0.008
(0.20)
0.504
(12.80)
0.500
(12.70)
0.022
(0.56)
.002
(0.05)
.004
(0.10)
0.001
(0.03)
0.007
(0.18)
1.316
33.43)
1.316
(33.43)
1.319
(33.50)
1.319
(33.50)
Roller concentricity
Roller squareness
FAN HUB
End Clearance
DRIVE UNITS
Fuel Pump, Compressor
Bushings
Generator Bushing
WATER PUMP WITHOUT IDLER
Impeller to shaft
press fit
Pulley to shaft
press fit
Impeller to body
Impeller to cover
WATER PUMP WITH IDLER
Impeller to shaft
press fit
Pulley to shaft
press fit
Impeller to body
clearance
Bearing bore on body
Seal bushing bore
on body
Bearing bore on
idler pulley
1.3205
(33.541)
1.3205
(33.541)
NEW MAXIMUM
INCH (mm)
.0012
(0.031)
0.007
(0.018)
0.0012
(0.031)
0.007
(0.018)
0.020
(0.51)
(0.51)
0.0026
(0.066)
0.0021
(0.53)
0.031
(0.79)
(1.02)
0.0012
(0.031)
0.001
(0.025)
0.0012
(0.031)
0.001
(0.025
(0.020
(0.58)
1.8085
(45.94)
1.8735
(47.59)
1.8085
(45.94)
0.0026
(0.066)
0.0025
(0.064)
(0.031
(0.79)
1.8095
(45.96)
1.8745
(47.61)
1.8095
(45.96)
1.810
(45.97)
1.8755
(47.64)
1.810
(45.97)
1-13
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Table 1-2. Repair and Replacement Standards - Continued
NEW MINIMUM
PART OR LOCATION
WORN LIMIT
NEW MAXIMUM
INCH (mm)
INCH (mm)
Idler shaft outside
diameter
0.864
(21.95)
0.8646
(21.96)
0.8651
(21.97)
Pivot shaft outside
diameter
Idler shaft bore
(idler arm)
Pivot shaft bore
(idler pulley hacket)
0.870
(22.098)
1.248
(31.70)
0.873
(22.17)
0.8745
(22.21)
1.247
(31.67)
0.872
(22.15)
0.8750
(22.23)
1.248
(31.70)
0.873
(22.17)
1-14
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Table 1-3. Parameters AC-0% Droop
CHARACTERISTIC PARAMETER
Voltage Characteristics
Regulation (%)
Steady-state-stability (variation)
(bandwith %)
Short term (30 seconds)
Long term (4 hours)
Transient performance
Application of 50% of rated load
Dip (%) - 60 Hz
Recovery (seconds)
Rejection of rated load
Rise (%) - 60 Hz
Recovery (seconds)
Waveform
Maximum deviation factor (%)
Maximum individual harmonic (%)
Voltage unbalance with unbalance load (%)
(Note 1)
Phase balance voltage (%)
Voltage adjustment range
50 Hz (120/208 volts)
50 Hz (240/416 volts)
60 Hz (120/208 volts)
60 Hz (240/416 volts)
Frequency Characteristics
Regulation (%)
Steady-state-stability (variation)
(bandwith %)
Short term (30 seconds)
Long term (4 hours)
Transient performance
Application of 50% of rated load
Undershoot (%)
Recovery (seconds)
Rejection of 50% of rated load
Overshoot (%)
Recovery (seconds)
Frequency adjustment range (Hz)
50 Hz
60 Hz
VALUE
TEST METHOD
MIL-STUD-705
2%
608.1
1%
2%
608.1
608.2
20%
3 sec
619.2
619.2
30%
no spec
619.2
619.2
5%
2%
5%
601.1
601.4
620.2
1%
508.1
190 to 213V
380 to 426V
197 to 250V
395 to 500V
511.1
511.1
0.25%
608.1
0.5%
1%
608.1
608.2
4%
4 sec
608.1
608.1
4%
4 sec
608.1
608.1
+5%
+4%
511.2
511.2
NOTE
1. The generator set connected for three phase output and supplying a single phase, unity power factor 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.
1-15
TM5-6115-593-34
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Table 1-4. Electrical Performance Characteristic Parameters AC-3% Droop
CHARACTERISTIC PARAMETER
VALUE
Voltage Characteristics
Regulation (%)
Steady-state-stability (variation)
Short term (30 seconds)
Long term (4 hours)
Transient performance
Application of rated load
Dip (%)
Recovery (seconds)
Rejection of rated load
Rise (%)
Recovery (seconds)
Waveform
Maximum deviation factor (%)
Maximum individual harmonic (%)
Voltage unbalance with unbalance load (%)
(Note 1)
Phase balance voltage (%)
Voltage adjustment range
50 Hz (120/208 volts)
50 Hz (240/416 volts)
60 Hz (120/208 volts)
60 Hz (240/416 volts)
Frequency Characteristics
Regulation (%)
Steady-state-stability (variation)
(bandwith %)
Short term (30 seconds)
Long term (4 hours)
Transient performance
Application of 50% of rated load
Undershoot (%)
Recovery (seconds)
Rejection of 50% of rated load
Overshoot (%)
Recovery (seconds)
Frequency adjustment range (Hz)
50 Hz
60 Hz
TEST METHOD
MIL-STUD-705
2%
608.1
1%
2%
608.1
608.2
20%
3 sec
619.2
619.2
30%
no spec
619.2
619.2
5%
2%
5%
601.1
601.4
620.2
1%
508.1
190 to 213 V
380 to 426 V
197 to 250 V
395 to 500 V
511.1
511.1
3
608.1
.5%
1%
608.1
608.2
4%
4 sec
608.1
608.1
4%
4 sec
608.1
608.1
+5%
+4%
511.2
511.2
NOTE
1. 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.
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CHAPTER 2
GENERAL MAINTENANCE INSTRUCTIONS
Section I. REPAIR PARTS, SPECIAL TOOLS, TEST, MEASUREMENT,
AND DIAGNOSTIC EQUIPMENT (TDME) AND SUPPORT EQUIPMENT
2-1. REPAIR PARTS. Repair parts and equipment are listed and illustrated in the Repair Parts and Special Tools List
manual covering the intermediate, direct, general support and depot maintenance for the generator set.
2-2. TOOLS AND EQUIPMENT. Tools and equipment are listed in the Repair Parts and Special Tools List manual
covering the intermediate, direct, general support, and depot maintenance for the generator set.
2-3. SPECIAL TOOLS, TEST, AND SUPPORT EQUIPMENT. Special tools, test, and support equipment are listed in
Table 2-1.
Section II. TROUBLESHOOTING
2-4. This section contains troubleshooting information for locating and correcting operating troubles which may develop
in the generator set. Each malfunction for an individual component unit, or system is followed by a list of tests or
inspections which will help you to determine probable causes and corrective actions to take. You should perform the
tests/inspections and corrective actions in the order listed.
2-5. This manual cannot list all malfunctions that may occur, nor all tests or inspections and corrective actions. If a
malfunction is not listed or cannot be corrected by listed corrective action, notify your supervisor.
2-6. Indicated malfunctions are those beyond the capacity of the generator set fault indicator panel. Generator set fault
indicators should always be checked prior to troubleshooting.
SECTION III. GENERAL MAINTENANCE
2-7. GENERAL. This section contains general instructions on repair practices such as cleaning, connecting and
disconnecting wires, soldering, and welding.
WARNING
COMPRESSED AIR USED FOR CLEANING AND DRYING PURPOSES CAN CREATE AIRBORNE
PARTICLES THAT MAY ENTER THE EYES. PRESSURE SHALL NOT EXCEED 30 PSIG AND USE
ONLY WITH ADEQUATE CHIP GUARDS AND CHIPPING GOGGLES.
2-8. CLEANING. Components may be cleaned with low pressure compressed air, then wiped clean with a dry, lint-free
cloth. Components may also be cleaned with a cloth dampened in cleaning solvent, Federal Specification P-D-680.
2-9. WIRING. Tag all wires and cables during removal procedure for correct identification during replacement
procedures. Before a part is unsoldered, note the position of the leads. If the part has several leads, tag each of the
leads before unsoldering any of them. If wiring must be replaced, use leads of the same length and gauge. Never use
replacement wire with a higher gauge number (smaller diameter).
2-10. SOLDERING. On printed circuit boards, use a pencil-type soldering iron with a 25-watt maximum heating
capacity. Make well-soldered connections, using no more solder than is necessary. Do not allow drops of solder to fall
into the unit. Do not allow a soldering iron to come into contact with insulation or other parts that may be damaged by
excessive heat. Do not disturb the setting of any
2-1
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uncalibrated control without pre-determining its proper setting prior to reengergizing the equipment.
2-11. WELDING. Proper preparation is an important factor in welding, reference TM9-237. Edges to be joined must be
clean. Necessary arrangements for holding parts in proper alignment during welding should be made. Oil, grease, paint,
or foreign matter of any kind must be removed. With edges properly prepared for welding, the steps should be taken to
make certain that the finished job will be in correct alignment.
Table 2-1. Special Tools, Test, and Support Equipment
ITEM
NSN or
REFERENCE NO.
REFERENCE
FIG NO.
PARA NO.
USE
Test stand, injector
leakage
ST-990
13-17
13-13
Test injectors
Plunger extension
ST-1089
-
13-13
Disassemble injectors
Spray angle tester
ST-668
13-18
13-13
Test injectors
Test stand, injector
ST-790
13-19
13-13
Test injectors
Holding fixture
ST-1298
-
13-13
Disassemble injectors
Retainer wrench
ST-995
-
13-13
Disassemble injectors
Crowfoot wrench
ST-1072
-
13-13
Disassemble injectors
Injector sleeve cutter
ST-884
-
13-27
Rebuilding of
cylinder head
Adapter wrench
ST-890
-
13-27
Rebuilding of
cylinder head
Hydrostatic tester
ST-1012
-
13-27
Hydrostatic test test
of cylinder head
Rod checking fixture
ST-561
-
13-33
Check piston rod
alignment
Puller
ST-647
-
13-17
Pull water pump
impeller
Ream Fixture
ST-490
-
13-14
Overhaul fuel pump
Injector sleeve holding
ST-1179
-
13-27
Hydrostatic test of
cylinder head
Valve seat insert cutter
set
ST-662
-
13-27
Rebuilding of
cylinder head
Fuel pump spring pack
adjusting tool
ST-984
-
13-14
Adjust governor
spring pack
Oil seal assembly tool
ST-419
-
13-8 and
13-10
Assemble tachometer
drive
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Table 2-1. Special Tools, Test, and Support Equipment (Cont'd)
ITEM
NSN or
REFERENCE NO.
REFERENCE
FIG NO.
PARA NO.
USE
Test stand, fuel pump
ST-848
13-26
13-14
Test fuel pump
Gear pump block plate
ST-884
-
13-14
Test gear pump
Test stand, governor
8909-032
-
12-2
Test and repair of
electric hydraulic
actuator
Centering box
8909-038
-
12-5
Test and repair of
electric hydraulic
actuator
Electronic counter
8959-028
-
12-5
Test and repair of
electric hydraulic
actuator
Magnetic pickup
8959-031
-
12-5
Test and repair of
electric hydraulic
actuator
Pilot valve wrench
370109
12-5
12-5
Test and repair of
electric hydraulic
actuator
Gauss meter, bell
110-A
-
12-6
Test and repair of
electric hydraulic
actuator
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Table 2-2. Generator Set, Troubleshooting
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1. ENGINE FAILS TO CRANK WHEN MASTER SWITCH IS MOVED TO START.
Move MASTER SWITCH to start. If the starter motor cranks and the engine does not turn over, the starter motor
gear is not engaging the engine's ring gear (flywheel).
Remove starter motor and test in accordance with paragraph 13-5/13-6
Inspect teeth of the ring gear (at the point where the starter motor was mounted). If the teeth have
broken off, replace the ring gear (refer to paragraph 13-22).
2. ENGINE CRANKS AT NORMAL SPEED BUT WILL NOT START
As engine is being cranked check position of the throttle arm on fuel injection pump.
If throttle arm is in no fuel position (toward the right), stop cranking. Disconnect electrical connector from
top of hydraulic governor. (This will allow the hydraulic governor to operate in its mechanical mode, free
of any control from governor controller A106.) Recrank engine. If engine starts, then A106 should be
tested and repaired as required (see paragraph 4-11).
If engine still does not start, disconnect one end of linkage between throttle arm and hydraulic governor.
Recrank engine as throttle arm is manually (and slowly) brought toward full fuel position (toward left). If
engine starts, hydraulic governor is probably at fault and should be checked and repaired as required
(see paragraph 12-2). If engine does not start, the fuel injection pump should be tested and repaired as
required (see paragraph 13-14).
3. ENGINE SHUTS DOWN SOON AFTER STARTING
Crank engine. As engine is being cranked check position of throttle arm on fuel injection pump.
If throttle arm is in no fuel position (toward the right), stop cranking. Disconnect electrical connector from
top of hydraulic governor. (This will allow the hydraulic governor to operate in its mechanical mode, free
of any control from governor controller A106.) Recrank engine. If engine starts, then A106 should be
tested and repaired as required (see paragraph 4-11).
If engine still does not start, disconnect one end of linkage between throttle arm and hydraulic governor.
Recrank engine as throttle arm is manually (and slowly) brought toward full fuel position (toward left). If
engine starts hydraulic governor is probably at fault and should be checked and repaired as required
(refer to paragraph 12-2). If engine does not start, the fuel injection pump should be tested and repaired
as required. Adjust in accordance with paragraph 12-3.
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Table 2-2. Generator Set, Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
4. ENGINE RUNS ERRATICALLY OR MISFIRES
Step 1. Check fuel lines into and out of the fuel injection pump for damage, blockage, or air leaks.
Air leaks occurring at any point prior to the fuel injection pump will cause erratic engine operation. Air
leaks are difficult to detect and a trial-and-error approach may be necessary. Check for loose fittings and
defective fuel filter gaskets. Placing a fairly heavy oil around a suspected fitting may reveal the
presence of air leaks. The oil would be sucked, quite noticeably, into the fuel line if air leaks are present.
Step 2. Check the engine's exhaust ports for presence of blackish smoke (unburnt fuel).
If present, note if smoke is coming from left or right exhaust port. If the left port is the source, it may be
assumed that one of the fuel injectors or cylinders on the left side of the engine is malfunctioning.
Stop engine and remove the valve cover associated with suspected side of engine (see Chapter 13).
Restart engine. Visually inspect valves, rocker arms, and push rods for improper or misadjusted
operation.
If, for example, one push rod appears bent, the associated rocker arm will not travel as far as adjacent
rocker arms and the corresponding valve not fully open. Thus, by comparing the motion of one rocker
arm to other rocker arms, a faulty rocker arm or push rod would be immediately apparent.
Step 3. Check KW and KVAR readings on Generator Control Panel.
If readings indicate excessive power draw, rearrange load distribution to restore normal power
consumption.
If readings indicate excessive power draw, rearrange load distribution to restore normal power
consumption.
If KW and KVAR readings are normal, refer to Chapter 13 on engine assembly testing.
5. GENERATOR OUTPUT FREQUENCY INCORRECT
Step 1. Inspect motor-operated potentiometer B4 (2, figure 4-10) according to paragraph 4-21 and refer to paragraph
4-23 for testing and replacement procedures.
Step 2. Stop engine. Unplug electrical connector from top of hydraulic governor, disconnecting output of A106.
Start engine.
If generator output is at correct frequency, governor controller A106 should be tested and repaired as
required (see paragraph 4-11).
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Table 2-2. Generator Set, Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Step 3.
Disconnect linkage between throttle arm (of fuel injection pump) and hydraulic governor. Set throttle arm
to mid-position and start engine. Adjust the throttle arm for correct generator output frequency.
If it is possible to adjust throttle for correct frequency, hydraulic governor should be tested and repaired
as required.
6. GENERATOR OUTPUT VOLTAGE INCORRECT OR FLUCTUATING.
Step 1.
Inspect motor-operated potentiometer B5 (4, figure 4-10) according to paragraph 4-21 and refer to
paragraph 4-23 for testing and replacement procedures.
Step 2.
Shut down engine. Disconnect and tag exciter field leads from F- and F+ terminals of voltage regulator
VR101. Observing polarity, connect exciter field leads to DC power supply (adjustable from 0 to 20 volts
and capable of delivering 2 amperes). Start engine. Adjust power supply for required generator output
voltage (as indicated on generator control panel).
If it is possible to obtain correct generator output voltage, proceed to next step.
If generator output voltage is still incorrect, generator should be tested and repaired as required. (see
Chapter 11).
Step 3.
Check PM generator output terminals 3 and 4 of VR1; voltage should be 135V AC + 15 percent.
If voltage is out of tolerance, disconnect leads from terminals 3 and 4 and recheck voltage at open leads
coming from generator.
If voltage is within tolerance, voltage regulator VR101 should be tested and repaired as required (see
Chapter 4, Section V).
If voltage is still out of tolerance, PM generator (part of main generator G1) should be tested and
repaired as required (see Chapter 11).
Section IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
2-12. GENERAL. This section contains procedures for the removal and installation of major components. Major
components include the control cubicle, AC-DC control box assembly, external power box assembly, radiator assembly,
generator, and the engine.
2-13. CONTROL CUBICLE. The control cubicle, figure 2-1, is mounted on four brackets attached on one side to the
AC-DC control box assembly, and on the other side, to the external power box assembly.
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a. Removal
(1)
If generator set has a housing, remove left and right access doors in accordance with Chapter 15.
(2)
Disconnect electric connectors J1 through J6 at rear of control cubicle.
(3)
Remove screws, nuts, and lockwashers, between brackets and control cubicle.
brackets from AC-DC control box assembly and external power box assembly.
(4)
Using a hoist, remove control cubicle by sliding out over bottom brackets.
Do not remove bottom
WARNING
OVERHEAD OPERATIONS HAVE INHERENT HAZARDS THAT CANNOT BE MECHANICALLY
SAFEGUARDED. HARD HATS AND SAFETY SHOES ARE REQUIRED.
b. Installation
(1)
Using a suitable hoist, line up unit on brackets (two on each side) and slide unit in.
(2)
Attach screws, nuts, and washers from control cubicle to each of the four angle brackets.
(3)
Connect electrical connectors to J1 through J6 at rear of control cubicle.
(4)
If generator set had a housing, replace left and right access doors in accordance with Chapter 15.
2-14. AC-DC CONTROL BOX ASSEMBLY. The AC-DC control box assembly, figure 2-2, is mounted on the left side of
the control cubicle
a. Removal
(1)
If generator set has a housing, remove left rear panel in accordance with Chapter 15.
(2)
Disconnect electrical connectors J5, J6, J26, J27, and J31 on enclosure assembly. Tag and disconnect
terminals of the shielded cable assembly, loosen adapter then remove shielded cable from AC-DC control box.
(3)
Remove screws, washers, and nuts attaching AC-DC control box assembly to the support frame upright.
(4)
Remove screws, washers, and nuts attaching AC-DC control box assembly base to the brackets on skid base.
(5)
Remove control cubicle per paragraph 2-13.a.
(6)
Using a hoist, remove AC-DC control box assembly.
b. Installation
(1)
Secure all generator set wiring and cables in vicinity of AC-DC control box assembly location.
(2)
Using a suitable hoist, locate unit on skid and attach to skid with screws, washers, and nuts (see figure 2-2)
(3)
Similarly, attach screws, washers, and nuts from unit to frame support upright.
(4)
Install control cubicle per paragraph 2-13 b.
(5)
Connect electrical connectors to J5, J6, J26, J27, and J31 on enclosure assembly. Connect terminals of
shielded cable assembly, remove tags, and tighten adapter.
(6)
If generator set has a housing, replace left rear panel in accordance with Chapter 15.
2-15. EXTERNAL POWER BOX ASSEMBLY.
The external power box assembly, figure 2-3, is mounted at the right of the control cubicle.
a. Removal
(1)
If generator set has a housing, remove left rear
2-7
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Figure 2-1. Location of Major Components
2-8
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Figure 2-2. AC-DC Control Box Assembly, Removal and Installation
WARNING
OVERHEAD OPERATIONS HAVE INHERENT HAZARDS THAT CANNOT BE MECHANICALLY
SAFEGUARDED. HARD HATS AND SAFETY SHOES ARE REQUIRED.
panel in accordance with Chapter 15.
(2)
Referring to figure 2-3, remove all screws, washers, and nuts attaching reconnection box and enclosure to the
external power box assembly.
(3)
Disconnect and tag all cables from reconnection box, circuit breaker, and cable tiedown at base of external
power box assembly.
(4)
Remove cables through sleeves and at front of generator set.
(5)
Disconnect electrical connectors J27 through J31 (and J32, if generator set is equipped with housing).
(6)
Disconnect buss bars (39, 42, and 45, figure 11-1) from the circuit breaker by removing screws, washers, and
nuts that attach bars to
2-9
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Figure 2-3. External Power Box Assembly, Removal and
Installation (Sheet 1 of 2)
NOTE
Be careful not to tear off cable tags in process.
circuit breaker. Also, remove bolts, washers and nuts that secure buss bars to vertical buss bars in
reconnection box. Remove bars through slot in external power box.
(7)
Referring to figure 2-3, remove screws, washers, and nuts attaching external power box assembly to the frame
support upright.
(8)
Remove screws, washers, and nuts attaching bottom of the external power box assembly to skid base.
WARNING
OVERHEAD OPERATIONS HAVE INHERENT HAZARDS THAT CANNOT BE MECHANICALLY
SAFEGUARDED. HARD HATS AND SAFETY SHOES ARE REQUIRED.
(9)
Remove control cable per paragraph 2-13.
(10) Using hoist, remove external power box assembly.
b. Installation
(1)
Attach suitable hoist to the external power box assembly.
2-10
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Figure 2-3. External Power Box Assembly, Removal and
Installation (Sheet 2 of 2)
(2)
Secure all generator set electrical cables in vicinity of installation.
(3)
Locate external power box assembly and attach screws, washers, and nuts at bottom of unit to the skid base
(see figure 2-3).
(4)
Attach screws, washers, and nuts securing unit to frame support upright (see figure 2-3).
(5)
Install control cable per paragraph 2-13 b.
(6)
Connect electrical connectors J27 through J31 (and J32, if equipped with a housing).
(7)
Thread heavy electrical cables through sleeves (on front) through unit, and connect to the reconnection box
and circuit breaker. Secure cable tiedowns, as required.
(8)
Attach screws, washers, and nuts securing unit to reconnection box and enclosure (see figure 2-3).
2-11
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(9)
Attach buss bars (39, 42, and 45, figure 11-1) to circuit breaker using screws, washers, and nuts. Secure
opposite ends of buss bars to vertical buss bars in reconnection box.
(10) If generator set has a housing, replace right side panel in accordance with Chapter 15.
2-16. RADIATOR ASSEMBLY.
a. Removal. The complete radiator assembly is removed from generator set in accordance with paragraph 7-3 a or 77 a.
b. Installation. Install radiator assembly in accordance with paragraph 7-3 b or 7-7 b and torque screws as shown in
figure 2-4.
2-17. GENERATOR.
a. Removal. Remove generator in accordance with paragraph 11-5 b(1).
b. Installation. Install generator in accordance with paragraph 11-5 b(2).
2-18. ENGINE.
a. Removal.
(1)
Drain the engine cooling and lube systems and hydraulic sump as instructed in the Operator/Crew and
Organizational Maintenance Manual.
(2)
Disconnect the batteries.
(3)
Disconnect the exhaust breather pipes from engine.
(4)
Disconnect and remove air cleaner assembly hoses from two air shutdown valves.
(5)
Disconnect and remove two hoses between air shutdown valves and turbochargers.
(6)
Disconnect and remove two exhaust hoses from the turbochargers.
(7)
Disconnect all cooling system hoses.
(8)
Disconnect interconnecting wiring harnesses. Be sure to tag all wires.
(9)
Tag and disconnect fuel lines.
(10) Uncouple generator from engine in accordance with paragraph 11-5 b. Disengage coupling from engine by
backing off the generator.
(11) Remove engine mounting bolts (see figure 2-5).
WARNING
CLEAR AREA OF PERSONNEL AND OTHER EQUIPMENT WHEN ATTEMPTING TO LIFT THE
ENGINE.
(12) If the engine is to be removed with an overhead hoist or crane, proceed as follows:
(a) Remove roof panels in accordance with Chapter 15.
(b) Remove silencer frame tie bar and frame support bar (5 and 13, figure 6-1) in accordance with paragraph 6-2.
WARNING
OVERHEAD OPERATIONS HAVE INHERENT HAZARDS THAT CANNOT BE MECHANICALLY
SAFEGUARDED. HARD HATS AND SAFETY SHOES ARE REQUIRED.
(c) Attach a suitable lifting device of at least 10-ton capacity to the engine hoist brackets.
(d) Hoist engine up forward to clear generator and lift off skid base. Place engine on a suitable engine support
stand.
(13) If engine is to be removed with a forklift, proceed as follows:
2-12
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WARNING
LIFTING DEVICES, CABLES, AND/OR CHAINS SHOULD BE INSPECTED FOE DETERIORATION
OR DAMAGE BEFORE USE. A STABILIZING TETHER SHOULD BE ATTACHED BETWEEN THE
ENGINE AND LIFTING HOOK FOR ADDED SAFETY AND STA"ILIZATION WHEN LIFTING THE
UNIT.
Figure 2-4. Radiator Assembly, Removal and Installation
(a)
Remove the roof panels in accordance with Chapter 15.
(b)
Depending on the side from which the engine will be removed, remove the left or right side housing panels
and doors in accordance with Chapter 15.
(c)
Remove either vertical support frames (26 or 27), figure 6-1).
(d)
If necessary, remove the radiator fan belt (code A only) and radiator fan motor (paragraph 7-3), if the engine
will be removed from the right side.
2-13
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(e) Using a forklift of at least 10-ton capacity, lift engine off skid base and place engine on a suitable engine stand.
b. Installation.
WARNING
CLEAR AREA OF PERSONNEL AND OTHER EQUIPMENT WHEN ATTEMPTING TO LIFT THE
ENGINE.
(1)
If engine will be installed with an overhead crane or hoist, proceed as follows:
(a) Remove housing roof panels and silencer frame tie bar and support tie bar and support if these components
were installed after engine removal.
WARNING
OVERHEAD OPERATIONS HAVE INHERENT HAZARDS THAT CANNOT BE MECHANICALLY
SAFEGUARDED. HARD HATS AND SAFETY SHOES ARE REQUIRED.
(b) Attach a suitable lifting device of at least 10-ton capacity to the engine hoist brackets.
WARNING
LIFTING DEVICES, CABLES, AND/OR CHAINS SHOULD BE INSPECTED FOR DETERIORATION
OR DAMAGE BEFORE USE. A STABILIZING TETHER SHOULD BE ATTACHED BETWEEN THE
ENGINE AND LIFTING HOOK FOR ADDED SAFETY AND STABILIZATION WHEN LIFTING THE
UNIT.
(c) Position engine on skid base and couple engine to generator. Align in accordance with paragraph 11-5 b(2).
(d) Reinstall housing roof panels and silencer frame tie bar.
(2)
If engine will be installed with a forklift proceed as follows:
(a) Remove housing roof panels, side panels and doors, and vertical support frames if these components were
reinstalled after engine removal.
(b) Using a forklift of at least 10-ton capacity, mount engine on skid base and align with generator in accordance
with paragraph 11-5 b(2).
(c) Reinstall housing roof panels, side panels and doors, and vertical support frames.
(3)
Secure engine with engine mounting bolts.
(4)
Install radiator fan motor and fan belts as required.
(5)
Reconnect fuel lines, coolant hoses, and all electrical wiring harness connections. Remove wire tags after
making connections.
(6)
Connect hoses to air cleaners, air shutoff valves, and turbochargers.
(7)
Connect exhaust breather pipes.
(8)
Replace coolant and fill to proper level check for leaks
(9)
Fill engine crankcase with proper lubricant. Check dipstick level at crankcase and governor pump.
(10) Reconnect batteries.
2-14
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Figure 2-5. Engine, Removal and Installation.
2-15/(2-16 blank)
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CHAPTER 3
MAINTENANCE OF EXTERNAL POWER ASSEMBLY
3-1. PREHEAT SYSTEMS CONTACTOR K107 AND HEATER CONTACTOR K109
a. Removal. Refer to Operator/Crew and Organizational Maintenance manual for removal of preheat system
contactor K107 (54, figure 3-1) and heater contactor K109 (54, figure 3-1).
b. Repair. (See figure 3-2.) Repair preheat system contactor K107 (54, figure 3-1) by replacing contacts, armature,
and coil, as follows:
(1)
Remove screws (1, figure 3-2) and cover (2). Disconnect wires from coil terminals. Remove coil (4) and
magnet assembly (3).
(2)
Separate the coil (4) from the magnet assembly (3).
NOTE
Contacts are not harmed by slight discoloration and pitting. Do not file them. Replacement is
necessary only when the contact has worn thin.
(4)
To replace movable contacts (6), place contactor (nameplate down) on a flat surface and insert a replacement
movable contact finger.
3-2. CONTACTOR K108
a. Removal. Refer to Operator/Crew and Organizational Maintenance manual for removal of preheat system transfer
contactor K108 (51, figure 3-1).
b. Repair. (See figure 3-3.) Repair transfer contactor K108 (51, figure 3-1) by replacing contacts, armature and coil in
each contactor, as follows:
(1)
Remove screws (3, figure 3-3) and cover (4). Disconnect wires from coil terminals. Remove coil (6) from the
magnet assembly (5).
(2)
Separate the coil (6) from the magnet assembly (5).
NOTE
Recommended driving torques for items 3 and 7 are 18 to 21 inch-pounds (2 to 2.4 joules).
(3)
When replacing coil (6) the magnet must be installed with the word FRONT appearing as shown in figure 3-3.
NOTE
Contacts are not harmed by slight discoloration and slight pitting.
Replacement is necessary when the contact is worn thin.
(4)
Do not file them.
Remove screws (7) on power plant. Replace movable contacts (8) by placing contactor (nameplate down) on a
flat surface and inserting replacement movable contact fingers.
3-3. CONTACTOR K120
a. Removal. Refer to Operator/Crew and Organizational Maintenance manual for removal of motor contactor (57,
figure 3-1).
b. Test. Make test connections to motor contactor K120 as shown in figure 3-4.
(1)
Set switch to on and adjust variable load to provide 1000 watt load. Ammeter should read approximately 8.3
amps.
(2)
Set switch to off.
(3)
Connect jumper across L1 and L2 terminals.
(4)
Remove and reconnect load to terminals X2 and T2.
(5)
Set switch to on. Ammeter
3-1
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 3-1. External Power Box Assembly, Exploded View
3-2
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND FOR FIGURE 3-1
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.
Screw
Nut
Space bar
Panel control assy
Weather stripping
Screw
Plate and sleeve assy
Screw
Neutral bar assy
Screw
Nut
Lockwasher
Washer
Compression lug
Plate
Bracket
Screw
Lockwasher
Compression lug
Locknut
Washer
Connector
Screw
Nut
Cover
Screw
Nut
Screw
Nut
Screw
Clamp
Screw
Clamp
34.
35.
36.
37.
38.
39.
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
Harness Assy
Screw
36A. Washer
Bolt
Lockwasher
Nut
Buss bar
Buss bar
Buss bar
Screw
Circuit breaker
Screw
Terminal board
Screw
Terminal board
Screw
Lockwasher
Transfer contactor K108
Screw
Lockwasher
Heater contactor K107 & K109
Screw
Lockwasher
Motor starter K120
Screw
Spacer
Terminal block assy
Nut
Lockwasher
Washer
Nut
Bolt
Terminal block
67.
68.
69.
70.
71
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
93.
94.
95.
96.
97.
98.
99.
Terminal block assy
Nut
Lockwasher
Washer
Jam nut
Bolt
Terminal block
Bushing
Bushing
Screw
Lockwasher
Clamp assy
Cushion
Clamp
Screw
Washer
Nut
Relay board assy
Screw
Lockwasher
Screw
Washer
Lockwasher
Nut
Screw
Lockwasher
Nut
Box and door assy
Screw
Nut
Door assy
Seal
Enclosure
should read approximately 8.3 amps.
(6)
Set switch to off.
(7)
Remove and reconnect jumper across L1 and L3.
(8)
Remove and reconnect load to X2 and T3 terminals.
(9)
Set switch to on. Ammeter should read approximately 8.3 amps.
(10) Slowly increase load to 4260 watts. Ammeter should read 35.5 amps and relay should trip between 4260 watts
(35.5 amps) to 4584 watts (38.2 amps)
(11) Set switch to off and reset overload handle.
(12) Adjust variable load to zero load.
(13) Set switch to on.
(14) Adjust variable load for 1000 watt load. Ammeter should read 8.3 amps.
(15) If ammeter readings are erratic, contacts are worn or badly pitted and should be replaced. If there is no
reading, armature, coil, or contacts may be defective and should be replaced. If overload relay does not trip at
specified load, replace overload assembly.
c. Repair. (See figure 3-4.) Repair motor contactor K120 (57, figure 3-1) by replacing contacts, armature, overload
assembly, and coil, as follows:
(1)
Remove screws (1, figure 3-4) and cover (2). Disconnect wires and magnet assembly (3).
3-3
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(2)
Separate the coil (4) from the magnet assembly (3).
(3)
When replacing coil (4) the magnet must be installed with the word FRONT appearing as shown in figure 3-4.
NOTE
Recommended driving torques for items 1, 5, and 7 are 18 to 21 inch-pounds (2 to 2.4 joules), and
item 6 is 6 to 9 inch-pounds (0.7 to 1 joules).
(4)
Remove and replace overload assembly (8) by removing screws (7).
NOTE
Contacts are not harmed by light discoloration and slight pitting. Do not file them. Replacement
is necessary only when the contact has worn thin.
(5)
To replace movable contacts (6), place contactor (nameplate down) on a flat surface and insert a replacement
movable contact finger.
Figure 3-2. Preheat System Contactor K107
and Heater Contactor K109, Exploded View
3-4
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 3-3. Transfer Contactor K108, Exploded View
LEGEND FOR FIGURE 3-4
1.
2.
3.
Screw
Cover
Magnet assy
4.
5.
6.
Coil
Screw
Contact kit
3-5
7.
8.
9.
Screw
Overload assy
Reset Bar
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 3-4. Contactor K120 Exploded View and Test Setup
3-6
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
CHAPTER 4
MAINTENANCE OF AC-DC CONTROL BOX ASSEMBLY
Section I. ENCLOSURE COMPONENTS
4-1. FUEL TRANSFER PUMP RELAY K20.
(3) Close the SPST switch. Ohmmeter should
show continuity.
a. Replacement. (See figure 4-1.) The fuel transfer
pump relay K20, (33, figure 4-1) is mounted on the right
side wall of the AC-DC control box assembly. It is
removed as follows:
(4) Open the SPST switch. Connect ohmmeter
to the smaller terminals. Meter should read
approximately 60 ohms.
WARNING
4-2. TERMINAL BOARD.
BEFORE
STARTING
ANY
MAINTENANCE PROCEDURE, SET
MAINTENANCE LOCKOUT SWITCH
TO
LOCKOUT.
DISCONNECT
NEGATIVE
CABLE
FROM
BATTERIES. REMOVE EXTERNAL
POWER
BY
OPENING
CB101
(EXTERNAL
POWER
CIRCUIT
BREAKER) AND DISCONNECTING
POWER CABLE FROM RECEPTACLE
J101 (120V RECEPTABLE).
4-3. REPLACEMENET. The six terminal boards (26
and 30, figure 4-1) are mounted on the right side wall of
the enclosure (75). Replace as follows:
a. Removal. Tag and remove leads. Remove each
terminal board (26 and 30) by removing two screws (24
or 28) and nuts (25 or 29).
NOTE
Diode (28) may also be tagged and
disconnected from terminal board
(30) at this time.
(1) Open door of AC-DC control box assembly
to gain access.
(2) Remove and tag wires connected to the
relay.
b. Replacement. Replace terminal board (26 or 30)
on the enclosure side wall by attaching two screws (24)
and nuts (25). Install diode (28) on terminal board (30)
and remove tags.
(3) Remove two screws (31) and nuts (32).
Remove relay (33).
4-4. RESISTOR R116. Resistor R116 (38, figure 4-1)
is located on the right side wall of the enclosure (75).
(4) Install relay (33) by mounting it to the side
wall of the enclosure with two screws (31)
and nuts (32).
a. Test. Disconnect either lead from resistor (38).
With an ohmmeter (set Rx1 scale) measure resistance.
It should be 5 ohms ±1 ohm. If not, replace.
b. Replacement.
(5) Connect wires and remove tags.
(1) Remove two nuts (35, figure 4-1) which
secure resistor lugs (36) to the standoff (37).
Then remove resistor (38) from clip (41) and
separate lugs (36) from lead
a. Testing
(1) Connect 24V DC to the small terminals on
the contactor in series with a SPST switch
as shown in figure 4-2.
(2) Connect ohmmeter (Rx1) scale to the larger
terminals of the contactor.
4-1
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
wire.
(2)
Crimp lugs on lead wires, then install resistor (38) into clip (41). Secure lugs (36) to standoff (37) with nuts
(35).
Section II. BATTERY CHARGER
4-5. GENERAL. This section covers inspection, replacement, testing, and repair of the battery charger.
4-6. DESCRIPTION. The battery charger transforms 120V AC to 24V DC at 20 amperes to charge the generator set
batteries. It automatically senses the condition of the batteries and delivers the amount of current required to keep the
batteries fully charged. The battery charger has a built-in cut out relay to prevent battery drain in the event of an AC
power failure. Figure 4-3 is the battery charger schematic.
4-7. INSPECTION. Check battery charger input and output cable connections for looseness or corrosion. Check all
components for loose mounting, poor solder connections, broken wires, overheated resistors, or any other signs of
damage.
4-8. REMOVAL AND REPLACEMENT.
a. Removal. (See figure 4-1.) The battery charger (45, figure 4-1) is mounted to the right side wall of the AC-DC
control box assembly enclosure. Open door (73) and remove as follows:
WARNING
BEFORE STARTING ANY MAINTENANCE PROCEDURE, SET MAINTENANCE LOCK-OUT SWITCH
TO LOCKOUT. DISCONNECT NEGATIVE CABLE FROM BATTERIES. REMOVE EXTERNAL
POWER BY OPENING CB101 (EXTERNAL POWER CIRCUIT BREAKER) AND DISCONNECTING
POWER CABLE FROM RECEPTACLE J101 (120V RECEPTACLE).
(1)
Open battery charger door.
Legend For Figure 4-1
1. Screw
2. Nut/washer
3. Ac-dc panel
4. Spacer bar
5. Stripping
6. Screw
7. Cover
8. Connector
9. Washer
10. Nut
11. Screw/washer
12. Nut
13. Screw, washer
14. Nut
15. Screw
16. Nut/washer
17. Clamp
18. Clamp
19. Clamp
20. Clamp
21. Screw/washer
22. Clamp
23 Harness
24. Screw
25. Nut/washer
26. Terminal block
26A.Jumper
27. Diode
27A.Lug
28. Screw
29. Nut/washer
30. Terminal block
31. Screw
32. Nut
33. Relay K20
34. Screw
35. Nut
36. Lug
37. Standoff
38. Resistor
39. Screw
40. Nut
41. Clip
42. Screw
43. Panel
44. Screw/washer
45. Battery charger
46. Screw
47. Washer
48. Voltage Regulator
49. Screw
50. Nut
51. Clamp
52. Screw
53. Nut
53A.Resistor assembly
54. Potentiometer
55. Lock
56. Governor
57. Sleeve
4-2
57A.Lug
58A.Washer
59. Screw
60. Clip
61. Screw/washer
62. Bracket
63. Screw
64. Washer
65. Washer
66. Nut
67. Screw
67A.Washer
68. Washer
69. Nut
70. Ac-dc box
71. Screw
72. Nut
73. Door assembly
74. Seal
75. Enclosure assembly
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 4-1. AC-DC Control Box Assembly, Exploded View
4-3
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 4-2. Fuel Transfer Pump Relay K20, Test Setup
and tag and disconnect input and output cables on terminal boards.
(2)
Remove six screws (44) supporting battery charger to wall. Remove battery charger.
b. Replacement.
(1)
Install battery charger (45, figure 4-1), to the enclosure with six screws.
(2)
Connect cables to terminals inside the battery charger.
OUTPUT connections. Remove tags.
Be sure to observe polarity, POS and NEG on
4-9. TESTING. (See figure 4-3) The ground test may be performed without removing the battery charger from the set.
Other tests are bench test procedures.
a. Ground or Short Circuit. Using an ohmmeter, check for a short to ground, primary to secondary breakdown, AC-DC
short, or DC ground as follows:
NOTE
Check fuses F1, F2, F3, and F4 for continuity.
(1)
With all power off, disconnect AC input power to INPUT connections on the unit. Disconnect the generator set
negative battery cable.
(2)
Set ohmmeter scale on ohms Rx100.
(3)
Measure from either INPUT terminal to either terminal of the OUTPUT. Meter should not indicate a reading. If
the meter reads full scale deflection, this indicates a
4-4
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
possible AC-DC short.
(4)
Carefully inspect the wiring to make certain the AC wires are not touching the DC wires. If no wires are
touching, the primary and secondary of transformer T1 or reactor T2 may be shorted. Disconnect the
secondary of transformer T1 from the diodes CR1 and CR2. Measure with ohmmeter from INPUT terminal to
one of the transformer T1 secondary leads. If there is an ohm-meter indication, there is an insulation
breakdown between primary and secondary windings. The transformer should be replaced.
(5)
Check both INPUT terminals to ground (chassis), and check both OUTPUT terminals to ground. If the meter
indicates full-scale deflection, a wire is touching ground.
b. Diodes.
(1)
Test silicon diodes (CR1 and CR2) as follows:
(a) Disconnect one end of the diode.
(b) Connect an ohmmeter (scale set Rx100) across the diode, note the reading. Now reverse ohmmeter leads to
the diode, and again note reading. A good diode will read high resistance one way and low resistance the other
way. A shorted diode will read full scale both ways. An open diode will read infinity (no reading) in either
direction. Check all diodes and replace disconnected leads.
(2)
Test zener diode (CR4) as follows (see figure 4-3):
(a) Connect a 20-40V DC variable power source to the battery charger.
(b) Connect a voltmeter across the zener diode (CR4) and resistor R1.
(c) Voltmeter must read only 22 volts while input voltage is varied from 20 to 30 volts DC.
c. Cutout Relay. Test the cutout relay (54, figure 4-4) as follows. See detail in figure 4-3.
(1)
Connect a 120V AC source with a SPST switch (S1) as shown.
(2)
With S1 closed, using an ohmmeter, check for continuity between contacts 3 and 6.
(3)
Open switch and disconnect 120V AC.
d. Transistor Control Circuit. (See figures 4-3 and 4-4.)
(1)
With power disconnect from battery charger, remove fuse F3. Connect a DC ammeter (0 to 50 amps) across
fuse holder.
(2)
Connect 120V AC input power to battery charger and record ammeter reading. Remove input power.
(3)
Remove two wires from T2 (46, figure 4-4) and Q1 (68) connected to terminal 1 of TB1 (65).
(4)
Temporarily connect these two wires together using a jumper.
(5)
Connect 120V AC input power to battery charger.
(6)
Record ammeter reading. If the reading is higher than reading recorded in step (2), the transistor control circuit
may be defective. Check CR4 (69), (paragraph b(2), above) and check for open resistor R1 (74). If CR4 and
R1 are not defective, replace transistor Q1 (68).
(7)
Remove ammeter from fuse
4-5
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
holder. Remove jumpers on relay K1. Replace wires from T2 and Q1 on terminal a and TB1. Replace fuse
F3.
e.
Dummy Load Test for Battery Charger.
(1)
Connect input of battery charger to 120V AC and output to two capacitors (1 and 2) and one resistor (3) in
parallel (see figure 4-3).
(2)
Connect an ammeter as shown. Ammeter reading must be 24 amps.
(3)
Connect a second resistor (4) in parallel.
(4)
Connect ammeter as shown. Ammeter reading must be 24 amps.
(5)
If battery charger does not provide correct amperage, it is defective and must be repaired or replaced.
4-10. REPAIR. Repair of the battery charger involves the replacement of parts and the soldering of wire leads.
a.
Adjustment of Variable Resistors. (See figure 4-3.) In the event that R1, R2, or R4 variable resistors are found to
be defective, and are replaced, readjust resistors in accordance with the following procedure:
(1)
Variable resistor R2 (9, figure 4-4).
(a)
Connect 120V AC to INPUT terminals of battery charger.
(b)
Connect a fully discharged 24V DC battery to OUTPUT POS and NEG terminals in battery charger.
(c)
Remove fuse F3. Connect an ammeter (0 to 50 amps) across fuse F3 fuseholder terminals.
(d)
Adjust R2 so that the battery charger current does not exceed 24 amps.
(2)
Variable resistor R4 (17, figure 4-4).
(a)
Connect 120V AC to INPUT terminals of battery charger.
(b)
Connect OUTPUT POS and NEG terminals of battery charger to 24V DC battery.
(c)
Adjust R4 so that the battery charger output does not exceed 2.33 volts per cell.
(3)
b.
Variable resistor R1 (74, figure 4-4).
(a)
Connect 120V AC to INPUT terminals of battery charger.
(b)
Connect OUTPUT POS and NEG terminals of battery charger to 24V DC battery.
(c)
Adjust R1 so that the battery charger total output voltage (28 volts) does not vary more than 5 percent under
"no load" to "full" condition.
Disassembly. Disassemble the battery charger as follows (see figure 4-4):
NOTE
All components, except resistors (9 and 17), are mounted on plate at rear of battery charger.
(1)
Resistors (9) and (17) are removed by unsoldering and tagging leads, and removing nut (3), washers (4 and 7) and
stud (8) from brackets (5 and 6).
(2)
Fuse clips (32 and 35) are mounted on a board attached to transformer (41).
(3)
Control circuit components are mounted on a separate board attached to the mounting plate (78).
(4)
Relay (54) and capacitor
4-6
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 4-3. Battery Charger Schematic
4-7
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 4-4. Battery Charger, Exploded View
4-8
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Screw
Washer
Nut
Washer
Clip
Bracket
Washer
Stud
Resistor
Screw
Nut
Washer
Washer
Clip
Bracket
Rod
Resistor
Screw
Washer
Screw
Washer
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
Legend for Fig. 4-4
Nut
43. Nut
Washer
44. Washer
Washer
45. Washer
Screw
46. Reactor Assy
Fuse
47. Screw
Fuse
48. Screw
Nut
49. Washer
Washer
50. Washer
Screw
51. Surge
Washer
Protector
Clip
52. Nut
Nut
53. Bracket
Washer
54. Relay,
Clip
cut-out
Screw
55. Capacitor
Washer
56. Diode
Not Used
57. Heatsink
Screw
58. Screw
Washer
59. Nut
Transformer
60. Washer
Screw
61. Washer
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
Screw
Washer
Nut
Not Used
Screw
Washer
Transistor
Diode
Screw
Nut
Washer
Washer
Resistor
Terminal board
Grommet
Enclosure
Baseplate
Voltmeter
Ammeter
Switch
Control unit assy
(5) Reactor assembly (46) is mounted
assembly (55) are mounted with brackets
directly to mounting plate (78).
attached with heat sink (57) onto mounting
plate (78).
Section III. GOVERNOR CONTROLLER
4-11. GENERAL. The governor controller A106 (56,
figure 4-1) is the electronic portion of the load sharing
and speed control unit which is part of the electric
hydraulic governing system. The governor controller has
two major functions, speed control and load sharing. It
measures engine speed via a magnetic pickup and
compares it to a speed reference. It then feeds
corrections to the hydraulic actuator governor on the
engine. It also has a speed sensing fail safe circuit, and
a time ramp circuit (deceleration to idle speed acceleration to rated speed).
adjustments on the unit. These pots
are factory set on each controller.
4-12. INSPECTION. Inspect the governor controller
front panel by removing the access cover (7, figure 4-1),
paragraph 4-2. Inspect the connections on terminal
boards for loose wires, inspect the potentiometers for
signs of damage, and the control panel for scratches,
dents or other damage.
4-13.
ADJUSTMENTS.
The controller has eight
adjustment controls located on the front cover. Perform
the following adjustments whenever the unit is replaced.
NOTE
Do not adjust the DE-DROOP, RAMP
TIME,
and
LOW
IDLE
SPEED
4-9
a.
Disconnect F- and F+ leads on voltage
regulator.
b.
Set RATED SPEED (10T) potentiometer
fully counterclockwise, then rotate 4 turns
clockwise.
c.
Set the STABILITY, GAIN, LOAD GAIN,
and DROOP potentiometer to mid-range
positions.
d.
Toggle the FREQUENCY SELECTOR
switch on the AC-DC Control Panel to the
50 Hz position.
e.
Start the generator set.
f.
Adjust
the
RATED
SPEED
(10T)
potentiometer to obtain 50 Hz. Monitor the
FREQUENCY meter on the Control Cubicle.
g.
Toggle the FREQUENCY SELECTOR
TM5-6115-593-34
NAVFAC P-8-631-34
T0-35C2-3-463-2
switch to the 60 Hz position.
(2)
Referring to figure 4-1, remove the six
screws (52) and nuts (53) attaching
the governor controller (56) to
mounting bracket (62).
(3)
Remove potentiometer R103 (54)
from mounting bracket (62) by
removing shaftlock (55). Mounting
bracket (62) may be removed by
removing six screws (61).
h.
Loosen locknut and adjust R103 (54, figure
4-1) for 60 Hz operation. Monitor the
FREQUENCY meter on the Control Cubicle.
Tighten locknut (55).
i.
Proceed to normal operation of the set and
toggle the FREQUENCY SELECTOR switch
to the 50 or 60 Hz position depending on the
load requirement.
j.
Run the engine until the coolant
temperature has stabilized and is normal.
(1)
k.
Turn the GAIN potentiometer clockwise until
the generator set becomes unstable. Then
back off this adjustment until generator set
just becomes stable.
Attach potentiometer (54) onto
mounting bracket (62) with shaftlock
(55).
(2)
Replace mounting bracket (62) with
six screws (61).
Rotate the STABILITY potentiometer 1/4
turn counterclockwise.
(3)
Attach governor controller (56) to
mounting bracket (62) with six screws
(52) and nuts (53).
(4)
Connect wires to terminal boards. Be
sure to connect potentiometer (54)
leads to terminals 16 and 20.
Remove tags from wires. Replace
warning plate.
(5)
Perform adjustment procedures in
accordance with paragraph 4-13.
l.
b.
NOTE
The governor controller in the master
unit may have to be readjusted to
obtain a balanced load condition
between the master set and other units
in parallel operation. KW meters must
be monitored for equal readings
(proper load sharing).
4-14. REMOVAL AND REPLACEMENT. To gain
access to the governor controller, access panel must be
removed first, see paragraph 4-2.
4-15. TESTING. Bench testing is accomplished by
simulating various parameters connected to the unit.
The following items are required for the test setup: 20 to
40V DC source; 2 SPST switches; 35-ohm 10-watt
resistor; AC signal generator, capable of producing 60
Hz with 10 rms volts output; and a DC voltmeter to 25
volts.
WARNING
BEFORE
STARTING
ANY
MAINTENANCE PROCEDURE, SET
MAINTENANCE LOCKOUT SWITCH TO
LOCKOUT. DISCONNECT NEGATIVE
CABLE FROM BATTERIES. REMOVE
EXTERNAL POWER BY OPENING
CB101
(EXTERNAL
POWER
BREAKER) AND DISCONNECTING
POWER CABLE FROM RECEPTACLE
J101 (120V RECEPTACLE).
a.
Replacement.
NOTE
Before performing test, visually check
for damage to the chassis, terminal
block, or printed circuit board.
a.
REMOVAL.
Make the following connections to the
governor A106 terminal boards (see figure
4-5).
(1)
(1)
Disconnect and tag all wires
connected to the two terminal boards.
Remove warning plate to gain access
to terminals 1, 2 and 3 connections.
.
4-10
Connect 20 to 40V DC source to 12(+)
and 13(-)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 4-5. Governor A106, Test Setup
(2)
Connect a closed SPST switch between 14
and 15.
(7)
Connect DC voltmeter between 16(-) and 17
(+) to monitor actuator voltage.
(3)
Connect a 35-ohm, 10-watt resistor between
16 and 17. This simulates the actuator coil.
(8)
Check that jumper between 29 and 30 is
installed.
(4)
Connect AC signal generator to 18 and 19.
This simulates the magnetic pickup.
(5)
Connect an open SPST switch between 22
and 23. This simulates the minimum fuel
switch.
(6)
b. Test as follows:
Turn RATED SPEED control fully clockwise.
4-11
(1)
Turn
RATED
SPEED
counterclockwise.
(2)
Turn on power supply.
control
fully
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 4-6. Governor Controller, Exploded View
4-12
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
1.
2.
3.
4.
5.
6.
Capacitor
Screw
Clip
Screw
Printed Circuit Board
Jack
Legend for Figure 4-6.
7.
Jumper
8.
Screw
9.
Washer
10. Screw
11. Plate
12. Spacer
13.
14.
15.
16.
17.
18.
Terminal Board
Terminal Board
Decal
Warning
Chassis
Resistor
(3)
Turn on AC signal generator. Set
generator to 1,800 Hz at 2 to 6 volts
rms.
towards 8V DC. Move frequency
below rated speed. Actuator voltage
will decrease.
(4)
Voltage measured on DC voltmeter
should approximate OV DC.
(11) Close the MINIMUM FUEL switch
between 22 and 23. DC voltage
should go to 8 volts.
(5)
Slowly
turn
the
speed
pot
counterclockwise until the actuator
voltage slowly starts to increase
toward 8V DC. This means the speed
setting has just crossed below the
speed (frequency) signal.
(6)
Decrease the frequency until the
actuator voltage starts to decrease.
This simulates a decrease in speed
and normal control response.
(7)
Open the RAMP SPST switch
connected to terminals 14 and 15.
Increase
the
signal
generator
frequency until the actuator voltage
decreases. The actuator voltage will
increase to 8V DC, and drop when the
frequency reaches idle speed.
4-16. REPAIR.
follows:
a.
b.
Repair the governor controller as
Disassembly of Chassis
(1)
Remove terminal boards (13 and 14,
figure 4-6), by removing screws (8
and 10), washers (9) warning plate
(11), washer (9), spacer (12), and
washer (9).
(2)
The printed circuit board assembly (5)
is accessible by removing four screws
(4) and unsoldering connections to
terminal boards.
Repair
of
Components.
Printed
Circuit
Board
(8)
Close the RAMP switch. The actuator
voltage will fluctuate, and then settle
at minimum voltage.
(9)
Turn off the signal generator. The
actuator voltage will go to 8V DC,
verifying the fail safe circuit is
working.
(1)
When replacing 3-watt or 5-watt
resistors, mount them at least 1/16
inch (1.6 mm) above printed circuit
board.
(10) Turn on the signal generator and
move signal general frequency from
below to above rated frequency to
simulate a speed increase.
The
actuator voltage should increase
(2)
When replacing transistors Q2, Q4, or
Q5, mount washer between the
printed circuit board and the
transistor.
NOTE
For repairs use a pencil-type low
wattage soldering iron.
4-13
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Section IV. VOLTAGE REGULATOR
(2)
4-17. GENERAL. The voltage regulator assembly
consists of the voltage regulator mounted with the
electromagnetic interference (EMI) filter pack as a
complete unit. The voltage regulator assembly senses
generator voltage, compares the voltage with a
reference voltage, and supplies field (stator) current to
the generator to maintain voltage regulation. The EMI
filter pack, associated with the voltage regulator,
provides EMI suppression. The voltage regulator
assembly is a separate unit mounted in the AC-DC
control box assembly.
(3)
NOTE
R1 in test setup substitutes for the
motor-operated potentiometer in the
AC-DC control box assembly. This
adjustment is provided to control the
generator voltage. When adjusted to
its maximum resistance position
(CCW), minimum generator voltage is
obtained. Maximum generator voltage
is obtained with minimum resistance
(cw).
4-18.
INSPECTION.
Remove cover to facilitate
inspection. Check voltage regulator wire connections on
the terminal board.
Check grounding straps for
looseness. Check all components for loose mounting,
poor connections, broken wires, or any other signs of
damage.
4-19. TEST. The voltage regulator is tested to
determine operational capability, as follows (see figures
4-7 and 4-8).
a.
Operational Test.
(1)
Disconnect leads from transformer T1
primary, and connect to the 120 volt
input tap.
Mark position of potentiometer R4 on
voltage regulator.
Connect voltage regulator as shown in
test setup, figure 4-7.
(4)
Set potentiometer R4 on voltage
regulator fully counterclockwise.
(5)
Adjust potentiometer R1 (in figure 47), for maximum resistance.
(6)
Slowly adjust R1 toward minimum
resistance. Before reaching minimum
resistance, light bulb should come on
to near full
Figure 4-7. Voltage Regulator, Test Setup
4-14
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
brilliance. If light does not come on,
adjust R3 on voltage regulator.
Normally, R3 is set to provide R1 with
an adjustment of ±10 percent of rated
range.
(7)
c.
Testing of Replaceable Components.
Refer to figures 4-8 and 4-9 and check the
following components as indicated.
(1)
Check diodes CR8 (29), CR9 (26),
CR13 (30), CR14 (25), CR15 (33),
and CR16 (34) by disconnecting one
end of each diode and connecting an
ohmmeter (set at Rx100) across the
diode.
Note reading.
Reverse
ohmmeter leads to the diode and not
reading again. A good diode will read
high resistance one way and low
resistance the other way. A shorted
diode will read full scale both ways
and an open diode will read infinity
(no reading) in either direction.
Replace shorted or open diodes.
Reconnect leads to good diodes.
(2)
Check sensing transformers T1 and
T2 (24) by applying inputs of 120
volts, 208 volts, 240 volts, 416 volts,
80 volts, and 600 volts. Check with a
multimeter for 31 volts across diodes
CR5 and CR2. Check for 31 volts
across diodes CR6 and CR3. Check
for 31 volts across diodes CR4 and
CR1.
If these voltages are not
present for all inputs, the sensing
transformers may be defective and
must be replaced.
(3)
After checking transformers T1 and
T3, apply voltage to transformer
inputs and verify opening and closing
of relay K1 (23) contacts as indicated
in schematic (figure 4-9). Remove
voltage and monitor contacts for
closing and opening as indicated.
(4)
Use an ohmmeter to check for 1.0
ohms across resistor R25 (21) and
150 ohms across resistor R1 (9).
When R3 and R1 are correctly
adjusted, a small change in R1 will
turn the light bulb on and off. If light
stays either "full on", or does not
come on at all, the voltage regulator
is defective.
NOTE
R4 on voltage regulator affects speed
with which light turns on and off.
Normally it is factory set in the
extreme clockwise position. This
setting
normally
assures
good
stability, but tends to slow the
response time to the generator. If
rotated counterclockwise, the system
response
time
becomes
faster.
However,
if
rotated
too
far
counterclockwise,
the
generator
voltage may oscillate (hunt). It should
then be rotated clockwise well above
the point where oscillating occurs.
The system voltage stability is very
critical at no load.
(8)
Reconnect leads to T1 primary as
they were originally connected.
(9)
Reset potentiometer R4 to its original
position.
(10) Disconnect test setup and reinstall
cover.
WARNING
MAINTENANCE PERSONNEL SHOULD
EXERCISE EXTREME CARE WHEN
TESTING EQUIPMENT WITH POWER
ON.
4-20. REPLACEMENT.
b.
On-Equipment Power Output Test. Use a
multimeter to check for the following outputs
at the F+ and F- terminals at the loads
specified below:
No load
- 12V DC at 1.1 amps
250 KW load
- 22 V DC at 1.9 amps
500 KW load
- 32V DC at 2.8 amps
a.
4-15
Repair by Replacement of Components. If
any of the diodes, transformers, relays, or
resistors are defective, the voltage regulator
is repairable by replacing the defective
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
component.
Components are replaced by
carefully unsoldering them from the printed circuit
board, and carefully soldering new component into
place.
Open AC-DC control box door, and remove
voltage regulator as follows:
WARNING
BEFORE STARTING ANY MAINTENANCE
PROCEDURE,
SET
MAINTENANCE
LOCKOUT
SWITCH
TO
LOCKOUT.
DISCONNECT NEGATIVE CABLE FROM
BATTERIES. REMOVE EXTERNAL POWER
BY OPENING CB101 (EXTERNAL POWER
CIRCUIT BREAKER) AND DISCONNECTING
POWER CABLE FROM RECEPTACLE J101
(120V RECEPTACLE).
(a)
Disconnect and tag all wires
from voltage regulator terminal
board, including grounds for
shielded cables.
(b)
Remove four screws (46) and
washers (47) securing voltage
regulator.
Remove voltage
regulator assembly.
(2) Installation.
(a)
Install
voltage
regulator
assembly (48, figure 4-1), to the
AC-DC control box enclosure
with four screws (46) and
washers (47).
(b)
Connect wires and shielded
cable grounds to the voltage
regulator assembly terminal
board and chassis. Remove
tags from wires
CAUTION
Do not apply excessive heat when
soldering or unsoldering components.
b.
Replacement.
(1)
Removal. The voltage regulator (48,
figure 4-1), is mounted in the AC-DC
Control Box Assembly enclosure.
.
Section V. PANEL COMPONENT BASE ASSEMBLY
4-21. GENERAL. The panel component base assembly
(43, figure 4-1) is located in the AC-DC control box
assembly enclosure. It contains the motor-operated
potentiometers P4 and P5, a shunt, two 24V DC relays
K1 and K50, an AC-DC control relay TB9, and time
delay modules TD1 and TD3. All components are
directly mounted to the shelf and interconnected with a
wiring harness. Relays K1 and K50 are plug-in type
relays.
4-22. SHUNT. The shunt (6, figure 4-10), is repaired by
replacing the entire assembly which is attached to the
shelf with two screws (5).
4-23. RELAYS K1 AND K50. Relay K1 is the run-stop
relay, and relay K50 is the battle short relay. Both
relays (7, figure 4-10), are six-pole, double-throw type
relays with four poles normally open and two poles
normally closed. Test and replace as follows:
b.
a.
Test. To test relays K1 and K50, connect a
24V DC power source and a SPST switch
as shown in figure 4-11.
4-16
(1)
Close SPST switch.
With an
ohmmeter, check for an open circuit
between terminals 1 and 2 and
terminals 13 and 14. Meter should
indicate continuity between terminals
3 and 4, terminals 5 and 6, and
terminals 11 and 12.
(2)
Open SPST switch,
With an
ohmmeter, check for continuity
between terminals 1 and 2 and
terminals 13 and 14. Meter should
indicate an open circuit between
terminals 3 and 4, terminals 5 and 6,
and terminals 11 and 12. If relays fail
this check, repair or replace the
defective relay.
Replacement. Relays K1 and K50 are plugin type relays mounted on the component
assembly panel
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 4-8. Voltage Regulator
4-17
TM5-6115-593-34
NAVFAC P-8-631-34
T0-35C2-3-463-2
LEGEND FOR FIGURE 4-8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Circuit board assy
Capacitor
Resistor
Resistor
Resistor
Resistor
Resistor
Capacitor
Resistor R1
Resistor R3
Resistor R4
Resistor
Capacitor
Resistor
Capacitor
Resistor
Capacitor
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
Capacitor
Capacitor
Resistor
Resistor R25
Bracket
Relay K1
Sensing transformer
Diode CR14
Diode CR9
Rectifier CR12
Paralleling transformer T3
Diode CR8
Diode CR13
Rectifier CR11
Filter choke L1
Diode CR15
Diode CR16
(shelf) of the AC-DC control box assembly.
To remove relay, close locking device
(under relay socket) and lift relay out of
socket. To replace plug relay in snugly,
until locking device is firmly in place.
c.
open position) when deenergized. If
any relay fails to either open or close
as indicated, it is defective and must
be replaced.
4-24. AC-DC CONTROL RELAY ASSEMBLY TB9.
The AC-DC control relay assembly (18, figure 4-10)
contains three terminal boards, two diodes (CR1 and
CR23), and eight relays:
REF.
(2)
Check diodes CR1 and CR23 for
polarity. A good diode will read high
resistance on way and low resistance
the other way. A defective diode will
read full scale both ways, or will read
infinity (no reading) in either direction.
(3)
Check terminal boards and printed
circuit wiring by repeating steps (1)
and (2), but apply 24V DC to TB9
terminals.
Repair. Repair relays K1 and K50 by
replacement in accordance with paragraph
4-23b.
DES.
K6
K8
K19
K20
K22
K24
K40
K54
a.
FUNCTION
Crank disconnect
Low fuel shutdown
Overcrank shutdown
Emergency stop
Main CB control
Ether control
Frequency selector
DC voltage slave
Test.
(1)
Check each relay using test circuits
shown in figure 4-12. Energize each
set of relay contacts individually by
applying 24V DC directly to leads.
Check for open or closed contacts (no
continuity or continuity) as indicated in
figure 4-12. Check that each set of
contacts revert (to either closed or
b.
Repair. If any of the relays or diodes are
defective, AC-DC Control Relay Assembly
TB9 is repairable by replacing the defective
component. If the printed circuit wiring, a
terminal board, or a non-replaceable
component proves defective, the entire
assembly must be replaced.
c.
Replacement.
(1)
4-18
Remove relay assembly (18, figure 410) as follows:
(a)
Tag and ten disconnect wires
from terminal boards.
(b)
Remove screws (19) to
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 4-9. Voltage Regulator Schematic
4-19
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND
1.
2.
3.
4.
5.
6.
7.
8.
Screw
Potentiometer
Screw
Potentiometer
Screw
Shunt
Relay
Screw
9.
10.
11.
12.
13.
14.
15.
Socket
Screw
Nut
Time delay module TD3
Screw
Bracket
Integrated time delay
module TD1
16.
17.
18.
19.
20.
21.
Screw
Nut
AC-DC control
relay assy
Screw
Bracket
Shelf
Figure 4-10. Component Base Assembly, Exploded View
remove relay assembly (18) and
brackets (20).
(c)
(d)
If
AC-DC
Control
Relay
Assembly is to be replaced,
remove screws (16) and nuts
(17) to release relay assembly
(18) from brackets (20).
(e)
Prepare relay assembly (18) for
installation
by
attaching
brackets (20) using screws (16)
and nuts (17).
(f)
If components are being
Components are replaced by
carefully unsoldering them from
the printed circuit board.
CAUTION
Do not apply excessive heat when
soldering or unsoldering components.
It may damage the printed circuit
wiring.
4-20
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 4-11. Component Assembly Panel, Relay K1 and K50, Test Setup
replaced, carefully solder new
component into place.
(g)
Install relay assembly (18) by
securing brackets (20) to shelf
(21) using screws (19).
(h)
Connect wires to terminal
boards, then remove wire tags.
4-25. TIME DELAY MODULES TD1 AND TD3. Time
delay module TD1 (15, figure 4-10) delays crank limit
relay K19 turn on by 30 seconds. Time delay TD3 (12)
times on and off periods averaging 5-second delays and
controls recrank inhibit relay K6.
a.
(2)
Check transistors Q2 and Q3 (5 and
4, figure 4-14) by connecting each to
a transistor tester and testing for
current gain of 40 minimum, leakage,
or short.
(3)
Check capacitors (C1 and C2 (6 and
7, figure 4-13) by connecting each to
a capacitor tester and checking for
leakage and capacitance. C1 must
read 10 microfarads, 25 volts ±5
percent.
CR2 must read 47
microfarads, 50 volts ±10 percent.
(4)
Check capacitor C1 (10, figure 4-14)
by connecting to a capacitor tester
and checking for leakage and
capacitance.
Cl must read 300
microfarads, 30 volts, ±5 percent.
(5)
Check resistors using an ohmmeter
for the following resistance’s:
Tests for Replaceable Components. Check
the following components on TD1 and TD3:
(1)
Check transistor Q1 (10, figure 4-13
and 16, figure 4-14) by connecting a
transistor tester for current gain of 100
minimum, leakage, or short.
4-21
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 4-12. AC-DC Control Relay Assembly, Test Setup
TD1
R4 (1)
R1 (2)
R2 (3)
TD3
R1 (1)
R2 (3)
R4 (6)
R7 (8)
R6 (9)
R5 (12)
R3 (13)
820 ohms, 25 watts, ±5 percent
2 k, 1 watt, ±5 percent
2.7 megohms, 25 watts, ±5
percent
(6)
2 k, 1 watt, ±5 percent
2 k, 1 watt, ±5 percent
20 k, 0.25 watts, ±5 percent
20 k, 0.25 watts, ±5 percent
200 ohms, 1 watt, ±5 percent
68 k, 0.25 watts, ±5 percent
6 k, 0.25 watts, ±5 percent
4-22
Check diodes CR1 (TD1), CR5, CR3
(TD3) as follows:
(a)
Disconnect one end of the
diode.
(b)
Connect an ohmmeter (scale
set Rx100) across the diode,
note the reading. Now reverse
ohmmeter leads to the diode,
and again note reading. A good
diode will read high
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
resistance one way and low
resistance the other way.
A
shorted diode will read full scale
both ways. An open diode will
read infinity (no reading) in either
direction. Check all diodes and
replace disconnected leads.
(7)
b.
Check zener diodes CR1 and CR4 by
connecting a voltmeter across each
zener and its associated resistor. CR1
must show reading of 6.8 volts across
input range-of 20 to 40V DC. CR4
must show reading of 15 volts across
input range of 20 to 40V DC.
(2)
Remove screws (13) to remove time
delay assemblies (12 or 15) with
brackets (14).
(3)
Components are replaced by carefully
unsoldering them from the printed
circuit board.
CAUTION
Do not apply excessive heat when soldering
or unsoldering components. It may damage
the printed circuit wiring.
(4)
If either TD1 or TD3 are to be
replaced as an assembly, remove
screws (10) and nuts (11) to release
time delay assembly (12 or 15) from
brackets (14).
(5)
Prepare time delay assembly (12 or
15) for installation by attaching
brackets (14) using screws (10) and
nuts (11).
(6)
If components are to be replaced,
carefully solder new component into
place.
Test of TD1.
(1)
Connect time delay module TD1 as
shown in figure 4-13.
(2)
Close switch S1. Time the period it
takes before lamp DS1 lights. The
lamp must light in 25 to 35 seconds,
or TD1 is defective and must be
replaced.
c.Test of TD3
(1)
Connect time delay module TD3 as
shown in figure 4-14.
(2)
Close switch S1 and time the period it
takes before lamp DS1 lights. The
lamp must light in 4.5 to 6 seconds, or
TD3 is defective and must be
replaced.
CAUTION
Do not apply excessive heat when soldering
or unsoldering components. It may damage
the printed circuit wiring.
NOTE
Wait at least 15 seconds before proceeding.
d.
Repair.
If any of the replaceable
components tested in a (above) are
defective, TD1 and TD3 are repairable by
replacing the defective component. If the
printed circuit wiring or a terminal board, or
a non-replaceable component, proves
defective (test b or c, above), the entire
assembly must be replaced.
e.
Install time delay assembly (12 or 15)
by securing brackets (14) to shelf (21)
using screws (13).
(8)
Connect wires to terminal boards,
then remove wire tags.
4-26. MOTOR-OPERATED POTENTIOMETERS P4
AND P5.
a.
Replacement.
(1)
(7)
Tag and disconnect wires to TD1 or
TD3 (12 or 15, figure 4-10).
4-23
Replacement.
The two motor operated
potentiometers P4 and P5 (2 and 4, figure
4-10), are mounted on the component panel
assembly (shelf) (43, figure 4-1) in the ACDC control box assembly enclosure.
Removal for either unit (P4 or P5) (figure 415), is as follows:
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND
1. Resistor R4
2. Resistor R1
3. Resistor R2
4. Jumper
5. Timer U1
6. Capacitor C1
7. Capacitor C2
8. Diode CR1
9. Terminal board
10. Transistor Q1
Figure 4-13. Time Delay Module TD1
4-24
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 4-14. Time Delay Module TD3
4-25
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
b.
(1)
Remove and tag wires to terminals 1
through 6 on the terminal board.
(2)
Remove four screws (1 and 3, figure
4-10) from each unit.
(3)
Replace motor-operated potentiometer P4 or P5 on shelf by attaching
four screws (1 and 3, figure 4-10).
(4)
Connect wires to terminals 1 through
6 on terminal board. Remove tags.
NOTE
If ohmmeter readings at steps (d) and
(e) are incorrect, cams need
adjustment.
(f)
The 230 ±5 ohm reading in step
(d) is adjusted with cam B. This
cam should be adjusted to stop
the motor at 230 ±5 ohms, see
figure 4-17.
(g)
The 8 ±5 ohm reading in step
(e) is adjusted with cam A. This
cam should be adjusted to stop
the motor at 8 ±5 ohms, see
figure 4-17.
Test.
The following testing procedure
applies to both motor operated potentiometers P4 and P5, unless otherwise
indicated.
(1)
Test chassis isolation with an
ohmmeter (set on high scale) by
measuring between chassis and
terminals 1 through 6 on the terminal
board. Meter reading should be no
continuity.
(2)
Referring to figure 4-16, provide a test
setup as follows:
(a)
(b)
NOTE
Potentiometer reading adjustments in
steps (f) and (g) are for motor-operated
potentiometer P5. For P4, readings
are 500 ±5 ohms in step (f), and 1 ±5
ohms in step (g).
(h)
Connect the (-) of a 24V DC
source to terminal 6. The (+)
side of the center terminal of
SPST switch as shown.
c.
Label switch RAISE and
LOWER. Connect the RAISE
terminal of SPDT switch to
terminal 5 and the LOWER
terminal of SPDT switch to
terminal 4.
Verify that the motor can be run
at 1 rpm to 3 rpm as R3 is
rotated from clockwise to
counterclockwise. Leave R3 set
for 3 rpm operation.
Repair.
Components within the motoroperated potentiometers that may be
repaired are: brush replacement in motor
M1, tightening of set screws on gears, cam
adjustments and clutch torque.
(1)
When motor M1 (9, figure 4-15)
brushes are worn under 0.25 inch (6.4
mm) long, they must be replaced.
(c)
Connect an ohmmeter between
terminals 2 and 3.
(2)
(d)
Turn 24V DC power on. Set
SPDT switch to RAISE. Meter
shall read 230 ±5 ohms
connected between terminals 2
and 3.
Remove cover (3) by moving three
screws (1) and washers (2). Tighten
setscrews (19) on gear assembly (20)
and setscrews (28) on gear (29).
(3)
Adjust cams A and B in accordance
with procedure in paragraph 4-26b (f)
and (g).
(e)
Set SPDT switch to LOWER.
Meter shall read 8 ±5 ohms
connected between terminals 2
and 3.
(a)
4-26
With cover (3) removed,
remove motor mounting plate
(17) and motor (9) by removing
two screws (8).
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 4-15. Motor Operated Potentiometer, Exploded View
4-27
TM5-6115-593-34
NAVFAC P-8-631-34
T0-35C2-3-463-2
LEGEND FOR FIGURE 4-15
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Screw
Lockwasher
Cover
Washer
Potentiometer R3
Screw
Plate
Screw
Motor M1
Ring
Cover
Nut
Spring
Spring
Case
Clutch plate
Plate
Pin
Setscrew
Gear Assy
Setscrew
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
Lockwasher
Potentiometer R1
Ring
Gear
Spacer
Stud
Setscrew
Gear
Spacer
Spacer
Bushing
Plate
Setscrew
Cam
Shaft
Bushing
Nut
Washer
Lever
Switch
Plate
Figure 4-16. Motor-Operated Potentiometer, Test Setup
4-28
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
Nut-stud assy
Plate
Grommet
Grommet
Grommet
Screw
Plate
Screw
Base Plate Assy
Nut
Terminal strip TB2
Screw
Washer
Resistor R4
Screw
Washer
Terminal strip TB1
Instruction plate
ID plate
Chassis assy
Friction kit
Oil cup
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 4-17. Motor-Operated Potentiometers, Cam Adjustment
(b)
(4)
(b)
Remove retaining ring (10)
friction cover (11) and spring
(13). Elastic stop nut (12) is
accessible for torque increase
or decrease. Clutch assembly
may be removed for torque
adjustment by removing set
screws (10).
Remove retaining ring (10)
friction cover (11) and spring
(13). Elastic stop nut (12) is
accessible for torque increase
or decrease. Clutch assembly
may be removed for torque
adjustment by removing set
screws (19).
Adjust clutch (16, figure 4-15) to 20 ±5
inch-ounce (0.15 ±0.15 ±0.04 joules).
Add shims if necessary to reduce
looseness between motor shaft and
clutch. Adjust torque with nut as
shown in figure 4-18. Clutch assembly
must be disassembled in accordance
with figure 4-15 as follows:
(a)
With cover (3) removed,
remove motor mounting plate
(17) and motor (9) by removing
two screws (8).
Figure 4-18. Motor-Operated Potentiometers, Clutch
Adjustment Nut
4-29
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Section VI. CAPACITOR, DIODE, AND CIRCUIT CARDS
4-27. CAPACITOR.
a.
(3)
Reverse ohmmeter leads to diode and
note reading.
(4)
A good diode will read high resistance
in one direction and low resistance in
the other direction. A shorted diode
will read full scale both ways. An
open diode will read infinity (no
reading) in both directions. Replace
diode as required.
Testing.
(1)
Disconnect capacitor (58, figure 4-1)
leads and remove capacitor from clip
(60).
(2)
With capacitor tester, check capacitor
(58) for 40 microfarad capacitance.
Replace capacitor if it does not meet
specified capacitance.
b.
b.
Replacement.
(1)
Install new capacitor (58) in clip (60).
(2)
Solder capacitor leads.
4-29. CIRCUIT CARDS.
a.
Testing. Test individual circuit cards for
obvious points of continuity using an
ohmmeter.
b.
Repair. If breaks on circuit card are minor
or few, repair by soldering an insulated
piece of wire between broken points of
continuity. If circuit card is badly burnt or
breaks are irreparable, repair card by
replacement.
4-28. DIODE.
a.
Testing.
(1)
Disconnect one lead of diode (27,
figure 4-1) from terminal board (30).
(2)
Connect ohmmeter (Rx100) across
diode and note reading.
Replacement. Reconnect leads of new
diode (27) on terminal board (30).
4-30
TM5-61 15-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
CHAPTER 5
MAINTENANCE OF CONTROL CUBICLE
5-1. GENERAL. The control cubicle is located at the
rear (generator end) of the generator set. It contains
two control panels, the engine control panel, and the
generator control panel. These instruments, and other
equipment necessary to start, operate, and monitor the
generator set. The control cubicle is removable from
the generator set as a single unit.
WARNING
BEFORE
STARTING
ANY
MAINTENANCE PROCEDURE, SET
MAINTENANCE LOCKOUT SWITCH TO
LOCKOUT. DISCONNECT NEGATIVE
CABLE FROM BATTERIES. REMOVE
EXTERNAL POWER BY OPENING
CB101 (EXTERNAL POWER CIRCUIT
BREAKER) AND DISCONNECTING
POWER CABLE FROM RECEPTACLE
J101 (120V RECEPTACLE).
5-2.
TRANSDUCERS A103, A107, AND A108.
Transducer A103 is mounted on the rear panel of the
control cubicle enclosure (31, figure 5-1, sheet 1).
Transducers A107 and A108 (thermal watt converters,
82, figure 5-1, sheet 2) are mounted at the base of the
control cubicle.
a.
Testing.
(1) Remove transducers A107 and A108
according to paragraph 5-2 b and test
as follows:
(2)
WARNING
HIGH VOLTAGES PRESENT DURING TEST.
DEATH
OR SEVERE BURNS MAY RESULT IF
PERSONNEL FAIL PRECAUTIONS
(a) Connect
transducer
(either
A107 or A108) as shown in
figure 5-2, using test equipment
as shown.
(b)
Adjust T1, T2, and T3 to their
minimum position, fully counterclockwise.
(c)
Close S1 and open S2 and S3.
(d)
Energize 120/208V AC. 3phase, 4 wire, 60 Hz power
source.
5-1
(e)
Adjust T1 until 0.7 ampere is
indicated on ammeter A1. At
this point, the percentage of
RATING METER shall indicate
33 percent.
(f)
With S1 closed, close switch
S2, and adjust T2 until 0.7
ampere
is
indicated
on
ammeter A2. The percentage
of RATING METER shall
indicate 66 percent.
(g)
With S1 and S2 closed, close
S3. Adjust T3 until 0.7 ampere
is indicated on ammeter A3.
The percentage of RATING
METER shall indicate 100
percent.
(h)
If requirements of steps (e), (f),
and (g) are not met, replace the
transducers.
Transducers A103. This transducer
and generator set frequency meter
are a matched set, and must be
tested as a set.
Refer to the
Operator/Crew and Organizational
level Maintenance manual and
remove frequency meter from the
generator panel of the control cubicle.
(a)
Connect a test setup as shown
in figure 5-3.
(b)
Vary the frequency from lowest
scale reading to full scale
reading at 120 volts and at
frequencies between 48 and 53
Hz, the generator set meter
shall read within 1 percent of
the generated frequency (to the
left); at 120 volts and at
frequencies
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 5-1. Control Cubicle, Exploded View (Sheet 1 of 2 )
5-2
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 5-1. Control Cubicle, Exploded View (Sheet 2 of 2)
5-3
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Sheet 1
1.
Screw
2.
Nut
3.
Door holder
4.
Screw
5.
Nut
6.
Engine panel
7.
Spacer
8.
Screw
9.
Nut
10. Door holder
11. Screw
12. Nut
13. Generator panel
14. Spacer
15. Screw
16. Lockwasher
17. Washer
18. Horn
19. Screw
20. Flasher
21. Terminal block
22. Screw
23. Nut
24. Terminal board
25. Diode
26. Resistor
27. Lug
28. Jumper
29. Screw
30. Nut
31. Transducer
32. Screw
33. Nut
34. Receptacle cover
35. Screw
36. Nut
37. Receptacle cover
38. Screw
39. Nut
40. Receptacle cover
LEGEND FOR FIG. 5-1
Sheet 1 (Cont.)
41. Screw
42. Clamp
43. Screw
44. Clamp
45. Screw
46. Clamp
47. Screw
48. Clamp
49. Harness assy
50. Locknut
51. Connector
52. Screw
53. Nut
54. Relay assy
Sheet 2
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
Screw
Transformer
Screw
Transformer
Screw
Phase sequence relay
Screw
Overload device
Relay
Screw
Relay socket
Screw
Reverse power relay
Screw
Overvoltage relay
Screw
Short circuit relay
Screw
Bracket
Screw
Nut
Annuncitor control
assy
between 57 and 62 Hz,
generator set meter shall read
within 1 percent of the
generated frequency (to the
right). The error at any point on
frequency meter shall not be
greater than 1 percent.
(c)
Sheet 2 (Cont.)
77. Screw
78. Undervoltage relay
79. Screw
80. Transformer
81. Screw
82. Sync check relay
83. Screw
84. Bracket
85. Screw
86. Nut
87. Integrated time
delay module
88. Screw
89. Bracket
90. Screw
91. Nut
92. Control relay assy
93. Screw
94. Transducer
95. Screw
96. Resistor assy
97. Terminal lug
98. Screw
99. Nut
100. Terminal board
101. Screw
102. Nut
103. Rectifier
104. Bracket
105. Screw
106. Lockwasher
107. Washer
108. Nut
109. Screw
110. Washer
111. Lockwasher
112. Nut
113. Control box
114. Flasher
115. Screw
116. Socket
b.
(1)
If the above requirements are
not satisfied, replace both the
frequency meter and transducer
as a matched set.
5-4
Replacement.
Replace thermal watt converters
(transducers) A107 and A108 (94,
figure 5-1) as follows:
(a) Tag and disconnect lead wires.
(b)
Remove screws (93) to remove
transducers (94).
(c)
Secure replacement transducer
(94) using screws (93).
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 5-2. Transducers A107 and A108, Test Setup
(d)
(2)
Connect lead
remove tags.
wires,
then
(d)
Secure replacement transducer
(31) using screws (29) and nuts
(30)
Replace transducer A103 (31, figure
5-1) as follows:
(e)
Connect wires to A103 and then
remove tags.
NOTE
Transducer A103 and the generator set
frequency meter must be replaced as a
matched set.
(a)
Replacement of the frequency
meter is within the scope of
Organizational
Maintenance,
and is performed in accordance
with
Operator
and
Organizational
Maintenance
Manual.
(b)
Tag and disconnect lead wires
to A103.
(c)
Remove screws (29) and nuts
(30) to remove transducer (31).
5-3. TRANSFORMERS.
WARNING
BEFORE
STARTING
ANY
MAINTENANCE PROCEDURE, SET
MAINTENANCE LOCKOUT SWITCH TO
LOCKOUT. DISCONNECT NEGATIVE
CABLE FROM BATTERIES. REMOVE
EXTERNAL POWER BY OPENING
CB101 (EXTERNAL POWER CIRCUIT
BREAKER) AND DISCONNECTING
POWER CABLE FROM RECEPTACLE
J101 (120V RECEPTACLE)
a.
5-5
Transformers T101 and T102, Testing (56
and 58, figure 5-1). Remove transformers
according to
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2(5)
paragraph 5-3 c and test as follows:
(1)
Referring to figure 5-4, use an
ohmmeter and check for continuity
between terminals H1 and H2,
terminals H2 and H4, and terminals
X2 and X1.
b.
If transformers do not meet above
check, replace them.
Transformer T103 (80, figure 5-1). Remove
T103 according to paragraph 5-3 c and test
as follows:
(1)
Refer to figure 5-5 and apply 120V AC
between terminals 1 and 2. Use a
voltmeter to check for indicated
voltages (within 3 percent) at test
points shown.
Connect a 240 volt input with the coils
in parallel and check for 120 volt
output.
(2)
Repeat procedure with inputs at
terminals 1 and 3, and at terminals 1
and 4.
Connect a 480 volt input with the coils
in series and check for 120 volt
output.
(3)
If transformer T103 fails to provide
any of the indicated voltages, it is
defective and must be replaced.
(2)
With ohmmeter set on high scale,
check for no continuity between
terminals H1 and H3, and terminals
H2 and X2.
(3)
(4)
Figure 5-3. Transducer A103, Test Setup
5-6
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 5-4. Transformers T101 and T102, Schematic
c.
Replacement.
Transformers T101, T102, and T103 (56, 58
and 80 figure 5-1, sheet 2) are removed
from the control cubicle base assembly by
disconnecting and tagging wires, and
removing four screws (66) on transformer
(79).
BREAKER) AND DISCONNECTING
POWER CABLE FROM RECEPTACLE
J101 (120V RECEPTACLE).
a.
24V DC Relay K23 (63, figure 5-1).
(1)
5-4. RELAYS. Relays K23, K102, K103, K106, K111,
K112, K113, and K114 are mounted at the base of the
control cubicle. Refer to figure 5-1, sheet 2.
RELAY
K23
K102
K103
K106
K111
K112
K113
K114
ITEM NO.
63
69
60
82
78
67
71
62
Test relay K23 by connecting 24V DC
and a single-pole single-throw switch
as shown in figure 5-6.
(a)
Close SPST switch. With an
ohmmeter, check for an open
circuit between terminals 1 and
2 and terminals 13 and 14.
Meter should indicate continuity
between terminals 3 and 4,
terminals 5 and 6, and terminals
11 and 12.
(b)
Open SPST switch. With the
ohmmeter, check for continuity
between terminals 1 and 2 and
terminals 13 and 14. Meter
should indicate an open circuit
between terminals 3 and 4,
terminals 5 and 6, and terminals
11 and 12. If relays fail this
check, replace in accordance
with (2), below.
FUNCTION
24V DC
Overvoltage
Phase Sequence
Synch Check
Undervoltage
Reverse Power
Short Circuit
Overload
WARNING
BEFORE
STARTING
ANY
MAINTENANCE PROCEDURE, SET
MAINTENANCE LOCKOUT SWITCH TO
LOCKOUT. DISCONNECT NEGATIVE
CABLE FROM BATTERIES. REMOVE
EXTERNAL POWER BY OPENING
CB101 (EXTERNAL POWER CIRCUIT
(2)
5-7
Replacement. Relay K23 is a plug-in
type relay mounted in a socket on the
box assembly panel at the base of the
control cubicle. To remove,
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
close locking device (under relay
socket) and lift relay out of socket. To
replace, plug in snugly, until locking
device is firmly in place.
b.
(c)
Close S1 and S2. Set voltage
to 120 volts on terminals 1 and
2 and vary the frequency from
50 to 60 Hz. DS1 shall stay lit
and
DS2
shall
remain
extinguished.
(d)
Slowly increase the voltage to
140 volts. Vary the frequency
from 50 to 60 Hz. DS1 shall
stay lit and DS2 shall remain
extinguished.
(e)
Slowly increase the voltage to
154 volts. Vary the frequency
from 50 to 60 Hz. DS1 shall
stay lit and DS2 shall remain
extinguished.
(f)
After each light transfer,
remove AC power to clear the
Overvoltage Relay K102 (69, figure 5-1).
(1)
Test. To test relay K102, connect
relay as shown in test setup figure 57.
(a)
(b)
Connect a variable 0 to 160V
AC
source
and
variable
frequency (50 to 60 Hz) source
to! terminals 1 and 2 with switch
S1 in series.
Connect lamps DS1 and DS2,
switch S2, and a 24V DC supply
as shown in figure 5-7.
Figure 5-5. Transformer T103, Schematic
5-8
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
c.
Phase Sequence Relays K103 (60, Figure 5-1).
(1)
Test. To test relays K103, connect as shown
in test setup, figure 5-8. This relay operates
on 190-520 volt, 3-phase, 60 Hz. When
incorrect phase sequence A, C, B (figure 5-8),
is applied the relay will energize until power is
removed. Ohmmeter connected to terminals
4 and 5 will indicate continuity at this point
until the correct phase sequence is applied,
then an open circuit will appear at terminals 4
and 5.
(2)
Replacement. Remove relay (60, figure 5-1,
sheet 2) by disconnecting and tagging wires
and removing four screws (59).
d. Sync Check Relay K106 (82 Figure 5-1).
(1)
Test. To test relay K106, connect as shown in
test setup, figure 5-9. Two separate 115V AC
sources are required: (1) a fixed frequency
115V AC 50/60 HZ source, and (2) a variable
frequency 115V AC source.
Two lamps
connected in parallel across the two sources
are also required. When the lamps turn off
together, the 115V AC sources are
synchronized. The ohmmeter must show
continuity, indicating that the relay contacts
are closed. Perform this test at both 50 and
60 HZ frequencies. If lights fail to turn off
together while variable frequency source is
within tolerance (47.5 to 52.5 Hz for 50 Hz
test, 57.5 to 62.5 Hz for 60 Hz test), K106 is
defective and must be replaced.
(2)
Replacement. Remove relay (82 figure 5-1,
sheet 2) by disconnecting and tagging wires
and removing four screws (81).
Figure 5-6. Relay K23, Test Setup
relay. Set the frequency at 50 Hz and
increase the voltage to 156 volts. DS1 shall
extinguish and DS2 shall light. Repeat for
the same voltage.
NOTE
Disconnect relay from test setup.
(g)
(2)
Using an ohmmeter, set on high scale,
connect one lead to the relay case and the
other lead to relay terminals one at a time.
Meter should read no continuity. Similarly,
connect ohmmeter between terminal 1 and
3, 4, 5, and terminal 1 and 6, 7, 8. There
should be no meter reading.
e. Undervoltage Relay K111 (78, figure 5-1).
(1)
Replacement. Remove (69, figure 5-1, sheet
2) by disconnecting and tagging wires and
removing four screws (68)
5-9
Test.
To test undervoltage relay K111,
connect relay as shown in test setup figure 510.
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 5-7. Overvoltage Relay K102, Test Setup
(a)
Connect a variable 0 to 160V AC source
and variable frequency (50 to 60 Hz) source
to terminals 1 and 2 with switch S1 in series.
(b)
Connect lamp DS1 and 24V DC power
supply in series with switch S2 to terminals
3 and 4, also with terminals 7 and 8 (DS2).
(c)
(d)
Adjust AC power supply to 120 volts, 60 Hz.
With S1 and S2 closed, lamp DS1 shall
extinguish and DS2 shall light.
Reduce voltage slowly to 104 volts and hold
for 2 minutes. Lamp DS1 and DS2 shall
maintain states.
5-10
(e)
Reduce voltage to 99 volts. DS1 and DS2
shall transfer states within 4 to 8 seconds.
(f)
Increase voltage slowly to 113 volts. Lamps
DS1 and DS2 shall transfer states.
(g)
Reduce voltage to 48 volts. Transfer of
states of DS1 and DS2 shall be
instantaneous.
(h)
Reduce frequency to 50 Hz and repeat the
procedures in steps (c) through (h) with the
same results.
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(2)
Hz source to terminals 6 and 7. Connect an
ohmmeter to terminals 4 and 5.
Replacement. Remove relay (78, figure 5-1,
sheet 2) by disconnecting and tagging wires and
removing four screws (77).
(b)
Reverse Power Sensing Relay K112 (67, figure
5-1).
Adjust the 0.05V AC power
(terminals 1 and 2) to 1 amp.
(c)
Turn the adjusting
counterclockwise.
(d)
If the contact between terminals 3 and 5
closes, then the polarity is incorrect and the
wires on terminals 6 and 7 must be
reversed, and the test must be started over.
(e)
Push the Press-to-test Button. The contact
between terminals 3 and 5 must close at
this time.
f.
NOTE
Check relay K112 fuse prior to
performing the following tests.
(1)
Polarity and Reverse Power Circuit Test.
NOTE
Ensure
that
the
adjusting
potentiometer is set fully clockwise
before starting this test.
(a)
(2)
(a)
Connect a 0 to 1.2 amp, 0.05V AC
maximum, power source to terminals 1 and
2 (see figure 5-11). Connect a 115V AC, 60
Figure 5-8. Phase Sequence Relay K103, Test Setup
5-11
potentiometer
Inverse Time Trip Curves Test.
Set the current source
source
fully
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 5-9. Sync Check Relay K106, Test Setup
on terminals 1 and 2 to 0.05 amp.
(3)
adjusting
potentiometer
g.
(b)
Turn the
clockwise.
fully
(c)
Push the Press-to-test Button.
(d)
Turn the adjusting potentiometer slowly
counterclockwise until the contact between
terminals 3 and 5 closes. Stop at that point
and release the Press-to-test Button.
(e)
Wait 15 seconds and push the Press-to-test
Button. The contact between terminals 3
and 5 must close after an interval of
approximately 4 to 5 seconds.
Short Circuit Relay K113 (71, figure 5-1).
(1)
Replacement. Remove relay (67, figure 5-1,
sheet 2) by disconnecting and tagging wires and
removing four screws (66).
5-12
Test.
(a)
Connect the relay in the test setup shown in
figure 5-12.
(b)
Connect a lamp and a 24V DC power supply
in series with terminals 5 and 6 (DS1), also
with terminals 7 and 8 (DS2) and switch S3.
Relay trip will be indicated by the two lamps:
DS1 shall extinguish; DS2 shall light.
(c)
Connect a variable 0 to 120V AC source (50
to 60 Hz) between terminals 1 and 4 and
slowly increase the voltage. The relay shall
transfer lights when voltage equals 24 volts
± volt.
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 5-10. Undervoltage Relay K111, Test Setup.
Repeat the test with the input connected to
2 and 4, and then again, between 3 and 4
by rotating switch S2. The trip points should
be within 1 volt of each other.
NOTE
(b)
With the 120/208V AC power source
energized, turn on the 24V DC power and
close switch S1. Lamp DS1 shall light and
DS2 shall be extinguished.
(c)
Adjust autotransformer T1, T2, and T3 until
ammeters A1, A2, and A3 indicate 0.75
ampere. DS1 and DS2 shall not change
states.
(d)
Adjust autotransformer T1 until ammeter A1
indicates 0.975 ampere.
After 8 ± 2
minutes, DS1 and DS2 must transfer states,
if not, replace.
(e)
Repeat step (d) for auto-transformers T2
and T3. The test shall be the same as for
T1.
Disconnect relay from test setup.
(d)
(2)
With an ohmmeter, check that terminals 5,
6, 7, and 8, and terminals 1, 2, 3, and 4 are
electrically isolated with the relay in either
position.
Replacement. Remove relay (71, figure 5-1,
sheet 2) by disconnecting and tagging wires,
and removing four screws (70).
h.
Overload Relay K114 (62, figure 5-1)
(1)
Test
(a)
(2)
Connect the relay in the test setup shown in
figure 5-13.
5-13
Replacement. Remove relay (62, figure 5-1,
sheet 2) by disconnecting and tagging wires and
removing two screws (61).
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i.
Time delay TD2 (87, figure 5-1).
(1)
R4
R1
R2
R3
WARNING
Tests for Replacement Components. Check
the following components on TD 2, figure 514.
(a)
Check transistor Q1 by connecting to
transistor tester and testing for current gain
or 100 min, leakage, or short.
(b)
Check capacitors C1 and C2 by connecting
each to a capacitor tester and checking for
leakage and capacitance. C1 must read 10
microfarads, 25 volts, ±5 percent. C2 must
read 47 microfarads, 50 volts, ±10 percent.
(c)
Check resistors, using an ohmmeter, for the
following resistances.
BEFORE
STARTING
ANY
MAINTENANCE PROCEDURE, SET
MAINTENANCE LOCKOUT SWITCH
TO
LOCKOUT.
DISCONNECT
NEGATIVE
CABLE
FROM
BATTERIES. REMOVE EXTERNAL
POWER
BY
OPENING
CB101
(EXTERNAL
POWER
CIRCUIT
BREAKER) AND DISCONNECTING
POWER CABLE FROM RECEPTACLE
J101 (120V RECEPTACLE).
(2)
820 ohms, 25 watts, ±5 percent
2 k megohms, 1 watt, ±5 percent
2.7 megohms, 25 watts, ±5 percent
390 k, 0.25 watt, ±5 percent
Test of TD2.
(a)
Connect time delay circuit as shown in
figure 5-14.
(b)
Close switch S1. Time the period it takes
before lamp DS1 lights. It must be 3.5 to
4.5 seconds or TD is defective.
(3)
Repair. If any of the replaceable components
tested in 1 (above) are defective, TD2 is
repairable by replacing the defective
component. If the printed circuit wiring or a
terminal
Figure 5-11. Reverse Power Relay K112, Test Setup
5-14
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Figure 5-12. Short Circuit Relay K113, Test Setup
board, or a non-replaceable component,
proves defective (test 2, above), the entire
assembly must be replaced.
(4)
WARNING
BEFORE
STARTING
ANY
MAINTENANCE PROCEDURE, SET
MAINTENANCE LOCKOUT SWITCH
TO
LOCKOUT.
DISCONNECT
NEGATIVE
CABLE
FROM
BATTERIES. REMOVE EXTERNAL
POWER
BY
OPENING
CB101
(EXTERNAL
POWER
CIRCUIT
BREAKER) AND DISCONNECTING
POWER CABLE FROM RECEPTACLE
J101 (120V RECEPTACLE).
Replacement.
(a)
Tag and disconnect wires to TD2 (87, figure
5-1).
(b)
Remove screws (83) to remove assembly
(87) with brackets (84).
(c)
Individual components are replaced by
carefully unsoldering them from the printed
circuit board.
(2)
(b)
Test of TD2.
(a)
Connect time delay circuit as shown in
figure 5-14.
(3)
5-15
Close switch S1. Time the period it takes
before lamp DS1 lights. It must be 3.5 to
4.5 seconds or TD is defective.
Repair. If any of the replaceable components
tested in 1 (above) are defective, TD2 is
repairable by replacing the defective
component. If the printed circuit wiring or a
terminal board, or
TM5-6115-593-34
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a
non-replaceable
component,
proves
defective (test 2, above), the entire assembly
must be replaced.
(4)
CAUTION
Do not apply excessive heat when
soldering
or
unsoldering
components. It may damage the
printed circuit wiring.
Replacement.
(a)
Tag and disconnect wires to TD2 (87, figure
5-1).
(b)
Remove screws (83) to remove assembly
(87) with brackets (84).
(c)
Individual components are replaced by
carefully unsoldering them from the printed
circuit board.
(d)
If TD2 is to be replaced as an assembly,
remove screws (85) and nuts (86) to release
time delay assembly (87) from brackets
(84).
(e)
Prepare TD2 assembly (87) for installation
by attaching brackets (84) using screws (85)
and nuts (86).
Figure 5-13. Overload Relay K114, Test Setup
5-16
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Figure 5-14. Time Delay TD2, Test Setup
(f)
If components are to be replaced, carefully
solder new component into place.
(g)
Install time delay assembly (87) by securing
brackets (84) using screws (83).
(h)
Connect wires to terminal boards, then
remove wire tags.
j.
Control Relay Assembly TB10 (92 figure 5-1)
(1)
Test.
(a)
(b)
(c)
continuity, TB10 is defective and must be
replaced.
(2)
Connect control relay assembly as shown in
figure 5-15.
Close switch S1. With ohmmeter (Rx1
scale) check for continuity between
terminals 1 and 5, and terminals 2 and 4. If
ohmmeter shows no continuity, TB10 is
defective and must be replaced.
Replacement.
(a)
Tag and disconnect lead wires to TB10 (92,
figure 5-1).
(b)
Remove assembly (92) by removing screws
(88).
(c)
Release assembly (92) from brackets (89)
by removing screws (90) and nuts (91).
(d)
Prepare new TB10 assembly for installation
by attaching brackets (89) using screws (90)
and nuts (91).
(e)
Install TB10 (92) using screws (88).
(f)
Connect lead wires and remove wire tags.
5-5. RESISTOR ASSEMBLY TB 107. The resistor
assembly TB107 (detail C, figure 5-1, sheet 2) is
mounted to the left inside wall of the enclosure.
Open switch S1, close switch S2. With the
ohmmeter, check for continuity between
terminals 7 and 9. If ohm meter shows no
5-17
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a.
b.
Test. Test by disconnecting one lead from each
resistor.
With an ohmmeter, check each
resistor for 7.5 ohms ± 0.5 percent.
a.
Test.
(1)
Check each relay using test circuits shown in
figure 5-16.
Energize each set of relay
contacts individually by applying 24V DC
directly to leads. Check for open or closed
contacts (no continuity or continuity) as
indicated in figure 5-16. Check that each set
of contacts revert (to either closed or open
position) when deenergized. If only relay fails
to either open or close as indicated, it is
defective and must be replaced.
(2)
Check diodes for polarity. A good diode will
read high resistance one way and low
resistance the other way. A defective diode
will read full scale both ways, or will read
infinity (no reading) in either direction.
(3)
Check terminal boards and printed circuit
wiring by repeating steps (1) and (2), but apply
24V DC to TB6 terminals.
Replacement. Remove resistors by unsoldering
leads and removing from clips.
5-6. ANNUNCIATOR CONTROL ASSEMBLY TB6 (76,
figure 5-1). The annunciator control relay assembly
contains four terminal boards, 20 diodes, and 13 relays:
REF DES
K25A
K25B
K26
K27
Temperature
K28
K29
K30
K31
K32
K33
K34
K35
K36
FUNCTION
Alarm Silence
Alarm Silence
Alarm Arming
High
Coolant
High Oil Temperature
Low Oil Pressure
Low Fuel Level
Overspeed
Overvoltage
Undervoltage
Reverse Power
Overload
Short Circuit
b.
Repair.
If any of the relays or diodes are
defective, Annunciator Control Relay Assembly
TB6 is repairable by replacing the defective
Figure 5-15. Control Relay Assembly TB10, Test Setup
5-18
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Figure 5-16. Annunciator Control Assembly, TB6 (Sheet 1 of 2)
5-19
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5-16. Annunciator Control Assembly, TB6 (Sheet 2 of 2)
5-20
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NAVFAC P-8-631-34
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Figure 5-17. Synchroscope, Test Setup
component. If the printed circuit wiring or a terminal
board proves defective, or a nonreplaceable component
is defective, the entire assembly must be replaced.
c.
(d)
If Annunciator Control Relay Assembly is to
be replaced; remove screws (74) and nuts
(75) to release relay assembly (76) from
brackets (73).
(e)
Prepare relay assembly (76) for installation
by attaching brackets (73) using screws (74)
and nuts (75).
(f)
If components are being replaced, carefully
solder new component into place.
(g)
Install relay assembly (76) by securing
brackets (73) using screws (72).
(h)
Connect wires to terminal boards, then
remove wire tags.
Replacement.
(1)
Remove relay assembly (76, figure 5-1) as
follows:
(a)
Tag and then
terminal boards.
disconnect
wires
from
(b)
Remove screws (72) to remove relay
assembly (76) and brackets (73).
(c)
Components are replaced by carefully
unsoldering them from the printed circuit
board.
5-7. FLASHING CIRCUIT FC1 . The flasher (20, figure
5-1, sheet 1) is mounted on the inside right wall of the
enclosure and plugs into a terminal block assembly (21).
Remove flasher and check by connecting it in series
with a 24V DC power source and test lamp. If the
flasher is good, the test lamp should flash. If not,
replace by plugging new flasher into place.
CAUTION
Do not apply excessive heat when
soldering
or
unsoldering
components.
It may damage the
printed circuit wiring.
5-21
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NAVFAC P-8-631-34
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the two voltages. The speed of the 'incoming'
must then be inched up or down until the
pointer takes a steady position at 12 o'clock.
5-8. SYNCHROSCOPE.
a. Inspection. Inspect the synchroscope (114, figure
5-1) for loose electrical connections and damaged or
scratched glass.
c.
Replacement. To remove the synchroscope from
the generator panel, tag and disconnect wires, and
remove attaching hardware. Replace in generator
panel with attaching hardware and reconnect
wires. Remove tags from wires.
b. Testing.
(1)
(2)
(3)
Connect the synchroscope as shown in figure
5-17 test setup. Frequency generators used
should be capable of providing minimum 50
volts, maximum 240 volts. Frequency 0 to 60
Hz. For testing the pull-in frequency is 48 Hz,
the drop-out frequency is 47 Hz.
5-9. RESISTOR AND DIODES. Resistor (26, figure 51, sheet 1) and diodes (25) are all mounted on terminal
boards (24) on the rear wall of the enclosure. They are
removed by unscrewing them from their terminals on
terminal boards.
The synchroscope axial polarizing coils are
energized from the 'incoming' frequency,
while the radial field coils are connected to the
'running' circuit. If there is no difference
between the two circuits either in phase angle
or frequency, the pointer will remain
motionless at the 12 o'clock position on the
dial. With no frequency difference, any phase
angle difference will cause the pointer to take
up a position away from this point.
If,
however, there is a difference in frequency,
this phase relationship will be constantly
changing and the pointer will consequently
rotate continuously in one direction or the
other at a speed corresponding to the
difference in frequency. If incoming' is at a
higher speed than the 'running', the pointer
rotates clockwise, and counterclockwise if its
speed is lower.
a.
Test resistor (26) by measuring with an
ohmmeter.
It should be 39,000 ohms ±5
percent.
b.
Test diodes as follows:
(1)
Disconnect one end of the diode.
(2)
Connect an ohmmeter (scale. set Rx100)
across the diode, note the reading. Now
reverse ohmmeter leads to the diode, and
again note reading. A good diode will read
high resistance one way and low resistance
the other way. A shorted diode will read full
scale both ways. An open diode will read
infinity (no reading) in either direction. Check
all diodes and replace disconnected leads.
5-10. DIGITAL CLOCK.
When the lamps turn off together, the two
sources are synchronized.
When the
'incoming' frequency has been adjusted to
equal that of the 'running' frequency, the
pointer will come to rest at a point on the
scale depending on the phase displacement of
a.
(1)
(2)
5-22
Testing.
Connect clock in test setup shown in figure
5-18.
Close switch S1 to test 60
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 5-18. Digital Clock, M111
5-23
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NAVFAC P-8-631-34
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Hz operation.
(3)
(5)
Open switch S1 to test 50 Hz operation (Code
"A" only) Place S1 to 60 cycle operation for
Code "B".
(6)
Close switch S5 (Code "A" only).
(7)
Observe display.
Numerals must be
illuminated and clock seconds must advance
or clock M111 is defective and must be
replaced. Open switch S5 (Code "A" only).
Close switch S5 (Code "A" only).
WARNING
BEFORE
STARTING
ANY
MAINTENANCE PROCEDURE, SET
MAINTENANCE LOCKOUT SWITCH
TO
LOCKOUT.
DISCONNECT
NEGATIVE
CABLE
FROM
BATTERIES. REMOVE EXTERNAL
POWER
BY
OPENING
CB101
(EXTERNAL
POWER
CIRCUIT
BREAKER) AND DISCONNECTING
POWER CABLE FROM RECEPTACLE
J101 (120V RECEPTACLE).
(4)
b.
Observe display.
Numerals must be
illuminated and clock seconds must advance
or clock M111 is defective and must be
replaced. Open switch S5 (Code "A" only).
Replacement.
(1)
Tag and disconnect all wires to the digital
clock.
(2)
Loosen screw (1) and carefully remove the
clock (7) from the rear of the generator panel.
(3)
Remove screw (1) to remove the shield (2),
plates (3 and 4), gasket (5), and light control
film (6) from the front of the generator panel.
(4)
Position shield (2), plates (3 and 4), gasket
(5), and
Figure 5-19. Control Cubicle, Relay Panel
5-24
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NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 5-20. Under and Overfrequency Devices, Test Setup
light control film (6) on the front of the panel using
screws (1).
(5)
Mount the digital clock (7) using screws (1).
(6)
Connect lead wires and remove tags.
b.
Test. Connect 24V DC across terminals 1 and 2
of alarm horn. If horn does not sound, it is
defective and should be replaced.
c.
Installation.
5-11. ALARM HORN.
a.
Removal. Remove alarm horn (18, figure 5-1)
as follows:
BEFORE
STARTING
ANY
MAINTENANCE PROCEDURE, SET
MAINTENANCE LOCKOUT SWITCH
TO
LOCKOUT.
DISCONNECT
NEGATIVE
CABLE
FROM
BATTERIES. REMOVE EXTERNAL
POWER
BY
OPENING
CB101
(EXTERNAL
POWER
CIRCUIT
BREAKER) AND DISCONNECTING
POWER CABLE FROM RECEPTACLE
J101 (120V RECEPTACLE).
Tag and disconnect wires to alarm horn.
(2)
Remove horn (18) by removing screw (15),
washer (16), and lockwasher (17).
Install horn (18) using screw (15), washer (16),
and lockwasher (17).
(2)
Connect wires and remove tags.
5-12.
RELAYS MOUNTED ON REAR PANEL OF
CONTROL CUBICLE (54, figure 5-1).
WARNING
(1)
(1)
a.
Underfrequency relay 81GU (9, figure 5-19).
(1)
5-25
Test the underfrequency relay by connecting
as shown in figure 5-20.
(a)
Switch S1 closed.
(b)
Adjust variable frequency generator for 50
Hz output.
(c)
With
ohmmeter
connected
between
terminals 5 and 7, adjust frequency
generator to 48.5 Hz. Relay should trip as
frequency is decreased. Ohmmeter will no
longer show continuity.
TM5-6115-593-34
NAVFAC P-8-631-34
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(d)
Open switch S1.
Adjust
generator for 60 Hz output.
(e)
Decrease frequency generator frequency to
58.2 Hz.
With ohmmeter connected
between terminals 5 and 6, relay should trip
at 58.2 Hz (57.7 to 58.7 Hz), at which time
ohmmeter will no longer show continuity.
(f)
(2)
b.
frequency
Turn adjustment screw clockwise to raise
trip point.
(c)
With
ohmmeter
connected
between
terminals 5 and 7, adjust frequency
generator to 51.5 Hz (51 to 52). At this
point, relay should trip. Ohmmeter will no
longer show continuity.
(d)
Open switch S1.
(e)
Set frequency generator output to 60.0 Hz
and connect ohmmeter between terminals 5
and 6.
Ohmmeter should indicate
continuity. Increase frequency generator
output to 61.8 Hz: relay should trip at 61.8
Hz (61.3 to 62.3) and ohmmeter should
indicate infinite ohms.
(f)
Turn adjustment screw clockwise to raise
trip point.
REPLACEMENT. Remove relay (9, figure 519) by disconnecting and tagging wires and
removing four screws (1).
Overfrequency relay 81GO (8, figure 5-19).
(1)
Test the overfrequency relay by connecting as
shown in figure 5-20.
(2)
(a)
Close switch S1.
(b)
Adjust variable frequency generator for 50.0
Hz output.
c.
REPLACEMENT. Remove relay (8, figure 519) by disconnecting and tagging wires and
removing four screws (1).
Over/under voltage relay 27/59G (7, figure 519).
Figure 5-21. Over/under Voltage Device, Test Setup
5-26
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 5-22. Relay Test Setup
(1)
(a)
Close S1 and adjust variac for 110V AC as
indicated by A.C. voltmeter.
(b)
With
ohmmeter
connected
between
terminals 5 and 7, reduce AC voltage.
Relay should trip at 108V AC. At this point,
ohmmeter will no longer show continuity.
(c)
With
ohmmeter
connected
between
terminals 5 and 6 adjust AC voltage source
to read 130V AC on voltmeter.
(d)
Increase voltage to 133V AC, relay should
trip at 132V AC. Ohmmeter will no longer
show continuity.
(2)
d.
Test the relay by connecting as shown in
figure 5-21.
(1)
Test any of the three relays by connecting as
shown in figure 5-22.
(a)
Close switch S1.
(b)
Using the ohmmeter, verify that all normally
open contacts have closed (zero resistance
on meter) and all normally closed contacts
have opened (infinite resistance on meter).
(2)
e.
REPLACEMENT. Remove relays (2, 6 or 4,
figure 5-19) by disconnecting and tagging
wires and removing two screws (1).
SRM, SYNCHRONIZING RELAY (3, figure 519)
(1)
REPLACEMENT. Remove relay (7, figure 519) by disconnecting and tagging wires and
removing four screws (1).
(a)
RELAYS, BCR, CR AND BTR (2, 6, and 4,
figure 5-19).
5-27
Test the SRM relay by connecting as shown in
figure 5-23, synchronizing test.
With 115V AC supplied, contacts 9 and 10
shall close causing ohmmeter to read zero
ohms resistance.
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 5-23. Synchronizer, Test Setup
5-28
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(2)
(a)
(b)
(3)
Test the SRM relay by connecting as shown in
figure 5-23, "Governor Control Test."
With 115V AC, 60 Hz supplied to terminals
1 and 2 adjust the frequency to terminals 3
and 4 to 59.7 Hz. The ohmmeter shall
indicate zero ohms resistance across
contacts 5 and 6.
Connect ohmmeter across terminals 6 and 7
and adjust the variable frequency source to
60.3 Hz. The ohmmeter shall now show
zero ohms resistance across contacts 6 and
7.
(a)
With 115 V AC connected to terminals 1
and 2 adjust the voltage to terminals 3 and
4 to 100 V AC.
The ohmmeter shall
indicate zero ohms resistance across
terminals R and C.
(b)
Connect the ohmmeter across terminals L
and C and adjust the variable voltage
source to 130V AC. The ohmmeter shall
now show zero ohms resistance across
terminals L and C.
(4)
Test the SRM relay by connecting as shown in
figure 5-23, "Voltage Control Test".
5-29/(5-30 blank)
REPLACEMENT. Remove relay (3, figure 519) by disconnecting and tagging wires and
removing four screws (1).
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
CHAPTER 6
MAINTENANCE OF THE SUPPORT FRAME ASSEMBLY
supporting the mufflers to the silencer frame tie
bar assembly (13), and remove mufflers.
6-1. GENERAL. The support frame assembly (figure 61) is mounted directly on the generator set base
assembly. It provides support for major components of
the generator set, as well as providing a support for the
optional housing kit. It is comprised of front, center, and
rear support frames held together by tie bars.
d.
Frame supports (4, 5, 6 11, and 12) are
removed by removing screws (1), nuts (3), and
washers (2).
e.
Remove silencer frame tie bar assembly (13) as
a complete unit.
6-2. REPLACEMENT. Removal and replacement of
support frame assembly members, are as follows:
WARNING
NOTE
SILENCER FRAME ASSEMBLY IS
HEAVY.
BE SURE TO PROVIDE
ADEQUATE SUPPORT.
If generator set had a housing kit,
mufflers would be partially removed
prior to removing the housing kit.
a.
Remove housing kit, refer to Chapter 15.
b.
Remove the AC-DC control box, external power
box, control cubicle and reconnection box (see
Chapter 2).
c.
f.
Support frames (uprights) (21, 22, 23, 24, 25,
and 26) are mounted to base assembly with
screws (18), nuts (20) and washers (19).
NOTE
The bar assembly (7) must be
removed before removing rear
support frames (25 and 26).
Partially disassemble the air-cleaner and muffler
assemblies in order to dismantle the support
frame. The air-cleaner bracket bolts mounted
on the top center support frame (5, figure 6-1)
must be removed.
Also, remove bolts
g.
6-1
Remove folding step (17) from center right hand
support frame (24) by removing screw (14), nuts
(16), and washers (15).
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 6-1. Support Frame Assembly
6-2
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
CHAPTER 7
MAINTENANCE OF RADIATOR ASSEMBLY
7-1. GENERAL. The radiator assembly consists of a
radiator core with removable tanks, fan, and fan motor.
The fan is enclosed by a guard and located in a shroud
attached to the radiator. An electric motor drives the fan
via belts and sheaves (Code. A) or directly (Code B);
see note below for explanation of codes. The radiator
system cools the engine, lubricating oil cooler, and the
intercooler.
It reduces engine temperature and
maintains coolant temperature at 125°F (52°C) when
generator set is operated at continuous loads. When
the housing kit is installed, a thermostatically controlled
shutter assembly controls airflow to radiator by means of
movable shutters.
b.
Radiator Core Test.
Remove radiator in
accordance with instructions in paragraph 7-3 or
7-7.
Test the radiator for leaks by placing the radiator,
with all outlet connections sealed, in a tank of water.
Apply compressed air at 10 to 15 psi (0.7 to 1
kg/cm2) at filler opening and observe for leakage
indicated by air bubbles in the water. Repair if
necessary.
7-3. RADIATOR REPLACEMENT, CODE A . Remove
and replace radiator assembly as follows:
a.
NOTE
The radiator installation on earlier
units (serial numbers FZ00001 thru
FZ00064) differs from later units
(serial
numbers
FZ09100
thru
FZ09150), therefore the former in the
following discussion is referred to as
Code A and the latter as Code B.
Removal.
(1)
If generator set has a housing kit installed,
remove panels and shutter assembly in
accordance with Chapter 15. (See figure 7-1)
(2)
Drain coolant from radiator, remove clamps
(26, 22, 29, 32, 6, 7 and 13) and disconnect
hoses (27, 25, 33, 16, 8, and 12).
(3)
Tag and disconnect electrical leads to fan
motor (64).
(4)
Remove belt guard (58) by removing screws
(55), nuts (57), and washers (56).
(5)
Loosen adjusting screw on motor mount base
(65) and slide base slightly together with fan
motor (64) to loosen belts (59).
(6)
Remove belts (59).
(7)
Remove screws (47), washers (48 and 49)
and nuts (50), that secure radiator assembly
to skid base.
(8)
Remove both support tubes (41).
7-2. TEST.
a.
Preliminary. Preliminary inspections consist of
checking for leaks (especially at hose
connections), and coolant level may be checked
at the sight glass. If coolant level is below sight
glass, remove radiator cap and check level in
upper tank.
WARNING
WHENEVER GENERATOR SET HAS
JUST BEEN SHUT DOWN, REMOVE
RADIATOR CAP SLOWLY TO ALLOW
PRESSURE TO ESCAPE BEFORE
REMOVING CAP.
Refill radiator with proper coolant to
approximately 2 inches (50 mm) below filler
neck level. Using a hydrometer, verify that
antifreeze is in accordance with table 3-1 in the
Operator/Crew and Organizational Maintenance
manual, TM5-615-593-12.
7-1
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
WARNING
(10) Replace housing kit (if installed) panels and
shutter assembly in accordance with Chapter
15.
OVERHEAD OPERATIONS HAVE
INHERENT HAZARDS THAT CANNOT
BE MECHANICALLY SAFEGUARDED.
HARD HATS AND SAFETY SHOES
ARE REQUIRED. DO NOT STAND
UNDER HOISTED LOADS.
(9)
b.
(11) Connect hoses (27, 25, 33, 16, 8, and 12) and
secure with clamps (26, 22, 33, 6, 7, and 13).
(12) Fill radiator with coolant.
(13) Check for leaks.
With a hoist, carefully lift radiator assembly
off skid base.
7-4. RADIATOR REPAIR, CODE A.
a.
Replacement.
Radiator.
follows:
WARNING
OVERHEAD OPERATIONS HAVE
INHERENT HAZARDS THAT CANNOT
BE MECHANICALLY SAFEGUARDED.
HARD HATS AND SAFETY SHOES
ARE REQUIRED. DO NOT STAND
UNDER HOISTED LOADS.
(1)
Using a hoist, carefully set radiator assembly
in place on skid base.
(2)
Attach both support tubes (41).
Install
supports (46), if not previously installed.
(3)
Attach radiator assembly to the skid base with
screws (47), washers (48 and 49) and nuts
(50).
(4)
(5)
Install fan motor (64) on slide base (65), if not
previously installed.
Turn fan motor base adjusting screw (62), so
that fan motor moves toward center of
generator set.
(6)
Install three belts (59) on sheave (60) and
pulley (61).
(7)
Adjust belt tension to allow 1/2 inch (13 mm)
maximum play for each belt.
(8)
Install belt guard (58) with screws (55),
washers (56), and nuts (57).
(9)
Connect electrical leads on fan motor (64).
Clean and repair radiator core as
(1)
Remove radiator
paragraph 7-3.
(2)
Remove top tank (82) and bottom tank (85).
(3)
Inspect tubes. Clean tubes with radiator core
brush, if necessary.
(4)
Replace top tank (82) and bottom tank (85).
(5)
Test the radiator for leaks by placing the
radiator with all outlet connections sealed in a
tank of water. Apply compressed air at 10 to
15 psi (0.7 to 1 kg/cm2) at filler opening and
observe for leakage, indicated by air bubbles
in the water.
(6)
Mark off any leaks in the radiator assembly.
(7)
Dry out and clean the radiator thoroughly.
(8)
Solder the leaks in the radiator with acid core
solder.
(9)
Straighten bent radiator fins.
(10) Replace radiator
paragraph 7-3.
in
in
accordance
accordance
with
with
7-5. MOTOR REPLACEMENT, CODE A.
Remove and replace fan motor, referring to figure 7-1
as follows:
a.
Removal.
(1)
7-2
Turn off all power. Disconnect electrical leads
on fan motor (64).
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 7-1. Radiator Assembly, Code A, Exploded View
7-3
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND FOR FIGURE 7-1
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.
Screw
Nut/washer
Clamp
Clamp
Extrusion
Clamp
Clamp
Hose
Reducer
Nipple
Fitting
Hose
Clamp
Bracket
Fitting
Hose
Nipple
Reducer
Nut
Washer
U-bolt
Clamp
Pipe
Hose
Hose
Clamp
Hose
Valve
Clamp
Screw
Washer
(2)
32.
33.
34.
35.
36.
37.
38.
39.
40.
41
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61
Clamp
Hose
Fitting
Drain cock
Nipple
Elbow
Screw
Washer
Nut
Support tube
Screw
Washer
Nut
Bracket
Support
Screw
Washer
Washer
Nut
Screw
Washer
Washer
Nut
Screw
Washer
Nut
Belt guard
Belt
Sheave
Pulley
Move fan motor mount (65) adjusting screw
and slide motor mount together with fan motor
to release belt tension.
(3)
Remove belt guard (58) by removing screws
(55), nuts (57), and washers (56).
(4)
Remove belts (59).
(5)
Remove screws (62) and washers (63) that
secure fan motor (64) to base (65).
b.
Disassembly. Disassemble fan motor as follows
(see figure 7-2).
(1)
Remove fan cover (2) by removing bolts (1).
(2)
Remove snap ring (3) and washer (4).
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
Bolt
Washer
Motor
Base
Bolt
Washer
Washer
Nut
Shaft
Bearing
Bolt
Washer
Washer
Nut
Fan guard
Bolt
Washer
Fan
Plate
Plate
Top tank
Cap
Shroud
Bottom tank
Core
Frame
Screw
Washer
Washer
Support
(3)
Remove fan (5) and key (6).
(4)
Remove nuts (7) and remove oppositve drive
end bracket (9).
(5)
Remove spring (10) and bearing (11).
(6)
Remove collar shield (13).
(7)
Remove nuts (7) and studs (8) and separate
drive end bracket (14) from stator frame (19).
(8)
Remove drive end bearing (15).
(9)
Remove shaft (18) and rotor assembly (17)..
(10) Remove stator core (20) and stator winding
(21).
7-4
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
c.
Inspection.
(3)
Install belts (59) on sheaves (60) and pulley
(61).
Inspect if insulation is dry, brittle or faded.
Revarnish as necessary.
(4)
Install belt guard (58) with screws (55), nuts
(57 and washers (56).
Check bearings for visible signs of damage,
excessive wear, or discoloration. Replace as
necessary.
(5)
Adjust belt tension, with motor mount (65)
adjusting screw, allowing 1/2 inch (13 mm)
maximum play of each belt.
Repair. Repair of the fan motor consists of
replacing broken, worn or defective components
found during inspection and drying or
revarnishing of windings if required as a result
of the megger test.
(6)
Connect electrical
Remove tags.
(1)
Inspect for burnt or broken insulation.
(2)
(3)
d.
e.
leads
on
fan
motor.
7-6. FAN AND BEARING REPLACEMENT, CODE A.
a.
Reassembly. Reassemble motor as follows
(see figure 7-2).
Inspection.
(1)
Inspect fan (79) for bent or deformed blades.
(2)
Inspect tightness of attaching bolt and washer
for each fan blade.
(3)
Inspect fan bearing (71) for visible signs of
damage, wear or deterioration.
(1)
Install stator winding (21) and core (20) inside
stator frame (19).
(2)
Install shaft (18) and motor assembly (17).
(3)
Install drive end bearing (15).
(4)
Install drive end bracket (14) and secure to
stator frame with studs (8) and nuts (7).
(1)
Turn off all power. Disconnect electrical leads
on fan motor (64).
(5)
Install collar shield (13).
(2)
(6)
Install rear bearing (11) and spring (10).
Remove fan motor mount (65) adjusting screw
and slide mount with motor to release belt
tension.
(7)
Install opposite drive end bracket (9) and
secure with nuts (7).
(3)
Remove belt guard (58) by removing screws
(55), nuts (57), and washers (56).
(8)
Slide fan (5) and washer (4) onto shaft (18).
Secure with snap ring (3).
(4)
Remove belt guards (58).
(9)
Install fan cover (2) using nuts (1).
(5)
Slide fan sheave (60) off bearing shaft (71).
Remove key from shaft.
(6)
Remove bolts (72), washers (73 and 74), and
nuts (75) and remove fan guard (76).
(7)
Remove bolts (77) and washers (78) and
remove fan blades from fan (79).
(8)
Remove bolts (66), washers
f.
b.
Replacement.
(1)
(2)
Install fan motor (64, figure 7-1) on motor
mount (65).
Attach with bolts (62) and
washers (63).
Install pulley (61).
7-5
Removal. Remove fan and bearing as follows:
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND
1.
2.
3.
4.
5.
6.
7.
8.
Bolt
Fan cover
Snap ring
Wave washer
Fan
Fan key
Nut
Stud
9. End bracket
10. Spring
11. Bering
12. Key
13. Collar
14. End bracket
15. Bearing
16. Rotor core
17.
18.
19.
20.
21.
22.
23.
Figure 7-2. Radiator Fan Motor, Code A
7-6
Rotor assy
Shaft
Stator frame
Stator core
Stator winding
Eyebolt
Conduit box
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(67 and 68) and nuts (67) and remove
bearing (71) with fan hub.
(9)
c.
Turn off all power and tag and
disconnect electrical leads to fan motor
(76).
(4)
Remove fan guard (68, figure 7-3) by
removing hardware (69, 70, and 71).
(5)
With hoist attached by fan motor (76)
taut, remove bolts, nuts and washers (47
thru 50) from top portion of support leg
(72).
(6)
Carefully slide fan motor and fan blade
out of unit.
Separate fan hub from bearing (71).
Replacement.
(1)
Install fan hub on bearing (71).
(2)
Install bearing (71) on fan mount frame
(87) with bolts (66), washers (67 and 68)
and nuts (69),
(3)
Install fan blades on fan hub using bolts
(77) and washers (78).
(7)
(4)
Install fan guard (76) and secure with
bolts (72), washers (73 and 74), and nuts
(75).
Remove fan by taking out key (13, figure
7-4) out of keyway on shaft (31).
(8)
Remove motor stool (74) by removing
screws (66) and nuts (67).
Install key on bearing shaft (70) and slide
fan sheaves (60) onto shaft.
(9)
Remove cross beam (73) by removing
hardware securing it to support legs (72).
(5)
(6)
(7)
Install fan belts (59) on fan sheave (60)
and motor pulley (61).
Adjust fan motor mount (65) adjusting
screw to provide about 1/2 inch belt play.
Tighten adjusting screw.
(8)
Install belt guard (58) using screws (55),
nuts (57), and washers (56).
(9)
Reconnect leads to fan motor (59).
Removal.
(1)
(2)
(10) Remove two support legs (72) by
removing screws (47), washers (48 and
49), and nuts (50).
WARNING
The following steps involve removing parts
that support the radiator and secure it to the
skid base. For safety, attach a taut hoist line
to radiator before proceeding to prevent
accidental tipping over of radiator when the
radiator becomes free standing.
7-7.
RADIATOR REPLACEMENT, Code B. Remove
and replace radiator as follows:
a.
(3)
If generator set has a housing kit
installed, remove panels and shutter
assembly in accordance with Chapter 15,
(see figure 7-3).
Drain coolant from radiator, remove
clamps (22, 29, 32, 6, 7 and 13) and
disconnect hoses (25, 33, 12, 8 and 16).
(11) Remove two support tubes (41) by
removing screws (38), washers (39) and
nuts(40).
(12) Remove fan cowl (65) by removing
screws (42), washers (43) and nuts (44).
Brackets (45 and 78) will also be
removed as they are secured with the
same hardware.
(13) Remove screws (47), washers (48 and
49) and nuts (50) that secure radiator to
skid base.
7-7
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 7-3. Radiator Assembly, Code B, Exploded View (Sheet 1 of 2)
7-8
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 7-3. Radiator Assembly, Code B, Exploded View (Sheet 2 of 2)
7-9
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND FOR FIGURE 7-3
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.
Screw
Nut/washer
Clamp
Clamp
Extrusion
Clamp
Clamp
Hose
Reducer
Nipple
Fitting
Hose
Clamp
Bracket
Fitting
Hose
Nipple
Reducer
Nut
Washer
U-Bolt
Clamp
Pipe
Hose
Hose
Clamp
Hose
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
Valve (Code A Only)
Clamp
Screw
Washer
Clamp
Hose
Fitting
Drain cock
Nipple
Elbow
Screw
Washer
Nut
Support tube
Screw
Washer
Nut
Bracket
Support
Screw
Washer
Washer
Nut
Screw
Washer
Washer
Nut
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.
81.
Screw
Nut
Filler cap
Top tank
Bottom tank
Strap
Strap
Gasket
Side member
Sight(Code B)
Fan cowl
Screw
Nut
Fan guard
Screw
Washer
Washer
Support leg
Cross beam
Motor stool
Plate
Motor
Fan
Bracket
Core brace
Gusset
Radiator core
WARNING
(4)
OVERHEAD OPERATIONS HAVE INHERENT
HAZARDS THAT CANNOT BE MECHANICALLY
SAFEGUARDED.
HARD HATS AND SAFETY
SHOES ARE REQUIRED.
DO NOT STAND
UNDER HOISTED LOADS.
b.
Attach two support tubes (41) with screws
(38), washers (39), and nuts (40).
(5) Attach two support legs (72) to skid base
with screws (47), washers (48 and 49)
and nuts (50).
(14) With a hoist, carefully lift radiator (58,
59, 81 and attached parts) off skid base.
(6)
Attach cross beam (73 to support legs
(72).
Replacement.
(7)
Attach motor stool (74) to cross beam
(73) with screws (66), and nuts (67).
(8)
Slide hub of fan (77) onto shaft of motor
(76). Use key supplied with motor.
Carefully place motor (76) in position on
motor stool (74) while at the same time
positioning fan (77) in fan cowl (65).
(1)
Using a hoist, carefully set radiator (58,
59, 81, and attached parts) in place on
skid base.
(2)
Attach radiator to the skid base with
screws (47), washers (48 and 49) and
nuts (50).
(9)
(3)
Attach fan cowl (65) with screws (42),
washers (43) and nuts (44). Also attach
brackets (45 and 78, two each) with the
same hardware.
(10) Attach motor (76) to motor stool using
hardware previously removed.
7-10
(11) Attach two-part fan guard
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(68) with screws (69) and washers (70
and 71).
(9)
(12) Attach plate (75) to fan guard (68) using
hardware previously removed.
(10) Straighten bent radiator fins.
(11) Replace radiator in accordance with
paragraph 7-7.
(13) Connect electrical leads on fan motor
(76).
(14) Replace housing kit (if installed) panels
and shutter assembly in accordance with
Chapter 15.
7-9. MOTOR REPLACEMENT, CODE B. Remove and
replace fan motor, referring to Figure 7-3 as follows:
(15) Connect hoses (25, 33, 12, 8, and 16)
and secure with clamps (22, 29, 32, 6, 7,
and 13).
7-8.
Solder the leaks in the radiator with acid
core solder.
a.
Removal. Remove fan motor (76) as
described in paragraph 7-7, a., steps (3) to (7).
b.
Disassembly. Disassemble fan motor as
follows (see figure7-4).
(16) Fill radiator with coolant.
(1)
Remove key (13).
(17) Check for leaks.
(2)
Remove mounting half (1) and gaskets
(3 and 6) by removing screws (2 and 5).
(3)
Remove plugs (7 and 10).
(4)
Remove fan cover (17) by removing
screws (16).
(5)
Remove fan (26).
RADIATOR REPAIR, CODE B.
a.
Radiator. Clean and repair radiator core (81)
as follows:
(1)
Remove radiator in accordance with
paragraph 7-7.
(2)
Remove top tank (58) and bottom tank
(59).
(6)
Remove couplings (8 and 11) and
nipples (9 and 12).
(3)
Inspect tubes. Clean tubes with radiator
core brush, if necessary.
(7)
Remove front bracket (32)
(8)
(4)
Check gaskets (62) for signs of erosion
and replace if necessary.
Remove bearing cap (28) by removing
screws (27).
(9)
Remove bearing (29) and spring (30).
(5)
Replace top tank (58) and bottom tank
(59).
(6)
(7)
(8)
(10) Remove shaft (31).
Test the radiator for leaks by placing the
radiator with all outlet connections
sealed in a tank of water. Apply
compressed air to 10 to 152psi (0.7 to 1
kg/cm2) at filler opening and observe for
leakage, indicated by air bubbles in the
water.
Mark off any leaks in the radiator
assembly.
Dry out and clean the radiator
thoroughly.
7-11
(11) Remove stator (23) and rotor (24) from
body assy (25).
(12) Remove slinger (18) and bearing (19) by
removing screws (20).
(13) Remove rear bracket (15) by removing
screws (14).
c.
Inspection.
(1)
Inspect for burnt or broken insulation.
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(2)
Inspect if insulation is dry, brittle or
faded. Revarnish as necessary.
(3)
Check bearings for visible signs of
damage, excessive wear, or
discoloration. Replace as necessary.
and nipples (9 and 12).
(9)
d.
Install fan (26) onto shaft (31).
(10) Install fan cover (17) and secure with
screws (16).
Repair. Repair of the fan motor consists of
replacing broken, worn or defective
components found during inspection and drying
or revarnishing of windings if required as a
result of the megger test.
(11) Install plugs (7 and 10).
(12) Install mounting half (1) and gaskets (3
and 6) and secure with screws (2 and 5).
(13) Install key (13) by placing on shaft (31).
e.
Reassembly. Reassemble motor as follows
(see figure 7-4).
f.
Replacement. Replace fan motor (76, figure 73) as described in paragraph 7-7, b., steps (8)
to (13).
(1)
Install rear bracket (15) and secure with
screws (14).
(2)
Install slinger (18) and bearing (19) and
secure with screws (20).
(3)
Install stator (23) and rotor (24) in body
assy (25).
(4)
Install shaft (31) by sliding drive end into
bearing (19).
(1)
Inspect fan (77) for bent or deformed
blades.
Install bearing (29) and spring (30) in
front bracket (32).
(2)
Inspect tightness of attaching bolt and
washer for each fan blade.
Install bearing cap (28) onto front
bracket (32) and secure with screws (27).
(3)
Inspect fan hub bearing for visible signs
of damage, wear or deterioration.
(5)
(6)
(7)
(8)
7-10. FAN REPLACEMENT, CODE B. Remove and
replace fan, referring to figure 7-3 as follows:
Install front bracket by sliding onto shaft
(31).
a.
Removal. Remove fan (77) as described in
paragraph 7-7, a., steps (3) to (7).
b.
Inspection.
c.
Install couplings (8 and 11)
7-12
Replacement. Replace fan (77) as described
in paragraph 7-7, b., steps (8) to (12).
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Mounting half
Screw
Gasket
Cover
Screw
Gasket
Plug
Coupling
Nipple
Plug
Coupling
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Nipple
Key
Screw
Rear bracket
Screw
Fan cover
Slinger
Bearing
Screw
Bearing cap
Eyebolt
Figure 7-4. Radiator Fan Motor, Code B
7-13/(7-14 blank)
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Stator
Rotor
Body assy
Fan
Screw
Bearing cap
Bearing
Spring
Shaft
Front bracket
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
CHAPTER 8
MAINTENANCE OF ENGINE PREHEAT ASSEMBLY
b.
8-1. GENERAL. The engine preheat system maintains
the engine in preheated, ready-to-start condition in
ambient temperatures from 125°F (52°C) to 32°F (0°C),
and with the optional housing kit installed, to -25°F
(-32°C). The system operates from an external 115V
AC power source. It consists of an electrically operated,
thermostatically controlled engine coolant heater, piping
and valves. Coolant temperature is thermostatically
controlled at 100 to 120°F (47 to 49°C). The engine
preheat assembly is located in the base assembly under
the engine. See figure 8-1.
8-3.
THERMOSTAT (see figure 8-2)
a.
8-2.
HEATING ELEMENT (see figure 8-2)
a.
Replacement. Remove cover (4) to gain
access to heating element terminations. Tag
and disconnect wires. Unscrew heating
element (6) from EB tank (23). When installing
new element add sealing compound MIL-515204C to pipe threads.
8-1
Test. Heating element is actually comprised of
two separate 120V, 2200 watt elements.
Utilizing a 120V AC 20 AMP power source,
energize each element in turn to verify that
each element current draw is approximately
18.5 AMPS. See figure 8-3. If any element
does not have proper current draw, replace
entire element.
Replacement. Remove cap (8) and grommet
(10) from cap (11) to gain access to sensing
unit (13) terminations. Tag and remove wires
from thermostat. Remove thermostat sensing
unit (13). Immerse sensing unit into hot water.
As hot water temperature reaches 120°F,
sensing element contacts shall open (infinite
ohms reading). As water temperature cools to
100°F, sensing element shall reclose (0 ohms
reading). See figure 8-4.
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Hose
Hose
Adapter
Lever valve
Elbow
Nipple
Tee
Nipple
Screw
Lockwasher
Washer
Heater assy kit
Figure 8-1. Preheat Installation
8-2
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 8-2. Heater Assembly
8-3
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND FOR FIGURE 8-2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Heater assy
Cord grip
Reducer
Cover
O-ring
Heater element
Swivel adapter
Cap
Washer
Grommet
Cap
Set Screw
Sensing unit
Swivel adapter
Bur
Nipple
Clamp
Hose
Screw
EC flange and valve assy
Gasket
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
Bolt assy
EB tank
Cord grip
Seal ring
Cord grip
Seal ring
Terminal block
Ground lug
Plate
Bolt assy
Junction box
Mounting plate
Lub oil heater assy
Cap
Washer
Grommet
Cap
Burr
Reducer
Heating Element?
Figure 8-3. Heater Element Test Set-up
Figure 8-4. Thermostate Test Set-up
8-4
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
CHAPTER 9
MAINTENANCE OF FUEL TRANSFER PUMP ASSEMBLY
9-1. GENERAL. The fuel transfer pump (figure 9-1) is
used to transfer diesel fuel from an external source to the
generator set fuel tank. It is mounted on the left side of the
generator set, in back of the AC-DC control box assembly.
The fuel transfer pump assembly fuel inlet connection is
located on the base assembly, below the fuel transfer
pump assembly. The fuel transfer pump is electric motor
driven and actuated by a control panel selector switch. In
the automatic AUTO position, transfer pump operation is
controlled by a float level switch in the generator set fuel
tank and the fuel flow is controlled by a solenoid valve on
the fuel transfer pump assembly.
9-2.
assembly (9 through 14), pump blade (34), motor hearing
(28 and 42), and motor brushes (25).
a.
Inlet Filter. Remove inlet filter assembly (7)
and seal (8) from end plate (31).
b.
Bypass Assembly. Unscrew plug (9) from end
plate (31). Remove spring (10), piston (11),
seal (12), sleeve (13), and bypass spring (14).
c.
Pump Blade.
(1)
Remove wire (29) from screws (30).
Remove screws and end plate (31).
(2)
Remove pump blade (34) with shaft (35),
drive blade (36), seal (37), plate (38),
seal (39), and liner (33) with pin (32).
REPLACEMENT.
a.
Removal.
(1)
With system off, disconnect hose
assemblies connected to the inlet and
outlet ports of the pump. Remove
fittings from pump (8 and 10).
Disconnect the electrical connector on
the pump motor.
d.
Motor Bearings. After pump blade assembly
has been removed, remove motor bearings as
follows:
(1)
Remove wire (15) from screws (16).
Remove screws (16) and washers (17),
and remove front head (18).
(2)
Separate front head (18) from body (43)
and housing (40).
(3)
Remove bearings (28) and (42) from
armature (41) shaft.
NOTE
When removing fuel transfer lines, guard
against siphoning from the external fuel
source.
(2)
b.
Remove four screws (13), washers (14),
and nuts (15).
Installation. (See figure 9-1)
(1)
Install pump (16) onto bracket (51) with
four screws (13), washers (14) and nuts
(15).
(2)
Attach fittings (8 and 10) and hose
assemblies to inlet and outlet ports of
pump.
9-3. REPAIR. (See figure 9-2.) Pump repairs involve
replacement of the inlet filter assembly (7), bypass
9-1
e.
Motor Brushes. Motor brushes are readily
removable by unscrewing caps (24) and
removing brushes (25). Replace brush after
2500 hours of operation or if square section of
brush is less than ¼ inch in length.
f.
Feed thru Capacitor. Remove wire (3) from
four screws (4). Remove connector shell (5)
and feed thru capacitor (6) by removing four
screws (4).
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
g.
(2)
Solenoid Valve L3.
(1)
Replacement. (See figure 9-1.)
Disconnect electrical connector from
solenoid valve. Disconnect hose
assemblies from elbows (8). Remove
screws (18) and remove solenoid valve
(19).
Test. Test solenoid valve 3 (19, figure
9-1) using an ohmmeter set on the
Rx1scale. Check for continuity. If
continuity is not indicated the valve is
defective and should be replaced.
9-2
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 9-1. Fuel Transfer Pump Installation, Exploded View
9-3
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND FOR FIGURE 9-1
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.
Screw
Nut
Bevel washer
Lockwasher
Washer
Bracket
Transfer Pumpfilter assy
Elbow
Hose
Connector
Hose
Hose
Screw
Washer
Nut
Pump
Elbow
Screw
Valve
Screw
Lockwasher
Filter-strainer assy
Drain cock
Screw
Washer
Can
Filter elements
Gasket
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
9-4
Drain cock
Nut
Washer
Can
Strainer
Rod assy
Nut
Filter-strainer
Screw
Washer
Strainer
Drain cock
Nut
Washer
Can
Strainer
Road assy
Nut
Strainer head
Screw
Nut
Clamp
Bracket
Screw
Bevel Washer
Lockwasher
Nut
Channel
Retainer
Gasket
Gasket
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 9-2. Fuel Transfer Pump, Exploded View
9-5/(9-6 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
CHAPTER 10
MAINTENANCE OF INTERCONNECTING ELECTRICAL HARNESSES
AND PARALLEL CABLE ASSEMBLIES
Section I. MAINTENANCE OF INTERCONNECTING ELECTRICAL HARNESSES
10-1. 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.
10-2. REPLACEMENT. Replace the interconnecting,
external power box, AC-DC control box or control cubicle
harness if 30 percent of the wires in the assembly are
defective. Refer to FO 10-1 through 10-21.
a.
Removal. Remove harness assembly as
follows:
Tag all wires, connectors, and terminal
boards.
(2)
Disconnect harness connectors from
receptacles by unscrewing connectors in
counterclockwise direction.
(3)
Remove all clamps that secure the
harness.
b.
Repair. Refer to Operator/Crew Organizational
Maintenance manual for repair procedures.
c.
Replacement. Replace harness as follows:
WARNING
SET MAINTENANCE LOCKOUT SWITCH TO
LOCKOUT. DISCONNECT NEGATIVE CABLE
FROM BATTERIES. REMOVE EXTERNAL
POWER BY OPENING CB101 (120V
RECEPTACLE BREAKER).
(1)
(1)
Secure harness with clamps.
(2)
Make necessary connections.
(3)
Remove wire tags.
Section II. MAINTENANCE OF PARALLEL CABLE ASSEMBLIES
10-3. GENERAL. There are two parallel cable assemblies, circuits between connector pins of the same receptacle.
a reactive load compensation cable and a governor circuit
cable, used to interconnect sets for parallel operation.
10-5. REPAIR. If a wire is broken from a connector,
resolder and reassemble.
10-4. INSPECTION.
10-6. REPLACEMENT. To remove parallel cables,
a.
Inspect connectors for damaged threads and
unscrew connectors from receptacles on generator set ACbent, loose, or missing pins. Inspect wiring for
DC control panel to replace parallel cables, unscrew dust
defective insulation.
caps on AC-DC control panel receptacles, labeled
GOVERNOR PARALLELING CIRCUIT and REACTIVE
b.
Perform continuity check, using ohmmeter
LOAD COMPENSATION. Attach parallel cables to these
between connecting points in the cable. Use
receptacles at both generator set AC-DC control panels.
wiring data in figure 10-1. Check for short
10-1
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 10-1. Parallel Cables, Diagram
10-2
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
CHAPTER 11
MAINTENANCE OF GENERATOR AND RECONNECTION ASSEMBLY
11-1. GENERAL. The generator is a single-bearing,
brushless type with integral exciter. It is directly driven
from the engine through a disc coupling. The bearing
requires no lubricant and can be replaced without removing
either the engine or generator. The excitation system
consists of an exciter and voltage regulator. The excitor
has a rotating armature and rotating rectifier. The
reconnection box assembly provides access for
reconnecting generator phase windings through current
transformers. Windings of each phase may be connected
in series or parallel on buss bars. Reconnection box also
provides a means of converting the generator set from
120/208 volt to 240/416 volt operation.
c.
11-2. RECONNECTION BOARD AND BUSS BARS
REMOVAL AND REPLACEMENT.
a.
Replace buss bars and jumper bars (38
thru 45, figure 11-1, sheet 1) by replacing
their attaching hardware.
(3)
Replace harness (71 and 73) and power
cables (74).
(4)
Replace panel support (13).
(5)
Replace front panel (12) by replacing
screws (1), washers (2 and 3), and hook
(4).
Limit Switch.
(1)
Test. Using an ohmmeter test limit
switch S120 (14, figure 11-1, sheet 2) for
continuity. Switch should have a distinct
clicking action when operated from one
position to another. Replace switch if no
continuity is indicated.
(2)
Replacement.
Removal.
(1)
Remove front panel (12, figure 11-1,
sheet 1) by removing screws (1),
washers (2 and 3), and hook (4).
(2)
Remove panel support (13).
(3)
Disconnect, tag, and remove harness
(71) and (73) and power cables (74).
(4)
Remove buss bars and jumper bars (38
thru (45) by removing their attaching
hardware.
(5)
Remove reconnection board assembly
(15, figure 11-1, sheet 2) by removing
the 14 screws (16), nuts (19), and
washers (17 and 18).
(a)
Remove limit switch S120 (14) by
removing locknut and washer that
secures switch to reconnection
board (15).
(b)
Install new switch on reconnection
board (100) and secure locknut
and washer.
11-3. CURRENT TRANSFORMER REMOVAL AND
REPLACEMENT.
a.
b.
(2)
Removal.
Replacement.
(1)
Replace reconnection board assembly
(15) by replacing the 14 screws (16),
nuts (19), and washers (17 and 18).
11-1
(1)
Remove reconnection board and buss
bars, par. 11-2 a.
(2)
Remove current transformer assembly
(22, figure 11-1, sheet 2) by removing
ten screws (20) and washers (21).
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 11-1. Generator Reconnection and Box Assembly, Exploded View (Sheet 1 of 2)
11-2
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Legend for Figure 11-1 (Sheet 1)
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.
b.
Screw
Washer
Washer
S hook
Screw/washer
Nut/washer
Chain
Snap hook
S hook
Chain
Sleeving
Front panel
Support
Screw
Washer
Washer
Nut
Angle
Screw
Washer
Washer
Nut
Plate
Screw
Washer
Washer
Nut
Enclosure
Screw
Washer
Screw
Screw
Washer
Screw
Screw
Washer
Nut
Buss bar
39.
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.
assembly. Refer to figure 11-1, sheet 2 and 11-2 to
provide access to current transformer for removal.
Replacement.
(1)
(2)
Buss bar
Jumper bar
Buss bar
Buss bar
Jumper bar
Buss bar
Buss bar
Screw
Washer
Nut
Buss bar
Buss bar
Screw
Washer
Washer
Nut
Block
Clamp
Clamp
Screw
Washer
Nut
Clamp
Screw/washer
Nut/washer
Clamp
Screw
Washer
Washer
Nut
Screw/washer
Nut
Harness
Grommet
Harness
Power cable
Lug
Cable
Screw
Replace current transformer assembly
(22, figure 11-1, sheet 2) by replacing
the ten screws (20 and washers (21).
a.
Replace reconnection boars and buss
bars, par. 11-2 b.
Inspection. Inspect the current transformers
(figure 11-2) for cracks in the plastic, breaks,
loose mounting, loose connections, or
corrosion.
CAUTION
11-4. CURRENT TRANSFORMERS. The current
transformers are mounted on a plate in the reconnection
box assembly enclosure, attached to the main generator.
An on-equipment test is not feasible for current transformer
11-3
Current transformers must be demagnetized
after checking any secondary terminals with
any DC current such as a Wheatstone bridge,
or their accuracy will be impaired.
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 11-1. Generator-Reconnection and Box Assembly
(Sheet 2 of 2)
11-4
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND FOR FIGURE 11-1 (Sheet 2)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
(a)
(b)
Screw
Washer
Washer
Reconn. Board assy
Bolt
Nut
Washer
Nut
Jumper bar
Connection bar
Jumper bar
Neutral bar
Connection bar
Limit switch
Reconn. Board
Screw
Nut
Current transformers CT1, CT2, CT3,
CT11, CT12, and CT13 (7, figure 11-2)
should read 7.5 ohms at 77°F (25°C).
Current transformer CT7 (16) should
read 0.089 ohms at 77°F (25°C).
(d)
Demagnetize the current transformers
following the resistance tests by
connecting secondary terminals to a
variable AC power source such as a
variac or similar device and slowly raise
the current to 2 amps for CT1, CT2,
CT3, CT11, CT12, and CT13 (10 amps
for CT4, CT5, CT6, CT10, and CT7),
then slowly lower current to 0 amps.
Washer
Washer
Screw
Washer
Transformer assy
Screw
Washer
Angle
Screw
Washer
Angle
Bracket
Screw
Nut
Washer
Generator assy
Clip
WARNING
SECONDARY TERMINALS SHOULD NOT BE
LEFT OPEN WHEN AC CURRENT IS APPLIED.
Current transformers CT4, CT5, CT6,
and CT10 (8) should read 0.420 ohms at
77°F (25°C).
(c)
(2)
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
(a)
Test CT1, CT2, CT3, CT11, CT12,
CT13, CT4, CT5, CT6, CT10, and CT7,
by wrapping 10 turns of a conductor
around the current transformer.
(b)
Apply an AC current of 10 amperes to
the conductor.
(c)
Current measured at current transformer
terminals must be 86 milliamps for CT1,
CT2, CT11, CT12, and CT13; 416
milliamps for CT4, CT5, CT6, and CT10;
and 500 ma for CT7.
(d)
Replace defective current transformers.
Replace rubber pads (21) when
reassembling current transformer (16).
Current Test.
c.
Replacement.
(1)
11-5
Removal. (See figure 11-2.)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 11-2. Current Transformer Assembly, Exploded View
11-6
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(a)
Remove and tag generator output
leads and pass them through the
associated current transformers,
freeing the current transformer for
removal.
(c)
Assemble current transformer (16)
with new rubber pads (21),
brackets
(20),
screws
(13),
lockwashers (14) and nuts (15).
Attach terminal block (12) with
screws (10) and nuts (11).
(d)
Secure
current
transformer
assembly to panel (22) with
lockwashers (19), washers (18),
and screws (17).
(e)
Refer to FO-10, Operator and
Organizational
Maintenance
manual and reconnect generator
output leads after passing them
through the associated current
transformers. Remove tags.
NOTE
Count number of turns of each output lead in
each current transformer.
(b)
(c)
(d)
(2)
Current transformers (7 and 8)
may be removed by first
disconnecting and tagging wires,
then removing screws (17) and
washers (18 and 19) or screws (1)
and washers (2 and 3).
Current transformer (16) may be
disassembled by removing screws
(13), washers (14), and nuts (15) to
separate brackets (20) and rubber
pads (21).
Remove current
transformer (16) and terminal
block (12) attached to bracket with
screws (10) and nuts (11).
11-5. GENERATOR.
Current transformers (7 and 8)
may be disassembled by removing
screws (4), washers (5), and nuts
(6) to separate brackets (9).
Remove current transformer (7
and 8).
Installation.
(a)
Install current transformers (7 and
8) by first replacing brackets (9)
with screws (1) and washers (2 and
3).
(b)
Secure current transformers (7 and
8) in brackets (9) with screws (4),
lockwashers (5) and nuts (6).
11-7
a.
Test. Start and operate the generator set.
Check voltage, current, and frequency outputs
as indicated in Chapter 2 of the Operator/Crew
and Organizational Maintenance manual. For
an overall operational test of the generator,
with specific testing condition, test setup, etc.,
refer to Chapter 16 of this manual.
WARNING
BEFORE TURNING OFF GENERATOR SET,
ENGAGE MAINTENANCE LOCKOUT SWITCH.
DISCONNECT AND ISOLATE ELECTRICAL
LEADS.
(1)
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 77°F (25°C). If
this value is not met, clean or dry out the
winding and repeat the test. Replace if
defective.
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
as the leads must be unsoldered
from all diodes before meggering
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.
(e)
Tag and disconnect the two leads
from the voltage regulator to
terminals in the lead separation
box. Connect positive side of a
DC ammeter to negative field
terminal (F-) and the positive
output of an adjustable DC source
to the positive field (F+) terminal.
Connect negative output of DC
source to negative side of DC
ammeter. The exciter field is rated
at 5.6 amps and 50V DC. The
adjustment should be set to
minimum voltage.
(f)
Select 60 Hz and start the engine.
With the speed at 1800 rpm, turn
on the adjustable DC power
supply. Adjust the DC voltage so
that the generator output voltage
(no load) reads 208 or 416 volts
depending on low or high voltage
connection. The exciter field
should draw approximately 1
ampere to produce rated voltage at
no load. The voltage across the
exciter field under these conditions
is approximately 10.8V DC, ±15
percent.
(g)
If the DC ammeter indicates
incorrect input exciter current to
obtain rated voltage in step (f)
above, the generator has failed. If,
however, the output is as specified,
the voltage regulator, control or
PM generator has failed.
(h)
Test rotating rectifier diodes
(paragraph 11-8b). If any
If the insulation fails to meet the test
standards, the generator may be dried
out by heat from a warm air oven, heat
lamps, or strip heaters. The temperature
should not exceed 167°F (75°C).
CAUTION
When oven drying, use a forced air circulation
oven, not a radiant type. Radiant type oven
would overheat some generator parts before
remote parts reached a satisfactory
temperature.
NOTE
If the generator must be dried out, then it is
necessary to revarnish the equipment
immediately after drying to prevent damage to
the unit.
(2)
Generator and excitation system test.
(a)
Generator Stator. Disconnect all
leads to voltage regulator and all
other points to completely isolate
the winding before meggering.
(b)
Generator Rotor. Disconnect field
leads from the rotating diode
assembly before meggering.
(c)
Exciter Stator. Disconnect both
field leads from terminals 1 and 2
of TB210.
(d)
Exciter Rotor. Check this only if
other windings have low insulation
resistance
11-8
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
protector 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.
defective diodes are replaced,
repeat step (2), above, to
determine if the generator defect
has been corrected.
(i)
(j)
(k)
Tag and disconnect the two top
leads at terminals 1 and 2 of
TB210 (14, figure 11-3). Read the
exciter field resistance at terminals
1 and 2 with a Wheatstone bridge.
The exciter stator field resistance
should be 10.7 ±10 percent ohms
at an ambient temperature of 77°F
(25°C).
Check insulation resistance with
megger between terminals 1 and 2
and the frame (paragraph
11-5a(1)). Reconnect the two
leads.
Disconnect generator rotor leads
from the rotating diode assembly
and measure the field resistance
with a Wheatstone bridge. The
resistance should be
approximately 1.66 ±10 percent
ohms at an ambient temperature
of 77°F (25°C).
(3)
(l)
Megger between field leads and
frame (paragraph 11-5a(1)).
(m)
Disconnect diodes and use a
double Kelvin bridge to read the
resistance between leads on the
exciter rotor. This value should be
0.048 ±10 percent ohms at 77°F
(25°C).
(n)
Check insulation resistance with
megger between exciter armature
leads and frame (paragraph
11-5a(1)).
(o)
Check resistance of surge
11-9
(p)
Tag and disconnect the twelve
stator leads to the voltage
reconnection panel and measure
each of the six stator windings with
a
Kelvin
double
bridge.
Resistance should be 0.00237 ±10
percent ohm in each circuit at
ambient temperature of 77°F
(25°C).
(q)
Connect all stator leads together
and read between the leads and
the generator frame with a megger
(paragraph 11-5a(1)).
Stator.
Perform the following stator
winding short circuit test.
(a)
Use an inside-type growler, and
test each coil in the stator.
Position the growler in the stator
and hold a thin metal strip, similar
to a hacksaw blade, parallel to the
core slots.
(b)
Energize the growler and explore
the core surfaces approximately
one pole distance on each side of
the growler. Continue testing one
core slot at a time until all coils are
tested. If the winding is shorted,
the metal strip will vibrate when
held over the slot containing the
faulty coil.
(c)
If the above test is not met,
proceed with the removal and
repair procedures.
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(4)
considered normal. If the PM generator output
is out of tolerance and checking the resistance
of the PM exciter field (as indicated in the
previous subparagraph 5) produces positive
results, the permanent magnet, by the process
of elimination, may be considered defective. If
defective, refer to paragraph 11-6 for
replacement procedures for permanent magnet
rotor assembly.
Rotor. Perform a growler test on the
rotor as follows:
(a)
Place the rotor on the growler and
energize.
(b)
Hold a thin piece of metal, such as
a hack-saw blade, 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.
b.
Replacement.
(1)
(c)
(5)
Removal. The following steps are for the
removal of the generator from the
generator set frame.
(a)
If generator set is equipped with a
housing kit remove panels (34 and
30, figure 15-21) and strip (27).
(b)
The permanent magnet assembly
must be removed prior to removing
generator from generator set, as
follows (see figure 11-3):
PM Generator Exciter Field. Perform
the following resistance checks:
(a)
At lead separation box, disconnect
and tag PM generator exciter field
leads (there are three; the
common; the 50 Hertz tap; and the
60 Hertz tap).
(b)
Using a double Kelvin bridge,
check the resistance between the
common lead and the 50 Hertz
tap. Resistance should be 1.1
ohms ±10 percent.
(c)
(6)
If the above test is not met,
proceed with the repair
procedures.
Using a double Kelvin bridge,
check the resistance between the
common lead and the 60 Hertz
tap. Resistance should be 1.35
ohms ±10 percent.
(1)
Remove screws (16 and 28), washers
(29), and nuts (27) and remove cover
(30).
(2)
Remove screws (31) and washers (32)
and remove permanent magnet stator
(33).
WARNING
PM Generator Permanent Magnet. The
strength of the magnet field surrounding
the permanent magnet (rotor), because
of its in accessibility, may not be
checked directly. However, if the AC
output of the PM generator is within ±10
percent of 135V AC at 1800 rpm, the
permanent magnet may be
11-10
USE EXTREME CARE WHEN REMOVING
ROTOR TO PREVENT INJURY TO HANDS DUE
TO MAGNETIC ATTRACTION BETWEEN THE
PERMANENT MAGNET GENERATOR ROTOR
AND THE PERMANENT MAGNET GENERATOR
STATOR OR GENERATOR SHAFT.
(3)
Remove bolt (34), washers (35) and
spring pin (36) and remove magnet rotor
(37).
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(c)
Bolts. To remove the generator from the skid base,
proceed as follows:
Reconnection Box. Disconnect and tag generator
wires, cables, and buss bars removed from the
reconnection box assembly.
(1)
(2)
Remove reconnection box enclosure (28,
figure 11-1), by removing screws, washers,
and nuts that attach enclosure to external
power box assembly and output box.
Remove screw (15, figure 11-3), nut (16),
and lockwasher (17) and separate lead
clamp (19) in order to remove generator
cables.
(3)
Disconnect and tag wires in lead box (14).
(4)
Remove screws (8), washers (9), screws
(23), and washers (24). Separate output
box (25) and wires and cables from
generator.
(1)
Remove covers (63 and 67, figure 11-3) by
removing screws (64), washers (66), and
nut (65),
(2)
Remove sixteen screws and washers
securing generator assembly (fig. 11-5) to
engine flywheel housing.
(3)
Remove six screws, washers and locking
plate to engine flywheel.
(4)
Remove the four generator mounting bolts
securing generator frame to the skid base
assembly. Lift the generator by attaching
an overhead hoist and slings to the eyebolts
on the generator frame.
WARNING
(d)
Air Cleaners. To remove generator using
hoist and sling assembly, air cleaners must be
removed from the support frame. Refer to figure
11-4 and proceed as follows:
(1)
OVERHEAD OPERATIONS HAVE INHERENT
HAZARDS
THAT
CANNOT
BE
MECHANICALLY SAFEGUARDED.
HARD
HATS AND SAFETY SHOES ARE REQUIRED .
Remove hose clamps connecting air
hoses to air cleaners.
CAUTION
(2)
Remove screws, washers, and nuts
supporting the two mounting channels
onto the frame assembly.
(3)
Remove air clean assembly.
(e)
Remove either EXTERNAL CONTROL
BOX per paragraph 2-15a or AC-DC BOX
per paragraph 2-14a.
(f)
Generator Mounting
Determine that the hoist is of sufficient
strength to adequately support the weight of
the generator. Hoist and hoist cables
should have a rating of not less than 6000
pounds (2,724 kg). Always make certain
extreme care is taken when moving the
generator to prevent its striking other
objects or personnel. Never apply a lifting
force to structural points other than those
provided for that purpose.
(2)
11-11
Installation. Install repaired, rebuilt, or overhauled
generator to the engine and skid base assembly are
follows:
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 11-3. Generator Assembly, Exploded View
11-12
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND FOR FIGURE 11-3
1. Screw
2. Washer
3. Plate
4. Screw
5. Washer
6. Cover
7. Screw
8. Nut
9. Washer
10. Terminal board
11. Screw
12. Nut
13. Washer
14. Lead box separation
15. Screw
16. Nut
17. Washer
18. Batten
19. Lead clamp
20. Screw
21. Washer
22. Bracket
23. Screw
24. Washer
25. Outlet box
26. Screw
27. Nut
28. Screw
29. Washer
30. Cover
31. Screw
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
Washer
Permanent magnet
Bolt
Washer
Pin
Permanent magnet
Exciter rotor unit
Diode
Nut
Washer
Diode
Nut
Washer
Screw
Nut
Washer
Washer
Screw
Lug
Surge protector
Setscrew
Key
Screw
Washer
Field
Screw
Bracket
Drive plate assy
Setscrew
Coupling hub
Key
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
93.
Cover
Screw
Nut
Washer
Cover
Screw
Washer
Adaptor
Screw
Washer
Fan
Screw
Washer
Setscrew
Hub
Baffle
Key
Screw
Washer
Washer
Washer
Cap
Endbell
Nut
Washer
Bearing
Shaft and rotor
Screw
Washer
Lifting eye
Frame and stator
NOTE
Set the dial indicator to zero. Turn the engine
through one complete revolution. Total indicator
reading should not exceed 0.005 inch (0.13 mm). If
reading exceeds allowable limits, excessive
vibration could result.
Do not assemble permanent magnet
generator assembly (stator and rotor) and
end cover on the generator prior to
installation.
(a)
Check to make certain generator bearing
end clearance is sufficient. Generator
bearing end clearance should not be less
than 0.015 inch (0.4 mm) plus 0.06 inch
(1.6 mm).
(b)
Check Flywheel Face Runout. Position the
indicator finger on the drive disc recess of
the flywheel as shown in figure 11-6.
(c)
11-13
Check pilot bore eccentricity. Position the indicator
finger on the bore of the drive disc pilot recess as
shown in figure 11-7. Rotate the engine through
one revolution. Total indicator reading should not
exceed 0.005 inch (0.13 mm).
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 11-4. Air Cleaner Assembly Removal
(d)
Check the Flywheel Housing Runout. Mount the
base of a dial indicator on the flywheel and position
the finger of the indicator on the machined surface
of the flywheel housing (bellhousing) which bolts to
the generator adapter. (See figure 11-8.) Set the
dial indicator to zero. Turn the engine through one
complete revolution. Total indicator reading should
not exceed 0.006 inch (0.15 mm). If reading
exceeds the allowable limit, excessive vibration
could result.
11-14
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 11-5. Generator Mounting Bolts
11-15
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 11-6. Checking Flywheel Face Runout
(e)
Figure 11-7. Checking Flywheel Pilot Bore Eccentricity
Measure the distance from the surface on the
generator adapter that bolts to the engine flywheel
housing to the outside surface on the drive discs
(Dimension "Y", figure 11-9). Then measure the
distance from the machined surface on the engine
flywheel (Dimension "C", figure 11-10). If the
distance from the bellhousing to drive disc recess
"C" is more than the distance from the generator
adapter to the drive discs "Y", install additional
spacers between the drive discs and the generator
drive hubs. If "Y" is more than "C", remove spacers
located between the drive discs and generator hub.
(f)
Make certain drive discs "seat" in the drive disc
recess.
WARNING
NEVER GRIND OD OF DRIVE DISCS
AND NEVER ATTEMPT TO "DRILL
OUT" HOLES IN DRIVE DISCS. IF
DRIVE DISCS DO NOT FIT PROPERLY,
REPLACE DRIVE DISCS.
(3)
11-16
Locating Generator. Lift the generator by attaching
an overhead hoist and slings to the eyebolts on the
generator frame.
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
and install four generator mounting bolts
(figure 11-5) securing generator frame to
the skid base assembly. Do not tighten
bolts at this time.
(c)
Install Control Box Assembly per
paragraph 2-14b.
CAUTION
If fan is moved, make certain that
before generator set is placed in
operation, fan is positioned with
about 1/2 inch (13 mm) clearance
between fan and baffle and all fan
bolts are installed and tightened .
(d)
Tighten mounting bolts to torque shown in
figure 11-5. Make certain generator
mounting pads contact the base evenly and
with equal pressure. Use of shims may be
required.
(e)
After generator is assembled to the engine,
check runout by placing the base of a dial
indicator on a generator frame rib and
positioning the indicator finger on the
generator shaft. Set dial indicator to zero.
Turn generator through at least one
revolution. Total indicator reading should
not exceed 0.005 inch (0.13 mm).
Figure 11-8. Checking Flywheel Housing Runout
CAUTION
Determine that the hoist is of sufficient
strength to adequately support the
weight of the generator. Hoist and
Hoist cables should have a rating of
not less than 6,000 pounds (2,727 kg).
Always make certain extreme care is
taken when moving the generator to
prevent its striking other objects or
personnel. Never apply a lifting force
to structural points other than those
provided for that purpose.
(a)
(b)
Install sixteen screws and washers securing
generator assembly (figure 11-5) and six
bolts and locking plate to engine flywheel
housing. Tighten screws.
NOTE
Use inspection mirror to read indicator. It
may be necessary to move fan out of the
way. See CAUTION following step (c).
(4)
Installing PMG.
(a)
Move generator to location on skid base,
line up mounting holes
Install the exciter rotor assembly and the
pilot exciter rotor. Make certain the key is
in place in the shaft before installing exiter
rotor assembly.
CAUTION
Do not apply force to rotating rectifier
or to the armature windings.
11-17
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 11-9. Obtaining Dimension Y
(b)
Install permanent magnet rotor (37, figure 11-3)
with spring pin (36), cover (30), bolt (34), and
washer (35).
(f)
Before placing generator set in operation, visually
inspect clearance between generator stationary and
rotating parts.
(c)
Install permanent magnet stator (33) with screws
(31) and washers (32).
(g)
Visually inspect alignment of the exciter armature
with the exciter field.
(d)
Install cover (30) with screws (26 and 28), washers
(29) and nuts (27).
(h)
(e)
Connect (+) and (-) leads from generator field onto
(+) and (-) terminals located on the heat sinks of the
rotating rectifier assembly.
Before placing generator set in operation, turn
engine through several revolutions, but do not
permit engine to start. visually inspect clearance
between generator stationary and rotating parts.
Listen for
11-18
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 11-10. Obtaining Dimension C
unusual noises such as produced by parts rubbing
together.
(i)
c.
NOTE
When generator installation has been
completed and inspected, install covers and
guards.
To remove coils from an iron core, it is
recommended that the part be heated in a
moderate oven temperature 302°F (150°C) to
facilitate removal. Single coils should not
be replaced as adjacent parts of the winding
may be damaged during, coil removal.
Repair. Repair of the generator consists of
testing, removing, replacing, and repairing
components as listed in table 11-1.
(1)
Replace or rebuild all defective parts.
d.
11-19
(2)
Apply varnish to any damaged areas of
insulation.
(3)
Replace damaged exciter rotor or stator.
Overhaul. Overhaul of the generator consists of
the
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
replacement of components after inspection and/or testing
indicates the need for replacement. The inspection, test,
replacement, and repair of generator components is
described in paragraphs listed in table 11-1.
Table 11-1. Repair of Generator Components
COMPONENT
PARAGRAPH REFERENCE
TEST
REMOVAL
REPLACEMENT
REPAIR
PMG stator and frame
11-6c
11-6d
11-6d
PMG rotor
11-7b
11-7c
11-7c
11-7d
Rotating rectifiers
11-8b
11-8c
11-8c
11-8d
Bearing
11-9a
11-9a
Drive plate
11-10b
11-10b
Fan
11-11a
11-11a
Rotor
Exciter stator
11-12b
11-13b
11-12c
11-13c
11-12c
11-13c
11-12d
11-13d
Exciter armature
11-14b
11-14c
11-14c
11-14d
Frame and stator
11-15b
11-15c
11-15c
11-15c
e.
accordance with specification MIL-T-704, type A,
semigloss, olive drab color no. X24087.
Rebuild. Generator rebuilding consists of
restoring generator to "like new" condition. This
requires the replacement of parts and the
rewinding of coils on fields and armatures, new
diodes and surge protector, bearing, covers, etc.
All metal parts are cleaned with Federal
Specification P-D-680 and thoroughly dried.
Cracks in frame and other components are
welded and painted parts are repainted in
NOTE
Machined surfaces, screw threads, leads,
and lead clamps are to be free from paint.
Rebuild generator components in accordance with
procedures described in paragraphs listed in table
11-1.
11-20
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
11-6. PERMANENT MAGNET STATOR AND FRAME
ASSEMBLY
a.
b.
c.
General. The permanent magnet generator
(PMG) stator furnishes power to the voltage
regulator. The stator (33, figure 11-3) is
bolted to the end-bell (85). It consists of
armature windings in a laminated core
welded to a steel frame. The revolving field
or rotor (37) is made up of permanent
magnets.
(1)
Cracked insulation of wiring.
(2)
Accumulation of dust, moisture or
other foreign matter.
(3)
Cracks or breaks in welded steel
frame.
(c)
Connect a Wheatstone bridge to the
stator leads.
(2)
Resistance should be 0.0024355
ohms per winding, at an ambient
temperature of 77°F (25°C).
OVERHEAD OPERATIONS HAVE INHERENT
HAZARDS THAT CANNOT BE
MECHANICALLY SAFEGUARDED. HARD
HATS AND SAFETY SHOES ARE REQUIRED.
(d)
Disconnect the PMG stator leads. Tag leads for
reconnection.
(e)
Disconnect and tag exciter field leads.
(f)
Remove exciter rotor (38) as follows:
If resistance reading is incorrect,
replace defective stator assembly.
Removal. Remove as follows:
(a) Remove screws (26 and 28,
figure 11-3), washer (29), and nut
(27), and remove cover (30).
(1)
Remove set screw (52).
(2)
The exciter armature is a "slip-fit" on the
generator shaft. If the armature cannot be
removed by hand, remove with a puller.
CAUTION
Replacement. When disassembling the
PMG stator from the generator, the PMG
rotor and exciter assembly is also removed.
(1)
Support the PMG stator with an overhead crane
or hoist.
WARNING
Test. A resistance check of the stator
winding can be made as follows:
(1)
Take out retaining bolt (34) and washer (35).
Observe WARNING above, and remove pin (36)
and PMG rotor (37).
NOTE
If the PMG rotor is to remain disassembled
for an extended period, install a keeper on
the rotor. Use a band of iron or steel.
Inspection. Inspect assembly for:
(3)
d.
(b)
Do not pull on rotating rectifier
assembly of the exciter armature
windings.
(3).
Install a cap or plug to protect the shaft center.
Using the tapped holes in the end of sleeve, bolt to
the end of sleeve spacers and a metal plate. Refer
to figure 11-11.
(4)
Hook a bearing puller to the metal plate and pull
exciter armature and rotating rectifier assembly
from the shaft.
WARNING
USE EXTREME CARE WHEN REMOVING
ROTOR TO PREVENT INJURY TO HANDS
DUE
TO
MAGNETIC
ATTRACTION
BETWEEN THE PMG ROTOR AND THE PMG
STATOR
OR
GENERATOR
SHAFT.
11-21
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
NOTE
(g)
(2)
Remove screws (31) and washers (32)
holding the PMG stator frame, and
screws (54) and washers (55) supporting
the exciter field (56) to the endbell (85).
Usually the exciter armature will slide
onto the shaft most of the way by
hand. The exciter armature can
usually be "seated" by tapping lightly
on the sleeve with a soft rubber or
fiber mallet. Make certain mallet hits
only the sleeve, not rectifier assembly
or armature windings
Replacement. Replace as follows:
(a)
Install exciter field (56) onto endbell
(85) with screws (54) and washers
(55). Connect exciter field leads to
reconnection box. Remove tags from
leads.
CAUTION
Make certain the key is in place in the
generator shaft and the keyway in the
exciter armature sleeve is aligned with
key before starting the exciter
armature onto generator shaft.
Figure 11-11. Removing Exciter
Armature and Rotating
Rectifier Assembly
(b)
If the "slip-fit" exciter armature and
rotating assembly will not easily slide
onto the shaft by hand, install with a
fixture as shown in figure 11-12.
Refer to figure 11-12 for fixture setup. Start
exciter armature and rectifier bridge on
shaft. Thread stud in rotor shaft. Install
large diameter washers on stud and start
stud nut. Pull exciter armature and rotating
rectifier onto shaft by turning stud nut.
(3)
Install exciter armature retaining bolt (34,
figure 11-3), washer (35), and pin (36).
Connect alternator field leads to positive (+)
and negative (-) terminals located on the
heat sinks of the rotating rectifier assembly.
Install exciter cover (30) with screws (26
and 28) washers (29), and nuts (27).
(c)
Using a crane or hoist, install the PMG stator (33)
over exciter assembly onto endbell (85) with screws
(31) and washers (32). Connect PMG stator leads to
reconnection assembly. Remove tags from leads.
(d)
Remove iron band (if used) from PMG rotor
assembly (37). Carefully attach PMG rotor (37), bolt
(34), and washer (35).
Install exciter rotor (38) on generator shaft
as follows:
(1)
(2)
11-22
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
figure 11-3) by removing screws 26 and 28), washer (29),
and nut (27).
WARNING
USE EXTREME CARE WHEN REMOVING
ROTOR TO PREVENT INJURY TO HANDS
DUE TO MAGNETIC ATTRACTION
BETWEEN THE PMG ROTOR AND THE PMG
STATOR OR GENERATOR SHAFT.
(b)
Remove bolt (34), washer (35), and pin (36) from
PMG rotor (37). Carefully remove PMG rotor (37)
from generator shaft.
NOTE
Figure 11-12.
(e)
If the PMG rotor is to remain disassembled
for an extended period, install a keeper on
the rotor. Use a band of iron or steel.
Installing Exciter Armature and
Rotating Rectifier Assembly
Replace cover (30) with screws (26 and 28),
washers (29), and nuts (27).
(2)
11-7. PERMANENT MAGNET ROTOR ASSEMBLY.
The permanent magnets and soft pale tips of the
revolving field are permanently attached to a steel hub by
nonmagnetic stainless steel bolts.
CAUTION
No attempt should be made to unbolt and
separate rotorparts. This will alter
permanent magnets, reducing their strength.
Do not expose rotor to excessive heat or
mechanical shock.
a.
Inspection. Inspect the rotor for metal chips
attracted to the magnets, accumulation of dust,
and check security of bolts holding each magnet
to hub.
b.
Testing. No testing of the PMG rotor is required.
c.
Replacement.
(1)
d.
(a)
Remove iron band (if used) from PMG rotor
(37).Carefully attach PMG rotor (37) to
generator shaft with pin (36), bolt (34), and
washer (35).
(b)
Replace cover (30) with screws (26 and 28),
washers (29), and nuts (27).
Repair. Since there are no bearings, brushes, or
slip rings and no semiconductor devices,
there is no repair of the PMG rotor.
NOTE
No attempt should be made to unbolt and
separate the parts of the rotor. Breaking the
magnetic circuit would alter the permanent
magnets, reducing their strength.
Reassembling the rotor would not restore
the magnetism to its prior state.
e.
Removal.
(a)
Replacement.
Remove cover (30,
11-23
Rebuild. Since there are no bearings, brushes, or
slip rings and no semiconductor devices, there is
no rebuild of the PMG rotor.
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
reading. The meter should indicate a low
resistance when leads are across rectifier in
one direction and a high resistance when
leads are across rectifier in the other
direction.
NOTE
No attempt should be made to unbolt and
separate the parts of the rotor. Breaking the
magnetic circuit would alter the permanent
magnets,
reducing
their
strength.
Reassembling the rotor would not restore
the magnetism to its prior state.
11-8. ROTATING RECTIFIER. The rotating rectifier
assembly is part of the exciter rotor. (See figure 11-13.)
The rotating rectifier assembly consists of a full wave
rectifier bridge made up of six semiconductor devices
mounted on aluminum heat sinks. Rectifiers are retained
in the heat sink assemblies with retaining nuts and
washers.
a.
b.
Inspection. Check wiring for loose
connections and diodes for looseness in
frame.
c.
If the meter indicates a low resistance in
both directions, the rectifier is shorted. A
high resistance in both directions indicates
an open rectifier.
(4)
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.
Replacement.
(1)
Test. Remove cover (20, figure 11-3) to
gain access to the rotating rectifier
assembly on exciter rotor (38).
(1)
(3)
Removal. Remove the rotating rectifier
assembly as follows:
(a)
Remove cover (30, figure 11-3) by
removing screws (26 and 28),
washers (29), and nuts (27).
(b)
Disconnect leads from (+) and (-)
terminals located on the heat sinks
of the rotating rectifier assembly.
Disconnect lead from diode under
test.
(2)
Refer to figure 11-14, then
connect ohmmeter leads across rectifier in
one direction. Note meter reading.
Reverse leads and note meter
Figure 11-13. Rotating Rectifier Assembly
11-24
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
sink with screws (45), washers (47 and 48), and
nuts (46).
11-9. BEARING. The generator bearing is permanently
lubricated and sealed. If a defective bearing is indicated
by vibration or noise at the bearing housing on the
endball, the bearing can be replaced without removal of
the generator from the set.
a.
Figure 11-14. Testing Rotation Rectifiers with an
Ohmmeter
(1)
Tag leads for later reconnection
(c)
(2)
Remove rotating rectifier with key (53 from
exciter rotor (38).
OVERHEAD OPERATIONS HAVE
INHERENT HAZARDS THAT CANNOT BE
MECHANICALLY SAFEGUARDED. HARD
HATS AND SAFETY SHOES ARE
REQUIRED.
(a)
Install rotating rectifier assembly
onto exciter rotor (38).
NOTE
(a)
Make certain the key is in place and the keyway in the
rotating rectifier is aligned with key before installing.
(b)
Connect leads to (+) and (-) terminals;
remove tags.
(c)
Replace cover (30) with screws (26 and 28),
washers (29), and nuts (27).
(1)
Remove cover (30) by removing screws (26 and
28), washers (29), and nuts (27).
WARNING
USE EXTRA CARE WHEN REMOVING
ROTOR TO PREVENT INJURY TO HANDS
DUE TO MAGNETIC ATTRACTION
BETWEEN THE PMG ROTOR AND THE
PMG STATOR OR GENERATOR SHAFT.
(b)
Remove and replace standard diodes (39,
figure 11-3), detail A) and reverse diodes
(42) on rotating rectifier heat sinks with
washers (41 and 44) and nuts (40 and 43).
Reconnect leads.
(2)
Remove and replace surge protector (51)
from heat
Removal. To gain access to the bearing (88,
figure 11-3), the endbell (85) with PMG
stator (33) and exciter assembly must be
removed as a unit. Use crane or hoist to
remove.
WARNING
Replacement.
d.
Repair. The rotating rectifier assembly repairs
involve replacement of diode and surge protector.
Replacement.
Remove PMG rotor (37) by removing pin (36),
screw (35), and washer (34).
NOTE
Do not subject PMG rotor to severe
mechanical shock.
(c)
Loosen setscrews (52) in exciter rotor (38).
(d)
Remove exciter rotor (38).
(e)
Remove screws (82) and washers (83) to free
bearing cap (84).
(f)
Attach crane or hoist to endbell (85). Remove
bolts (80) and washers (81). Remove endbell (85)
and PMG
11-25
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NAVFAC P-8-631-34
TO-35C2-3-463-2
stator and exciter stator as a unit.
NOTE
Tap lightly with rubber mallet to loosen
endbell. Check for shims in the endbell
bearing housing (well). Make certain shims,
when incorporated, are reinstalled when unit
is assembled.
(g)
(h)
(1)
Remove nut (85) and lockwasher (86).
Use a puller to remove the bearing from the
shaft. (See figure 11-15.) Protect the shaft
end with a cap. If bearing is to be used
again, make sure puller applies pressure
only against the bearing inner ring.
Figure 11-15. Removing Bearing from Generator
Shaft
Bearing Inspection. The following inspection of
the bearing should be made: Results of the
inspection will determine if the bearing is to be
replaced.
(a)
Wash the bearing and inspect the residue.
If hips and flakes are found, replace the
bearing.
(b)
Observe the outer diameter of the bearing
and the inner surface of the bearing
housing section of the endbell for evidence
of spinning.
(c)
Check the bearing for flaking or denting by
grasping the outer race and rotating slowing
to feel for dented or flaked balls or races.
Replace bearing if excessive roughness is
felt.
(d)
Examine the cage for wear. If a bad
condition of smearing exists, remove the
bearing from service.
(2)
(e)
Inspect the inner race. Examine the ball path
to see that it is smooth and free from
breaks. Dirt denting is not considered
serious if it is not concentrated.
(f)
Inspect the balls. Examine them visually to
determine if metal has flaked from the
surface. If flaking has occurred, remove the
bearing from service. A small amount of
evenly distributed denting marks on the ball
is usually not considered serious. Several
concentrated denting marks is serious
enough to reject the bearing for further
service.
(g)
If there is a doubt that the bearing is not
completely satisfactory, replace the
bearing.
(h)
If the bearing is satisfactory, replace it two
thirds full with grease (MIL-G, type
23827AMI).
Replacement.
(a)
11-26
Heat the bearing to a
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
temperature of from 220 to 250°F (103 to 121°C) in a
clean thermostatically controlled oven. Start the heated
bearing into the shaft. Then use a fiber or soft metal tube
to tap bearing into place. (See figure 11-16.) Make
certain that pressure is applied only to the bearing inner
ring.
(35), and washer (34).
(i)
Replace cover (30) with screws (26 and 28),
washers (29), and nuts (27).
11-10. DRIVE PLATE ASSEMBLY.
a.
General. The generator shaft is directly
driven by the engine shaft through the drive
plate assembly, figure 11-17. The coupling
compensates for misalignment between the
two shafts to eliminate injurious stress on
the connection components.
b.
Replacement.
(1)
Removal. Remove drive plate
assembly (59, figure 11-3) as follows:
(a)
Remove cover (63) and cover (67)
by removing screws (64), washer
(66), and nut (65).
(b)
Remove screws attaching drive
plate assembly to engine flywheel.
(See figure 11-18.)
(c)
Loosen setscrew (60) in coupling
hub (61).
(d)
Push drive plate assembly as far as
possible towards the generator fan,
in order to gain access to the hub
screws (57).
(e)
Remove screws (57) by
straightening locking plate (58).
Remove drive plate assembly.
Figure 11-16. Install Bearing on Generator Shaft
(b)
Press bearing onto shaft until inner ring is
against bearing shoulder on the shaft.
Continue assembly after
the bearing has cooled.
(c)
Using a crane, install endbell (85) and PMG
stator and exciter assembly, over generator
shaft.
(d)
Install screw (80) and washers (81).
(e)
Install screws and lockwashers (82 and 83)
attaching bearing cap (84) to endbell (85).
(f)
Line up lockwasher (87) and tighten nut (86)
to secure bearing.
(2)
Replacement. Install drive plate assembly
as follows:
(g)
Tighten setscrew (52) in exciter rotor (38).
(a)
(h)
Install PMG rotor (37) with pin (36), scres
11-27
Locate drive plate assembly onto hub (61)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 11-18. Drive Plate Assembly and Engine
Flywheel Housing
11-11. FAN. The internal fan draws cool air through the
cover at the exciter end of the generator, and exhausts
warm air through the screen over the adapter assembly.
The fan is key mounted directly to the drive plate
assembly coupling hub.
a.
Replacement. Remove and replace fan as
follows:
Figure 11-17. Drive Plate Assembly
(1)
Removal. Refer to figure 11-3. To remove
the fan, the drive plate assembly must be removed.
Refer to paragraph 11-10.
and attach with screws (57) and locking plates
(58). After tightening, turn tabs up on locking
plates to lock bolts in place.
(b)
(c)
Push drive plate assembly (with coupling hub
attached) toward engine flywheel. Align holes
and install bolts. Tighten and torque to 112
footpounds (157 joules) when dry. (See figure 1118.)
Tighten setscrew (60) on coupling hub (61).
(a)
With covers and drive plate
assembly removed, remove adapter (70) by removing
bolts securing adapter to engine flywheel housing and
screws (68) and washers (69) securing adapter to
generator frame.
(b)
Remove generator mounting
bolts, and with crane, move
11-28
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
generator away from engine enough to allow
removal of coupling hub (61).
CAUTION
Make certain that before generator set is
placed in operation, fan is positioned with
about 1/2 inch (13 mm) clearance between
fan and baffle and all fan bolts are installed
and tightened.
WARNING
OVERHEAD OPERATIONS HAVE INHERENT
HAZARDS THAT CANNOT BE
MECHANICALLY SAFEGUARDED. HARD
HATS AND SAFETY SHOES ARE REQUIRED .
(c)
Remove coupling hub (61) from shaft.
Remove fan hub (73) by loosening screw
(74) with washer (75) and
loosen setscrews (76).
(d)
Remove fan (73) with hub (77) attached.
(e)
Remove hub (77) from fan (73) by
removing screws (71) with washers (72).
(2)
Inspection. Inspect fan hub and blades for visible
signs of damage or wear.
(3)
Replacement. Reinstall fan as follows: (See
figure 11-3.)
(f)
Tighten screw (74) with washer (75) on fan
hub (77). Tighten setscrews (76) on fan
hub (77).
(g)
With crane, move generator back to its
original location and tighten mounting bolts.
Refer to figure 11-5.
(h)
Replace covers (63 and 67), bolts (64),
washers (66), and nuts (65).
11-12. ROTOR ASSEMBLY. The rotor assembly is
supported at one end by a single bearing in an endbell
bolted to the stator frame. The opposite end of the rotor
is provided with a fan assembly and drive plate assembly
which bolts directly to the engine flywheel.
a.
(a)
(b)
Attach hub (77) to fan (73) with screws (71)
and washers (72).
Attach coupling hub (61) to drive plate
assembly (59) with screws (57) and lock in
place with lockplates (58).
(c)
Attach adapter (70) to generator frame with
screws (68) and washers (69).
(d)
Insert baffle (78) and fan (73) into adapter
(70).
Inspection.
(1)
Inspect rotor for loose, frayed, or burned
windings.
(2)
Inspect shaft for burrs or signs of wear.
(3)
Inspect rotor assembly for cracks or other
signs of damage.
b.
(e)
Slide coupling hub (61) (with drive plate
assembly) onto generator shaft aligned with fan hub (77)
with both keys (62 and 79) in keyways.
11-29
Test. Check field winding resistance and
shorts as follows:
(1)
Connect a Wheatstone bridge to field
winding leads.
(2)
The resistance shall be 1.691 to 1.725
ohms at an ambient temperature of 77°F
(25°C).
(3)
Megger between field leads and rotor frame
with a megohmmeter to measure the
resistance between the winding and frame.
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(4)
to adequately support the weight of the generator.
Hoist and hoist cables and slings should have a rating
of not less than 6,000 pounds (2,727 kg). when
moving unit with a fork lift, make certain it is
completely onto and balanced on the fork lift tines.
Insulation resistance shall be at least 1 megohm
at 77xF (25xC). If this value is not met, clean or
dry out the winding and repeat test. Replace rotor
if defective.
NOTE
WARNING
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.
OVERHEAD OPERATIONS HAVE INHERENT
HAZARDS THAT CANNOT BE MECHANICALLY
SAFEGUARDED. HARD HATS AND SAFETY SHOES
ARE REQUIRED.
CAUTION
(5)
Perform a growler test on the rotor as follows:
(a)
Place the rotor on the growler and energize.
(b)
Hold a thin piece of metal, such as a
hacksaw blade, 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.
(c)
c.
Always make certain care is taken when
moving the generator to prevent its striking
other objects or personnel. Never apply a
lifting force to structural points other than
those provided for that purpose.
NOTE
Avoid maintenance locations which would
subject the generator to excessive
moisture, dust, steam or the fumes from
acids, alkalines, or other corrosive
chemicals.
If the above test is not met, proceed with
the removal and repair procedures.
Replacement. For removal and replacement of the
generator rotor assembly, the generator must be
removed from the generator set. (See paragraph
11-5b). After generator has been removed from the
generator set, locate it in a suitable maintenance area
affording sufficient accessibility for maintenance and
sufficient unobstructed flow of coolant air. Move the
generator to the maintenance location either by
attaching an overhead hoist to the eyebolts installed
in the generator frame or by lifting the generator from
underneath the base with a fork lift.
Determine that the hoist, when used, is of sufficient
strength
(1)
Removal. Remove the rotor from the generator
as follows: (See figure 11-3.)
(a)
Remove cover (30) by removing screws (26
and 28), washers (29), and nuts (27).
WARNING
USE EXTREME CARE WHEN REMOVING ROTOR
TO PREVENT INJURY TO HANDS DUE TO
MAGNETIC ATTRACTION BETWEEN THE PMG
ROTOR AND THE PMG STATOR OR
GENERATOR SHAFT.
(b)
Remove PMG rotor (37) by removing pin
(36), screw (35), and washer (34).
NOTE
Do not subject PMG rotor to severe mechanical
shock.
(c)
11-30
Loosen setscrew (52) in exciter rotor (38).
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(d)
Remove exciter rotor (38).
(e)
Remove screws (82) and washers (83) to free
bearing cap (84)
(f)
Attach crane or hoist to endbell (85). Remove
screws (80) and washers (81). Remove endbell
(85) and PMG stator and exciter stator as a unit.
pipes and remove rotor assembly (89) from stator
and frame (93). Make certain air gap is
maintained between the rotor and stator during
removal of the rotor.
NOTE
Install bearing as described in paragraph
11-9 and PMG and exciter as described in
paragraphs 11-6 and 11-7. Make certain
generator armature (stator) and the exciter
armature is aligned with the exciter field.
NOTE
Tap lightly with rubber or fiber mallet to
loosen endbell. Check for shims in the
endbell bearing housing (well). Make certain
shims, when incorporated, are reinstalled
when unit is assembled .
(b)
11-13. EXCITER STATOR. The brushless exciter
provides excitation current for the generator. The stator is
the stationary field for the exciter assembly.
(g)
Remove nut (86) and lockwasher (87).
(h)
Use a puller to remove the bearing form the shaft.
(See figure 11-15.) protect the shaft end with a
cap. If bearing is to be used again, make sure
puller applies pressure only against the bearing
inner ring.
a.
(i)
Install pipes over generator shaft on the drive
and exciter end of rotor. Attach slings and hoist
to pipes and remove rotor assembly (89) from
stator and frame (93). Make certain air gap is
maintained between the rotor and stator during
removal of the rotor.
b.
CAUTION
Make certain pipes are of sufficient
strength to support weight of rotor
and that pipes do not have rough
edges which would damage shaft
surface.
(a)
Install generator as described in paragraph 11-5.
Install pipes over generator shaft on the drive and
exciter end of rotor. Attach slings and hoist to
11-31
Inspect. Inspect the exciter stator as follows:
(1)
Inspect for loose, frayed, or burned
windings.
(2)
Inspect frame for cracks and burred mating
surfaces.
Test. Disconnect all leads on the stator to
completely isolate the winding.
(1)
Using a Wheatstone bridge connected to a
field winding, resistance shall be between
10.57 and 10.79 ohms at an ambient
temperature of 77°F (25°C).
(2)
Check insulation resistance with a
megohmmeter between winding and frame.
Resistance of each winding shall be at least
1 megohm at 77°F (25°C). If this value is
not met, clean or dry out winding, and
repeat test. Replace if defective.
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
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.
Windings may be dried out by heat from a
warm air oven, heat lamps, or strip heaters.
The temperature should not exceed 167°F
(75°C).
WARNING
WHEN OVEN DRYING, USE A FORCED AIR
CIRCULATION OVEN, NOT A RADIANT
TYPE.
RADIANT TYPE OVEN WOULD
OVERHEAT SOME GENERATOR PARTS
BEFORE REMOTE PARTS REACHED A
SATISFACTORY TEMPERATURE.
c.
Replacement. For removal and replacement of
the exciter stator, refer to paragraph 11-6.
d.
Repair.
(1)
Replace or rebuilt all defective parts.
relocating the sleeving over the splice after completion.
The sleeving is to extend a minimum of
1/2 inch (13 mm) beyond the bare
uninsulated portion of wire. The sleeving
material is to be the same as that used
for crossovers 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.
(b)
Enamel is to be cleaned from coil
extensions. Cleaning is to start as near
sleeving as possible. Clean a 1/2 inch (13
mm) section of wire end projecting from a
sleeving.
Maximum uncleaned wire
projecting from a sleeving section shall be 3
inches (76 mm) minimum to 5 inches (127
mm) 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
slot tube) shall be 1/4 inch (6 mm).
Position of the
NOTE
To remove coils from core, heat in a
moderate oven temperature 302°F (150°C) to
facilitate removal. Single coils should not
be replaced as adjacent parts of the winding
may be damaged during coil removal.
e.
(2)
Apply varnish to any damaged areas of
insulation.
(3)
Replace damaged exciter stator.
Rebuild.
(1)
(a)
Rebuild exciter stator as follows:
Single wires may be spliced by brazing.
The splice is to be insulated by sliding
sleeving over the wire prior to brazing
and
11-32
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
tubes should be adjusted so that height of sides is
equal.
(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 linked 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 wedges in place with their
overhanging ends equally spaced. These ends
should project approximately 1-1/2 inches (38
mm) 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 (13 mm) 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 (0.2 to 0.6 mm) of edge projects
beyond edge of wires. Phase insulating strips
may extend 1/2 inch (13 mm) beyond wire on coil
outer diameters.
(i)
Top sticks shall be carefully inserted so that slot
tubes and wire are not damaged. The over
hanging ends should be equal and they should be
level. Top sticks which are broken or split during
insertion should be replaced.
(j)
Connections shall be twisted together and brazed
using brazing alloy. The distance from the first
twist to the film coating on
11-33
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
portion of wire, wrap one layer of tape over the
connection, pressing the two adhesive sides
together for approximately 1/4 inch (6 mm). 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 thickness of tape.
the wire must not exceed 1-1/2 inches (38 mm).
End of connection forming pigtail shall be fusion
welded as much as possible with addition of alloy.
When coil pole leads and ends consists of
multiple wires, care must be taken to ensure 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 makeshift
arrangements.
(l)
Sleeving must be positioned to cover the coil to
which it is attached to a point at least 1/2 inch (13
mm) under two layers of tape. The sleeving at
the coil end must be positioned to provide a
minimum of 3/8 inch (9.5 mm) creepage path
from the coil extension to adjacent coils.
(m)
All connections in stator winding shall be taped
with tape per MIL-I-19166. Where tape is wide
enough to cover the uninsulated wire and extend
a minimum of 1/2 inch (13 mm) over insulated
(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 1/2 inch (13 mm) lap plus 1/8 inch (3 mm)
(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 (13 mm) 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 (76 mm). 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
11-34
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
left on untaped coil after insertion, to help keep
wires from being displaced.
(q)
Wind stator coils using number of turns and wire
per winding data, figure 11-19.
(r)
Sleeve leads with flexible braided glass treated
sleeving.
(s)
Apply slot liner insulation 5-5-5 (item (C)) and coil
separator (item (B)) as shown in stator slot detail,
figure 11-20.
(t)
Make 14 pole series connections per winding
diagram.
(u)
Insert slot wedge (item A)) in slot as shown in
figure 11-19.
(v)
Make high potential test. Test voltage to be 2000
volts per coil connected in series.
(w)
Bake stator as follows:
11-14. EXCITER ARMATURE. The exciter armature is
the rotor part of the brushless exciter that provides
excitation current for the generator. The exciter armature
and rotating rectifer assembly is mounted on the shaft of
the generator. The rotating rectifier has six diodes and a
surge protector mounted on heat sinks.
a.
b.
(1)
Vacuum impregnate until bubbling ceases.
(2)
Allow to drain.
(3)
Bake in 300°F (149°C) oven for 8 hours.
(x)
Type epoxy class F.
(y)
The wound stator should be examined for
complete coverage with not strings or beads, and
with openings between extended position of slot
tubes, blistering or peeling, and complete cure
with tack-free surfaces and good bonding
strength.
Inspect. Inspect the rotor as follows:
(1)
Inspect for loose, frayed, or burned
windings.
(2)
Inspect shaft for burrs or indications
of wear.
Test. Disconnect leads from rotating diode
assembly before testing.
(1)
Growler Test. Perform a growler test
on the rotor as follows:
(a)
Place the rotor on the growler and
energize.
(b)
Hold a thin piece of metal, such as a
hacksaw blade, 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.
(c)
If the above test is not within the
limits specified, proceed with the
repair procedures.
(2)
Rotating Rectifier Test. Refer to paragraph 11-8b
and test the diodes and surge protector on the
rotating rectifier assembly.
c.
Replacement. For removal and replacement of
the exciter rotor, refer to paragraph 11-6.
d.
Repair.
(1)
11-35
Replace or rebuild all defective parts.
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 11-19. Exciter Stator Winding Data
11-36
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
number of turns and wire per winding date.
(See figure 11-20).
NOTE
To remove coils from core, heat in a moderate over
temperature 302°F (150°C) to facilitate removal.
Single coils should not be placed as adjacent parts of
the winding may be damaged during coil removal.
e.
(2)
Apply varnish to any damaged areas of
insulation.
(3)
Replace damaged excitor rotor.
Rebuild. Rebuild exciter rotor as follows: (See
figure 11-20.)
(1)
Inspect winding slots for any sharp corners
at edge and in slot. Clean up as necessary.
(2)
Wind armature coils using
(3)
Sleeve leads with flexible braided glass
treated sleeving.
(4)
Apply slot liner insulation 5-5-5 (polyestermylarpolyester) as shown in slot detail, Item
A, figure 11-20.
(5)
Make pole series wye connections per
winding diagram. (See figure 11-20.)
(6)
Insert slot wedge (Item B) in slot as shown
in slot detail and extend 1/4 inch (0.35 mm)
beyond armature.
(7)
Make high potential test. Test voltage to be
1500
Figure 11-20. Exciter Rotor Winding Data
11-37
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
volts per coil connected in series, to
ground.
(8)
(9)
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.
Bake armature as follows:
(a)
Vacuum impregnate until bubbling ceases.
(b)
Bake in 300°F (149°C) oven for 8 hours.
Type epoxy class F.
(3)
11-15. FRAME AND STATOR COMBINATION. The
generator stator is installed in the frame. Eyebolts on the
top of the frame provide a means of lifting. The stator is
mounted in an endbell positioned on the stator frame.
a.
b.
Perform the following stator winding short
circuit test:
(a)
Use an outside-type growler, and test
each coil in the stator. Position the
growler in the stator and hold a thin
metal strip, similar to a hacksaw
blade, parallel to the core slots.
(b)
Energize the growler and explore the
core surfaces approximately one pole
distance on each side of the growler.
Continue testing one core slot at a
time until all coils are tested. If the
winding is shorted, the metal strip will
vibrate when held over the slot
containing the faulty coil.
(c)
If the above test is not met, proceed
with repair procedure.
Inspection.
(1)
Inspect stator frame for cracks and burred
mating surfaces.
(2)
Inspect stator of generator for loose, frayed,
or burned windings.
(3)
Inspect for missing or defective hardware.
Test. Disconnect all leads to completely isolate
the winding.
(1)
(2)
Measure each of the six stator windings
with a Kelvin double bridge. Resistance
shall be 1.691 to 1.725 ohms in each
circuit.
Connect all stator leads together and
measure between the leads and the
generator frame with a megger. 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 77°F (25°C). If
this value is not met, clean or dry out the
winding and repeat the test. Replace if
defective.
c.
Replacement. The generator stator core is not to
be removed from the stator frame because the
concentricity
between bore and rabbit fits
would be disturbed and cause voltage modulation
problems.
d.
Repair.
11-38
(1)
Repair frayed insulation on leads connected
to the stator windings by covering with tape
or sleeving.
(2)
Replace eyebolts if defective.
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(3)
if necessary. Cover stator windings before
sanding and/or painting generator.
If frame mounting assembly is cracked, weld,
sand, and paint the damaged area.
(4)
Repaint generator frame,
e.
11-39/(11-40 blank)
Rebuild. Seet step c, above
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
CHAPTER 12
MAINTENANCE OF ELECTRIC HYDRAULIC ACTUATOR
12-1. GENERAL. The electric hydraulic governing
system controls the engine speed, either independently, in
parallel with other sets, or with commercial power.
Components of the system include the electronic
governor controller A106, and the hydraulic governor
actuator. The governor actuator is a proportional actuator
with a backup centrifugal governor. The actuator has a
transducer which directs oil pressure to actuate the fuel
control mechanism on the engine. The governor actuator
has two major sections, the electric governor section, and
the centrifugal governor section.
shown in figure 12-1, to hold speed adjustment screw.
12-2. TEST. The following test is required after repair
or overhaul using a test stand.
a.
(4)
Turn spring seat (56, figure 12-3) until the pilot
valve plunger for the actuator gently bottoms,
then back off two turns. Screw spring seat screw
(56) until actuator's power piston (152, figure
12-3) is all the way up, eliminating interference
from the actuator.
(5)
Check pointer alignment with maximum position
on dial plate by rotating terminal shaft in the
increase fuel direction until the power piston is all
the way up.
Recommended Tools. Recommended tools are
listed in tables 2-1 and 12-1.
Table 12-1. Recommended Tools
Electric Hydraulic Actuator
PART NUMBER
NAME
8909-032
8909-038
8959-028
8959-031
370109
110-A
b.
Test Stand
Centering Box
Electronic Counter
Magnet Pickup
Pilot Valve Wrench
Gauss Meter, Bell Model
Preliminary Steps. (See figures 12-1, 12-2, 12-3
and 12-4.)
NOTE
This is important since the unit operates
below minimum position due to the linkage
arrangement between the actuator and
governor. The unit becomes unstable when
operated below minimum. This check of the
dial plate and pointer position insures that
the unit is operating in its correct range.
(1)
Mount unit on test stand and
connect oil inlet, pump pressure and drain
connections (see figure 12-4). A minimum
oil pressure of 5 psi (0.07 kg/cm2) at a
temperature of 140 to 150°F (60 to 66°C) is
required.
(2)
Drive the unit in the normal
clockwise direction of rotation.
(6)
Surge the unit by setting speed
droop to zero and opening needle valve
(92). Zero speed droop is set when the pin
on bracket (32) is on a centerline
(3)
Remove cover (13, figure 12-3)
and use adapter plate
12-1
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 12-1. Speed Setting Adapter Plate
with the shaft hole in the droop lever (33).
zero. Move the speed droop bracket towards the ballhead
to increase droop. Speed droop is normally set in the
range of 3 to 6 percent.
(7)
Close needle valve (92) 1/4 to 1/2
turn from bottoming to stabilize unit.
e. Centering Pilot Valve Plunger.
(8)
Check governor section for leaks,
hunting, drifting and oil pressure.
c.
(1)
Adjust speed adjusting screw until
governor is approximately 5 percent above
steady-state speed.
Governor Needle Valve Setting. Eliminate any air
trapped in the actuator passages if not already done
in the preliminary set-up. With the governor
controlling, open needle valve (92) until the unit hunts
or surges. After 2 or 3 minutes, gradually close the
needle valve until the speed just settles out. Closing
the needle valve further than necessary makes the
unit slow to return to set speed after a load change.
Never close the needle valve tight. Test the unit by
manually disturbing the speed. Only a small
overshoot or undershoot should occur before the unit
returns to its steady-state speed. The actuator has no
needle valve adjustment.
(2)
Disconnect test stand linkage
from terminal shaft.
(3)
Back out actuator pilot valve
plunger screw (63) 1-1/2 to 1-3/4 turns after
bottoming very carefully against spring.
Use a 7/64 inch (2.8mm) hex wrench.
(4)
Set test circuit (figure 12-2) to
OFF and connect to transducer plug on
actuator case.
d. Speed Droop Adjustment. Speed droop is adjustable
internally. The speed droop bracket (32) is clamped
to the speed droop lever with a setscrew. A pin on
the droop bracket carries the floating lever (19).
When this pin is aligned with the droop lever shaft the
droop will be
(5)
Connect a 9 VDC power source
to test circuit. Set test circuit to CENTER.
(6)
Adjust test circuit potentiometer
to 400 ma then set switch to OFF.
(7)
Adjust spring seat screw (56) with
a 1/8 inch (3.2 mm) hex wrench until
terminal shaft rotates approximately to its
midpoint of travel. Turn spring seat screw
(56) clockwise to move terminal
12-2
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 12-2. Actuator Test Circuit
shaft towards maximum fuel and counterclockwise to
move it towards minimum fuel.
(8)
8 (a) 2. and 3. until no movement of the
terminal shaft occurs when the test circuit is
moved from OFF to ENTER. Continue on
to step (9) and calibrate terminal shaft.
Set test circuit to CENTER. Observe and note
direction and position of terminal shaft
movement.
(b)
If terminal shaft did not move
from its original position, the pilot valve
plunger is centered. Continue to step (9)
and calibrate terminal shaft.
(a)
If terminal shaft moves to another
position set test circuit to OFF.
4.
1.
For a clockwise
movement turn pilot valve plunger
screw (63) slightly
counterclockwise.
(9) Turn test circuit to OFF and set potentiometer to zero
ma.
2.
For a counterclockwise
movement turn screw (63) slightly
counterclockwise.
CAUTION
Do not exceed 200 ma during
remainder of test to prevent damage to
the magnetic properties of the magnet.
3.
Note the new position for
reference in case more adjustment
is needed.
(10)
Set test circuit switch to NORMAL.
(11)
Adjust potentiometer to 20 ma.
Repeat steps 8(a)1. and 3. or
(12)
Turn spring seat (56) counterclockwise until
actuator terminal shaft
12-3
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 12-3. Governor Actuator, Exploded View
12-4
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND FOR FIGURE 12-3
1. Screw
2. Lockwasher
3. Screw
4. Nut
5. Screw
6. Lockwasher
7. Receptacle
8. Screw
9. Washer
10. Screw
11. Socket
12. Gasket
13. Cover
14. Pin
15. Cotter pin
16. Screw
17. Nut
18. Pin
19. Lever
20. Pin
21. Tapered plug
22. Seal
23. Shaft
24. Lever
25. Bushing
26. Spacer
27. Pin
28. Pin
29. Screw
30. Lockwasher
31. Washer
32. Bracket
33. Lever
34. Link
35. Ring
36. Pointer
37. Screw
38. Plate
39. Plate
40. Retaining ring
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.
Pin
Packing
Spring
Pin
Retaining ring
Shaft
Bushing
Seal
Washer
Screw
Plug
Pin
Pin
Pin
Nut
Seat
Spring
Lever
Cotter pin
Sleeve
Bearing
Pin
Screw
Spring assy
Screw
Lockwasher
Screw
Lockwasher
Washer
Plate
Pin
Lever
Pin
Bracket
Cup
Solenoid
Washer
Magnet
Cover
Pin
moves to minimum position on dial. Turn seat
(56) clockwise until shaft moves 1 to 2°toward
maximum.
(13)
81. Pin
82. Washer
83. Link
84. Nut
85. Seat
86. Bearing
87. Ring
88. Pin
89. Ring
90. Ball arm
91. Ball Head
92. Needle valve
93. Packing
94. Screw
95. Packing
96. Ring
97. Cap
98. Packing
99. Ring
100. Plug
101. Packing
102. Spring
103. Piston
104. Coupling
105. Screw
106. Lockwasher
107. Pin
108. Plug
109. Plug
110. Check valve
111. Plug
112. Packing
113. Spring
114. Spacer
115. Plunger
116. Sleeve
117. Base
118. Ring
119. Packing
120. Bushing
(14)
Adjust potentiometer for 160 ma. Terminal shaft
movement should be an additional 29 (±1/2°)
towards maximum.
12-5
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.
Plunger
Bushing
Ring
Gear
Stud
Bushing
Plunger
Ring
Spring
Bushing
Pin
Washer
Piston
Pin
Nut
Washer
Piston
Pin
Pin
Pin
Pin
Lever
Pin
Screw
Lockwasher
Lever
Link
Link
Ring
Washer
Packing
Piston
Sleeve
Plug
Screw
Nameplate
Case
If adjustment is necessary, loosen screws (67)
slightly and turn eccentric pin (71) in restoring
lever (72) as required to shift position of ration
adjustment clamping plate (70). Move plate tang
towards transducer lever (58) to increase terminal
shaft travel and away from lever to decrease
terminal shaft travel.
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(15)
Repeat maximum and minimum
ma adjustments until terminal shaft travels
correct distance and steps (12), (13) and
(14) are satisfied.
d.
Simulate an overspeed condition until the
terminal shaft travels to a position just short (1 to
2°) of the minimum line on the dial plate. At this
point the speed should rise by the amount of
droop percentage. If the speed droop needs to be
increased, move the droop bracket towards the
flyweights. Move the droop bracket away from
the flyweights to decrease droop.
(16)
Shut off test stand, if used.
Disconnect test circuit. Remove speed
setting adapter plate and replace it with
cover. Be sure speed setting screws
protrude the same distance below edge of
case, or that the governor's speed is
sufficiently high to prevent interference with
actuator portion.
e.
12-4. REPLACEMENT.
(17)
Disconnect unit, remove and
drain test fluid.
f.
If droop is readjusted, readjust the speed as
required to obtain the desired results.
a.
Adjustments After Tests. When actually
operating, set the governor section approximately
5 percent higher than the actuator section. This
allows the actuator to control.
Removal. Remove the governor/actuator from
the engine as follows:
CAUTION
Disconnect negative terminal cable
from battery. Remove external power.
12-3. ADJUSTMENTS. Speed adjustments may be
performed with the governor actuator installed on the
engine.
a.The speed adjustment screw in on top of
the unit. Turn the adjustment screw
clockwise to increase the speed and
counterclockwise to decrease speed.
b.Figure 12-3 shows the speed adjustment
shaft (23), and the high (16) and low (3)
speed stop screws. Use the speed
adjusting shaft to change speeds between
these preset ranges. Speed may be
changed remotely with the speed adjusting
shaft and the proper connections.
(1)
Disconnect linkage (figure 12-4) on
governor/actuator.
(2)
Disconnect electrical connector on
governor/actuator.
(3)
Disconnect oil line to the governor/actuator.
(4)
Remove bolts securing unit to sump. Pull straight
up, and remove unit and gasket.
b.
Replacement. Reinstall or replace unit as follows
(see figure 12-4):
(1)
Using a new gasket between the
base of the unit and the mounting pad,
mount the governor/actuator unit on the
mounting pad. Square the unit with the
engine linkage and in line with the drive.
Fit the splined drive shaft into the drive with
a free, slip fit; no tightness is permitted.
Set the unit on the mounting pad of its own
weight without any force being applied.
Also, make allowance for unrestricted oil
flow drainage through the drive shaft bore
and annulus within the base mounting
c.Adjust the unit's speed using the speed
adjustment screw or speed adjusting shaft
until the desired steady-state speed is
obtained. Simulate an underspeed
condition until the terminal shaft travels to a
position just short (1 to 2°) of maximum line
on the dial plate. Readjust the speedsetting screw if necessary to obtain terminal
shaft position at the required speed.
12-6
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
oil supply to the inlet of the unit.
pilot. Install mounting bolts.
(2)
(3)
Connect electrical connector.
(4)
Maximum and minimum lines on the terminal
shaft dial plate indicate the limits of terminal shaft
travel during normal operation (approximately
32°). The pointer is preset at the factory and
should not be moved.
(5)
12-5. REPAIR.
Adjust the fuel linkage to use approximately 20°
of the terminal shaft travel from no-load to fullload. Divide the unused terminal shaft travel
equally on each side of the 20°range. The
engine linkage must not bind and backlash must
be minimal.
a.
Disassembly. When repairing, do not
disassemble the unit or its various subassemblies
any further than necessary. Refer to figure 12-3.
(1)
Remove screw (1), lockwasher
(2), cover (13), and gasket (12).
(2)
Remove pins (14) from speeder
spring assembly (43), pin (18) from floating
lever (19) and take out floating lever.
(3)
Remove pin (20) and tapered
plug (21). Do not damage shaft bushing
(25), or bore.
Connect the oil line from the
(4)
Drive speed adjusting shaft (23)
toward opposite side
Figure 12-4. Governor/Actuator Mounting on Engine and Actuator Test Connections
12-7
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
of case to knock out the oil seal (22).
a 10-32 nut and two washers from the cover as a puller.
(5)
Remove speed adjusting shaft (23), speed
adjusting lever (24), bushings (25) and spacer
(26). Do not remove bushings (25) unless they
need replacement.
(11)
Remove retaining ring (45) from terminal shaft
(46) and pull shaft from case. Remove bushings
(47) only if replacement is necessary, oil seal (48)
and washer (49) from both sides of the case.
(6)
Remove speed droop lever pin (28) connecting
speed droop lever (33) and piston link (34).
(12)
Remove screws (50) that attach plug (51) to case.
Do not disconnect plug from solenoid leads.
(7)
Remove two rings (35) and both dial plates (38
and 39) from the case (157).
(13)
Remove pin (53) and disconnect restoring lever
(72) from piston link (83).
(8)
Remove retaining ring (40), pull out pivot pin (41)
and take out speed droop lever (33).
(14)
Remove pin (54) from transducer bracket (74).
Lift out transducer lever (58), spring seat (56) and
spring (57).
NOTE
NOTE
If the speed droop bracket is removed,
mark its position on the speed droop
lever for ease in reassembly.
(9)
(10)
If spring seat is to be removed from transducer
lever, measure and record projection of seat
above top of transducer lever for ease in
reassembly.
Use pilot valve wrench, figure 12-5, and place it
between speeder spring (43) coils on spring seat
(85). Disengage spring from its seat. Hold seat
with wrench and bend spring towards open end of
bottom coil. At the same time turn spring to
disengage coil from seat lip.
(15)
Remove screw (63) and restoring spring
assembly (64) including attached parts (59)
through (62).
(16)
Remove screws and lockwashers (65 and 66) and
lift out transducer bracket assembly (74, 72, 71,
and 67 through 70).
Remove taper pin (44) from terminal lever (146)
using
NOTE
If ratio adjustment plate (70) is
removed, mark its position on
restoring lever (72) so it can be
replaced in the same position.
Figure 12-5. Pilot Valve Wrench P/N 370109
12-8
(17)
Lift out temperature compensation cup (75),
solenoid (76), washer (77), magnet (78), and
cover (79) as a unit. Do not remove spring (129)
from pilot valve plunger.
(18)
Remove pivot pin (81) and piston link (83).
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(19)
Hold spring seat (85) with pilot valve wrench and
remove nut (84).
(33)
Remove idler gear (124).
(20)
Remove spring seat (85) while holding pilot valve
plunger (121) stationary.
(34)
Remove bushing (126, pilot valve plunger (127)
and retaining ring (128).
(21)
Remove thrust bearing (86).
(35)
(22)
Remove retaining ring (87) from bushing (120)
and lift flyweight assembly (87 through 91) out of
case.
Disengage magnet spring (129) from pilot valve
plunger (127) and remove compensating bushing
(130).
(36)
Remove cotter pin (27), pin (131) and push power
piston (133) out of case from top.
Disassembly right (89) and ball arm (90) from ball
head (91).
(37)
Remove pushrod pin (134).
(24)
Remove needle valve and packing (92 and 93).
(38)
(25)
Remove screw and packing (94 and 95).
Remove nut (135) and pivot washer (136), and
push linkage return piston (137) out of case from
top. Count number of turns when removing the
nut for reassembly.
(26)
Remove ring (96) and pull out buffer cap (97) with
smooth jaw pliers. Remove packing (98).
(39)
Lift free end of floating lever (142) and turn it to a
position where pin (138) can be driven out.
(40)
Remove floating lever (142), terminal lever (146),
terminal lever link (147) and pivot link (148).
(41)
Remove snap ring (149).
(42)
Remove power piston (152) through top of case.
(43)
Pull sleeve (153) out of case using a hook-shaped
tool.
(23)
(27)
Remove retaining ring (99) and buffer system
(100 through 103). Thread a base bolt into plug
(100) to ease removal.
(28)
Turn actuator over on its top with base up and
remove drive coupling (104).
(29)
Remove screws and lockwashers (105 and 106).
Place two screwdrivers into the slots provided on
each side of the base. Carefully work base off by
twisting and prying to free taper pins and remove
base. When separating the base from case be
careful of parts falling out and becoming
damaged.
(30)
Remove oil seal ring (118), packing (119), plug
(111), and packing (112).
(31)
Remove relief valve parts (113 through 116).
b.Ball Head Repair. Use an arbor press
and tool T93163 to disassemble the ball
head. See figure 12-6. Press the drive cup
and ball head out of the cover.
Disassemble the drive cup, ball head,
bearing and flyweights. Note which side of
the bearing is "up" in the drive cup and
reassemble it with the same side up.
(32) Remove rotating bushing (120), pilot valve plunger
(121), compensation bushing (122) and retaining
ring (123) from case.
12-6. OVERHAUL. Check all parts for wear, cracks,
nicks, corrosion, or other damage. Check threads and
serrations for tooth damage. Check the electrical
connector for cracks or damage and wiring connections
for breaks. Check all bearings for wear and damage.
Replace flyweights if worn areas on the toes are greater
than 3/64 inch wide.
12-9
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Insert flyweight pins in the flyweights and check for
brinelling (wear pockets), looseness, or stickiness. At the
same time check the flyweight bearings. Replace both
flyweights together if either one is damaged.
Figure 12-7. Check Valve Installation
speed adjusting lever as shown in figure 12-8.
(4)
Assembly governor pilot valve bushing (120),
pilot valve plunger (121), compensating bushing
(122) and retaining ring (123), figure 12-9.
(5)
Assemble actuator pilot valve bushing (126,
figure 12-10), pilot valve plunger (127),
compensating bushing (130), magnet adjusting
spring (129 and retaining ring (128).
Check the magnet's magnetic field strength; it should be
1100 gauss. Jumper contacts 3 and 4 of plug (51) and
measure total resistance across terminals 1 and 2. This
resistance should be 31.6 (±5 percent) ohms at 70°F
(21°C).
(6)
Assembly clamp bracket (74, figure 12-11),
restoring spring assembly (59 to 62, 64),
transducer lever (58), restoring lever (72),
eccentric pin (71), adjustable spring seat (56), and
pilot valve plunger nut (55).
a.
Assembly. Lubricate all packings with
petrolatum. Lubricate all seals and metal parts before
installation. Numbers on callouts of figures are the same
as numbers on figure 12-3 for cross-reference.
(7)
See figure 12-12.
Figure 12-6. Ball Head Disassembly
Power pistons, buffer pistons, pilot valve bushings and
rotating bushings must have sharp edges on all lands.
Replacement is necessary if any nicks, roundness or
damage is found.
(a)
Assembly packing (98), buffer
cap (97) and retaining ring (96) in the case.
(1) Install all pipe plugs in case and
base per exploded view figure 12-3.
(b)
Assembly packing (95) and screw
plug (94) in case.
(2) Install check valves (110) in the
case (157) bottom and base (117) as
shown in figure 12-7.
(3) Assembly floating lever and
12-10
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(c)
Assembly spring (102), buffer
piston (103), spring (102, packing (101),
buffer plug (100), and retaining ring (99) in
case.
(d)
Assembly pivot pin
(83)with straight pin (80).
(81) to piston link
(10)
Insert power piston (152) and floating lever (142)
assembly into case per figure 12-15.
(11)
Insert terminal lever (146), terminal lever link
(147) and pivot link (148) into the case (figure 1216). Insert floating lever (142) through the slot in
pivot link (148). Fasten together with pin (141)
and secure with a cotter pin.
(12)
Insert piston link (83) and pivot pin (81) into top
hole in power piston. Secure with washer (82)
and cotter pin.
See figure 12-3.
(13)
Refer to figure 12-17 and 12-18.
NOTE
Insert buffer piston (103) into case correctly
with cup ent out.
(8)
13).
(9)
Assembly needle valve (92) in case (figure 12-
See figure 12-14.
(a)
Assembly power piston (152) and
floating lever (142) with pin (138) and ring
(149).
(a)
Insert pin (134) into power piston
(133). Place this assembly in case.
(b)
Assemble pivot link (148) and
terminal lever link (147) with pin (140), and
fasten together with roll pin (139).
(b)
Attach solid end of piston link
(34) to power piston (133) with headed pin
(131), washer (32) and secure with a cotter
pin.
(c)
Assembly terminal lever (146) to
terminal lever link (147) with pin (143).
Figure 12-8. Speeder Spring Subassembly
12-11
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(c)
Place piston (137), pivot washer (136),
and elastic stop nut (135) into the case as
shown. Threat nut (135) onto pivot link (148)
nine to nine and a half turns.
(b)
Insert pilot valve bushing
assemblies (120 and 126) and idler gear
(124) into case as shown. Gears should
all mesh.
(d)
Tighten and loosen nut (135) until no
pivot motion exists between power pistons (152
and 133). Optimum adjustment is when the
pistons have no play and are not tight.
(14)
(15)
(16)
Refer to figure 12-21.
(a)
Lubricate packing (151) and place it on
load sensing sleeve (153) and insert sleeve into
case.
Refer to figure 12-19 and place packing (l119) in
base. Lubricate and put packing (112) on plug
(111) and push into base. Put spring washer
(150) (concave side up) in place on top of plug
(111) in base.
(b)
Insert sleeve (116), plunger (115),
spring (112), and spacer (114) into case.
(17)
Place ballhead assembly (91) in case on pilot
valve plunger (121). Secure with retaining ring
(87). (See figure 12-22.) :
(18)
Install thrust bearing (86), speeder spring seat
(85) on pilot valve plunger (121) and secure with
nut (84). Do not tighten nut (84).
Refer to figure 12-20.
(a)
If idler gear stud (125) has been
removed (although this should not be
necessary), press it into case until its end
is just below face surface.
Figure 12-9. Governor Pilot Valve Assembly
12-12
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 12-10. Actuator Pilot Valve Assembly
Figure 12-11. Clamp Bracket Subassembly
(19)
Check centering of pilot valve plunger (121) by
holding the pilot valve bushing (120) with one
hand and pushing on the ball arm flyweight (90)
toes with the other to lower the pilot valve plunger
(121) as far as possible. Check distance "A" in
figure 12-23. Pivot flyweights out as far as
possible and check distance "B". Distance "A"
must equal distance "B" when
flyweights have been moved from their extreme inward to
their extreme outward position. If the pilot valve
plunger is too low, use pilot valve wrench (figure
12-5) to hold spring seat (85) stationary, and turn
pilot valve plunger counterclockwise to raise it. If
the plunger is too high, hold spring seat and turn
plunger clockwise to lower it. When pilot
12-13
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 12-13. Needle Valve Assembly
Figure 12-12. Buffer System Parts Layout
Figure 12-13. Needle Valve Assembly
Figure 12-14. Power Piston Linkage Assembly
12-14
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(21)
Assembly transducer cup (75), transducer
solenoid (76), washer (77), magnet (78), and
coil cover (79). See figure 12-25. Plug (51) is
attached to the transducer.
(22)
Install transducer assembly on pilot valve
plunger and attaching plug (51) to case with
screws (50). Be sure connections of plug (51)
match the connections in cover.
(23)
Install clamp bracket assembly (74, figure 12-3)
with screws (65) and lockwasher (66). Line up
guide pin on bracket (74) with slot in link (83).
Insert centering screw (63) through hollow
center of adjustable spring seat (64). Bottom
centering screw to prevent binding when plate
(70) is installed. Final adjustment is made later.
(24)
Insert transducer compression spring (57) in
position and pivot the transducer lever over to
lie on top of the spring. Attach plate (70) to
restoring lever with
Figure 12-15. Power Piston Assembly
valve plunger is centered, tighten nut (84),
figure 12-22, to 70 inch-pounds (8 joules).
(20)
Lubricate base oil seal (118, figure 12-24) and
place it in groove on base. Line up pins (107).
Assembly base to case and secure it with
lockwashers (106) and screws (105). Check
bushing rotation for freeness before tightening
screws.
Figure 12-16. Power Piston and Linkage Installation
12-15
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 12-17. Piston Placement
screws (67) and washers (68 and 69).
(25)
(26)
Insert terminal shaft (46, figure 12-26) through
side of case (figure 12-26) and through terminal
lever (146). Insert tapered pin (33) into hole tight
enough for alignment and thread screw (144) with
washer (145) into terminal lever (146). Insert
tapered pin (44) into hole tight enough for
alignment and thread screw (144) with washer
(145) into terminal lever and tighten. Tap taper
pin until it is tight.
(27)
Lubricate packings (42, figure 12-28 and place on
speed pivot pins (41). Place speed droop-lever
assembly in the case in line with hole above
terminal shaft (46). Insert pivot pins (41) on both
sides of case through holes into speed droop
lever. Secure pivot pins with retaining rings (40).
(28)
Attach dial plates (38 and 39) with screws (37,
figure 12-29). Place oil seal (48, cup towards
case) and washer (49) on terminal shaft. Turn
terminal shaft to maximum position. Place
pointers (36) on terminal shaft with pointer
pointing at MAX., and secure them in place with
retaining ring (35). Adjust dial plate (38) until
MAX, line and
Assembly speed droop adjustment bracket (32,
figure 12-27) on speed droop lever (33) with
screw and washers (29, 30, and 31).
12-16
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 12-18. Piston Link Assembly
pointer are aligned.
(29)
Place speeder spring assembly (43) figure 12-30)
on top of ball head assembly. Press down and
twist the spring clockwise to seat the spring on
the spring seat (85).
Figure 12-20. Bushing Assemblies
Figure 12-19. Base and Parts
(30)
Figure 12-21. Relief Valve and Piston Sleeve
Assembly
Insert speed adjustment shaft (23, figure 12-31)
through speed adjusting lever (24), spacer (26)
and into hole on opposite side of case. Keep
0.005 to 0.010 inch (0.3 mm)
clearance between bushing (25) and speed
adjusting lever (24), and bushing (25) and spacer
(26).
(31)
12-17
Install cover (13, figure 12-3) and gasket (12) on
case (157) with bolts and washers (1 and 2).
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 12-24. Base Assembly
Figure 12-22. Ball Head Assembly
Figure 12-25. Transducer Parts Assembly
Figure 12-23. Centering Pilot Valve Plunger
Figure 12-26. Terminal Shaft Installation
12-18
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 12-30. Speeder Spring Assembly
Figure 12-27. Speed Droop Lever
Figure 12-28. Speed Droop Lever Assembly
Figure 12-31. Speed Adjusting Shaft Assembly
Figure 12-29. Dial Plate and Seal Assembly
12-19
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
12-7.
GOVERNOR LINKAGE ADJUSTMENT
e.Rotate the governor output shaft to the
full counterclockwise position. Tighten the
governor lever lockscrew.
a. Adjust the fuel pump lever so that it rests
against the idle stop at the angle shown in
Fig. 12-32. Lock the lever in this position.
f. Loosen the locknuts on both uniballs.
Take care not to rotate the control rod.
b. Assemble the governor control rod
linkage with the dimension between the
uniball mounting hole centerlines as shown
in Fig. 12-32. Mount the lever to the
governor shaft, but do not tighten the
lockscrew.
g.Rotate the fuel pump lever fully
counterclockwise (full fuel stop) and hold
the lever in this position.
h.Rotate the control rod just enough to raise
the governor lever from its stop while the
fuel pump lever is held at the full fuel stop.
Tighten the uniball locknuts. Take care not
to rotate the control rod.
c. Attach the uniball to the innermost hole in
the fuel pump lever..
d. Use one 1 x 5/16 inch capscrew and
lockwasher to attach the other uniball of the
control rod assembly to the governor lever.
See fig. 12-32 for the position of the
governor lever-.
i. Check the linkage for full free travel to
make sure that there is no binding between
the levers and uniballs.
EGB-2P
ACTUATOR LEVER
FUEL PUMP
LEVER
EGB- 2P
GOVERNOR LEVER ANGLE ·
MIN. FUEL POSITION (A) :
FUEL PUMP LEVER ANGLE.
MIN. FUEL POSITION (B)
DISTANCE BETWEEN UNIBALL
CENTERS - INCH
68
55
*10-1/4
* IF THE LINKAGE ROD CANNOT BE ADJUSTED TO REQUIRED LENGTH, CUT (TYPICALLY 1-1/4") FROM THE
RIGHT HAND THREAD END OF THE ROD AND RETHREAD.
Figure 12-32. Governor Linkage Adjustment
12-20
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
CHAPTER 13
MAINTENANCE OF ENGINE ASSEMBLY
Section I. GENERAL
13-2. REMOVAL OF ENGINE ASSEMBLY. Refer to
Chapter 2, Section IV, and remove the engine or
generator assembly, as required, for the replacement of
parts, repair, rebuilding, and overhaul of specific
components listed in this chapter.
13-1. DESCRIPTION. This chapter contains detailed
instructions for maintenance of the engine assembly
which provides the mechanical power to drive the main
generator. The engine assembly consists of a 12cylinder, V-type, turbocharged, after cooled diesel engine.
Section II. SPEED SWITCH, TACHOMETER DRIVE AND ADAPTER, AND STARTER
13-3. SPEED SWITCH (Code "A"). To adjust and repair
the mechanical type speed switch, refer to figures 13-1
and 13-2 and proceed as follows:
a.
(4)
Speed switch element S9-3
consists of two sets of contacts which are
set to transfer at an engine speed 2250
±25rpm to shut down the engine and
prevent damage to the equipment.
Shutdown is achieved by de-energizing the
fuel shut-off valve, cutting off fuel to the
engine, and closing the air box solenoid.
General.
(1)
The speed switch, driven by the
camshaft through a tachometer drive
assembly and an adapter, provides
sequenced control of circuits during engine
startup and protection against engine
overspeed during operation. Three sets of
contact elements, S9-1, SO-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.
(5)
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.
(2)
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.
b.
Speed Switch Removal. Refer to Operator/Crew
and Organizational Maintenance manual for
removal of the
speed switch.
c.
Speed Switch Tests, Adjustment, Repair and
Installation (Mechanical Type Switch).
(1)
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.
(3)
When the engine reaches the
speed range of 1180 to 1220 rpm, element
S9-2 closes, energizing the
electrichydraulic governor which takes
control of engine speed.
(2)
With an ohmmeter on the R1
scale, reading from the speed switch
connector, check for the contact conditions
of elements S9-1,
13-1
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 13-1. Speed Switch,-Exploded View (Mechanical Type Switch) (Code "A")
S9-2 and S9-3 illustrated in figure 13-2.
(3)
and C. The ohmmeter should indicate a closed
contact.
When contact conditions are verified, as shown in
figure 13-2, start variable drive and gradually
increase speed, with ohmmeter connected to pins
B and A. At a speed of 290 rpm's per minute, the
ohmmeter should indicate that contact A and B
opens. Hold the variable speed drive at that
speed and transfer the ohmmeter leads to pins A
(4)
13-2
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
13-2. To verify operation of element S9-1
contacts A and C, increase
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
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 13-2.
drive speed gradually and observe that the
contacts close in the 290 to 310 range.
(5)
(6)
Connect ohmmeter leads across pins D and E
and verify an open circuit. Increase drive speed
and observe that elements S9-2 (contacts D and
E) closes in the speed range of 590 to 610 rpm.
Gradually reduce speed to 490 minimum rpm.
Observe that element S9-2 resets to the
condition shown in figure 13-2.
(7)
Connect ohmmeter across pins H and G
connector and verify a closed circuit. Increase
drive speed gradually. The contacts should
open at a speed of 1100 to 1150 rpm. Hold
drive speed and read contacts F and J. Meter
should indicate a closed circuit. Reduce drive
To obtain the required performance
characteristics during tests (3) through (6),
adjustments can be made. By loosening screws
(1, figure 13-1) and rotating the cap and cover
assembly relative to the body assembly, the trip
points of all those 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 13-2
and turning appropriate set screw located
beneath cover screws with a 1/16 inch Allen
wrench.
Figure 13-2. Speed Switch Sensitivity Tests (Mechanical Type Switch) (Code “A")
13-3
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
d.
Speed Switch Disassembly. Refer to figure 13-1,
cut safety wire and disassemble in sequence of
index numbers observing the following:
(4)
Start variable drive and
gradually increase speed. Using a
DC voltmeter (0-50V DC minimum
scale) across pins B (+) and (-) verify
that voltage goes to zero between
290 and 310 rpm. At this speed
voltage at pin C should be at 24V DC.
(1)
If either the rotor assembly, the
body assembly, or the spacer are damaged
or defective, replace, defective part.
Reassembly. is the reverse order of figure
13-1 sequence of index numbers. Refasten
with lockwire after readjustment.
(5)
Reduce speed gradually
and verify that voltage at pin C goes
to zero volts 0-100 rpm lower than
pick-up rpm in step 4. At this speed
voltage at pin B will return to 24V DC.
(2)
Repeat the test and adjustment
procedures in paragraph C, above.
(6)
With voltmeter between
pins E (+) and I (-), zero voltage
should be indicated. Increase speed
and verify that pin E voltage goes to
24V DC between 590 and 610 rpm.
(3)
Refer to Operator/Crew and
Organizational Maintenance manual and
install speed switch.
13-4. ELECTRONIC TYPE SPEED SWITCH (Code "B").
To test speed switch refer to figure 13-3 and the following:
(7)
Reduce speed gradually
and verify that pin E voltage returns
to zero volts 0-100 rpm lower than
pick-up rpm in step 6.
a.General. The electronic speed switch
performs in the same manner as described
in paragraph 13-3a except, rather than
operating by centrifugal force the switch
operates electronically. Output switch
contacts are rated for 10 amps. Elements
S9-1 and S9-2 reset anywhere between 0
and 100 rpm (typically set for 50 rpm)
below actuation speed.
(8)
With voltmeter (+)
connected to pin J, zero volts should
be indicated. Gradually increase
speed and verify that voltage goes to
24V DC between 1100 and 1150 rpm.
At this speed, voltage at pin H will be
at zero volts.
b.Speed Switch Removal. The electronic
speed switch is removed in the identical
manner to the centrifugal switch referred to
in the Operator/Crew and Organizational
Maintenance Manual.
(9)
Reduce drive speed to
zero rpm. Voltage at pin H should
remain at zero and voltage at pin J
should remain at 24V DC until the
blue reset button is depressed.
c.Speed Switch Tests
(10)
All trip speed settings are
factory set and cannot be field
adjusted.
(1)
With an ohmmeter on the
RX1 scale, verify that the switch
contacts are as shown in figure 13-3.
d.
(2)
Connect a variable speed
drive device to the speed switch
drive. The drive device must have a
tachometer in order to determine the
device speed in rpm's.
Speed Switch Disassembly Since there are nib
moving parts except the speed switch drive with
virtually no load applied, disassembly is not
required since wear is practically non-existent.
13-5. STARTER ASSEMBLY (Code A). To service the
components of the starter
(3)
Apply 24V DC (+) to pins
A, D and F and (-) to pin I.
13-4
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 13-3. Speed Switch Test (Electronic Type) (Code B)
assembly, the ether lines and lubricating oil bypass filters
must first be removed.
(2)
Disconnect lubricating
bypass oil filter hose couplings from
tee on oil pan.
a. Removal.
(3)
Disconnect bypass oil
filter inlet hose coupling at top of rear
bypass oil filter, then remove six
screws securing bypass oil filter
support bracket to engine block to
remove bypass oil filter assembly.
(1)
Remove six screws
securing ether line support clamps to
engine, then loosen ether line fittings
from manifolds and solenoid valve
(located on upright support) to
remove ether lines. Store ether lines
in a safe place to avoid damaging
them.
(4)
removing
13-5
Remove starter by
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
caused by tight, dirty or worn
bearings, bent armature shaft or
loose pole shoes, a shorted or
grounded armature and fields.
battery cable connections to starter and
three screws which secure housing (16,
figure 13-4) to engine. Tag and remove
wires to the pilot relay (6, figure 13-4).
b.
c.
(b)
Failure to operate with
high current draw indicates a direct
ground in the terminal or fields.
Inspection. Remove inspection plug (102, figure
13-4). If any brush is less than 3/8 inch (9.5 mm)
long, the complete set of brushes should be
replaced.
(c)
Failure to operate with no
current draw indicates an open field
circuit, open armature coils, broken
brush' springs, worn brushes, high
insulation between commutator bars
or other conditions resulting in poor
contact between the brushes and
commutator.
Test. Testing of the starter motor assembly
consists of a no-load test of the complete unit and
component tests to determine part serviceability.
Before conducting the no-load test check the
armature for freedom of rotation. Use a screw
driver to turn the pinion on the exposed drive
assembly (25, figure 13-4) in the drive housing
(16). Tight bearings, bent armature shaft, or a
loose pole shoe screw will cause armature
binding. If the armature does not turn freely,
disassemble the unit immediately. If the
armature rotates freely, conduct the no-load test
below before disassembling the motor.
(d)
Low speed and low
current draw indicates high internal
resistance due to poor connections,
defective leads or a dirty commutator.
(e)
High speed and high
current draw indicate shorted fields.
Replace the field coil assembly and
retest the motor.
CAUTION
Do not allow the starter motor to operate more than
30 seconds. Allow it to cool at least two minutes
before reenergizing the motor. Overheating will
damage the motor.
(4)
Disassemble the starter motor,
inspect and test components as necessary.
d.
(1)
Connect the starter assembly as
shown in figure 13-5.
(2)
Close the switch and vary the
carbon pile to obtain 20 volts on the
voltmeter.
Disassembly. Disassemble the starter motor
only to the extent necessary to repair or replace
defective parts. Disassemble in accordance with
figure 13-4.
(1)
Note the relative positions of the
nose housing (16), lever housing (37), and
solenoid switch (36) so that the motor can
be reassembled in the same manner.
(3)
Starter motor speed at a
minimum current draw of 95 amps shall be
5500 rpm. Motor speed at the maximum
current draw of 120 amps shall be 7500
rpm.
(2)
Tag and disconnect the field coil
connector from the solenoid M terminal and
lead from the ground terminal.
(3)
(a)
Low speed and high
current draw indicate armature drag
13-6
Remove four screws and
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
lockwashers (1) and remove pilot relay (6).
Separate the solenoid switch (36) from the
lever housing (37).
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
compressed air.
(4)
Remove six screws (54) and
lockwashers (55), and remove the
commutator end frame (61) with associated
parts, and the plate assembly (65).
(5)
Clean solenoid relay assembly
parts with a clean cloth dampened with
cleaning solvent, Federal Specification PD-680, and dry with low-pressure
compressed air.
(5)
Remove three screws (9) and
remove the nose housing (16) and drive
assembly (25) and associated parts.
(6)
Clean brushes with a clean, dry
cloth only. Do not permit cleaning solvent
to come in contact with the brushes.
(6)
Remove screws (26) and washers
(27) and remove the lever housing (37) and
associated parts.
f.
(7)
Remove nuts (92 and 94), and
washers (93, 95, and 96).
(1)
Inspect drive assembly pinion for
chipped or badly worn teeth. Replace
assembly if defective.
(8)
Remove the pole shoe screws
(90), pole shoes (91), field coil (99), and
armature (89).
e.
Inspection.
(2)
Inspect internal splines in drive
assembly shell for cracked, chipped, or
broken condition. Replace drive assembly
if defective.
Cleaning.
(1)
Blow out all dirt inside field frame and
wipe interior with a clean cloth.
(3)
Inspect coil terminal lugs for
damaged threads.
CAUTION
(4)
Check brushes for excessive
wear. If any brush is less than 3/8 inch (9.5
mm) long, the complete set of brushes
should be replaced.
Do not submerge armature, field coils,
solenoids or clutch drive in solvent.
(2)
Clean field coils and frame
thoroughly with a cloth dampened with
cleaning solvent, Federal Specification PD-680. Be careful not to damage protective
insulation and fungus coating. Dry
thoroughly with compressed air.
(5)
Inspect if the armature
commutator is worn, dirty, out of round, or
has high insulation resistance. Clean or
overhaul the armature as necessary.
(6)
Inspect gaskets and O-rings for
damaged or worn condition. Replace as
necessary.
(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 lowpressure compressed air.
g.
Armature Test. Check the armature for short
circuits or grounds as follows:
(1)
(4)
Clean brush holders and springs
with a brush and cleaning solvent, Federal
13-7
Use a growler to locate
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
armature short circuits. As the armature
revolves in the growler, hold a steel strip
(such as a hacksaw blade) above it. The
blade will vibrate above the area of the
armature core on which the short circuit is
located.
reading permissible is one megohm.
i.
Solenoid Test. Disconnect all leads from the
solenoid and make test connections as shown in
figure 13-6.
(1)
To check the hold-in winding,
follow connections shown in solid line.
(2)
Use a 110 volt test lamp with test
points to detect grounds. Place one test
point on the armature core or shaft and the
other on the commutator. If the lamp lights,
the armature is grounded.
h.
(2)
Use the carbon pile to adjust the
voltage to 20 volts. Voltmeter shall read 20
V DC and ammeter shall read 6.1 to 6.8
amps. A high ammeter reading indicates a
shorted or grounded hold-in winding. A low
reading indicates excessive resistance.
Field Coil Test. Test field coil insulation
resistance with megger connected between frame
and one coil terminal. Minimum resistance
LEGEND FOR FIGURE 13-4
1. Screw and lockwasher
2. Screw
3. Washer
4. Lockwasher
5. Nut
6. Pilot relay
7. Lead
8. Bracket
9. Screw
10. Screw
11. Plug
12. Wick
13. Plug
14. Plug
15. Bushing
15A. Plug
16. Housing
17. Plug
18. Gasket
19. Nut
20. Ring
21. Packing
22. Packing
23. Lever
24. Lever
25. Drive assy
26. Screw
27. Washer
28. Oil seal
28A. Bushing
29. Plug
30. Plug
31. Plug
32. Wick
33. Gasket
34. Brake washer
35.
36.
37.
38.
39.
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.
Lead
Switch
Lever housing
Ring
Retainer
Spring shift lever
Retainer
Boot
Washer
Plunger
Nut
Washer
Nut
Lockwasher
Washer
Insulator
Packing
Plug
Wick
Screw
Lockwasher
Bushing
Plug
Plug
Bushing
Packing
Frame
Screw
Washer
Brush
Plate assy
Screw
Lockwasher
Screw
Screw
Spring
13-8
71. Lockwasher
72. Brush holder
73. Plate
74. Screw
75. Lockwasher
76. Washer
77. Brush holder
78. Insulator
79. Plate
80. Screw
81. Lockwasher
82. Washer
83. Plate and stud assy
84. Support plate
85. Brush
86. Packing
87. Washer
88. Washer
89. Armature
90. Screw
91. Pole shoe
92. Nut
93. Lockwasher
94. Nut
95. Washer
96. Washer
97. Gasket
98. Bushing
99. Coil
100. Insulator
101. Insulation
102. Plug
103. Gasket
104. Housing
105. Plug
106. Bushing
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 13-4. Starter Assembly, Exploded View (Code A)
13-9
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(5)
Replace switch if either winding is
shorted or shows excessive resistance.
j.
k.
Figure 13-5. No Load Test Circuit (Code A)
Repair. Repair of the starter motor consists of
repairing commutator bars whenever possible (if not
badly burnt) and replacement of parts found defective
during inspection. Repair commutator bars as
follows:
(1)
Using rosin flux, resolder or weld leads in the
riser bars.
(2)
Turn down the commutator in a lathe.
(3)
Undercut and clean the commutator as
indicated in paragraph k.
Overhaul. Overhaul of the starter motor consists of
overhauling the armature commutator and
replacement of parts found defective during
inspection. Overhaul the commutator as follows:
(1)
Turn down commutator in an appropriate
lathe.
(2)
Undercut the insulation 1/32 of an
inch wide and 1/32 of an inch deep.
Remove any trace of dirt or copper dust
between slots.
(3)
Sand the commutator lightly with
No. 00 sandpaper to remove any burrs
resulting from the undercutting procedure.
l.
Figure 13-6. Checking Solenoid Hold-In and Pull-In
Windings (Code A)
Assembly. Assemble the motor in accordance with
figure 13-4.
(1)
Install the pole shoes (91) and secure with
pole shoe screws (90).
(2)
Install the armature (89) and field coil (99)
in the housing (104).
(3)
Install the lever housing (37) with screws
(26), and washers (27)..
(4)
Position the washer (34) and gasket (33) in
the lever housing and install the drive
assembly (25) in
CAUTION
Do not leave pull-in winding energized for more than
15 seconds.
(3)
To check the pull-in winding, connect the
other battery lead to the M terminal (shown in dotted line).
(4)
Adjust the voltage to 5 volts. Voltmeter
shall read 5V AC and ammeter shall read 10 to 11.5
amps.
13-10
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
the housing. Make sure that the shift lever(24)
properly engages the drive assembly.
(7) Install the commutator end frame (61) and
packing (60) on the housing (104) and secure
with screws (54) and lockwashers (55).
(5) Secure the nose housing (16) to the lever
housing with screws (9). Torque the screws to
11-15 foot-pounds.
(8) Secure the solenoid switch (36), pilot relay (6)
with bracket (8) on the housing with four screws
and lockwashers
(6) Install the end plate assembly (65) in the
housing. Make sure that the brushes (64) ride
on the commutator. Manually check that the
brush springs (70) provide firm contact between
the brushes and the commutator.
(1). Make sure that the plunger (44) engages the
shift lever (24) properly.
m. Adjustments. Adjust pinion clearance as follows:
(1) Connect the starter motor as shown in figure 137.
(2) Momentarily flash a jumper lead between
terminals M and G. The drive will shift into
cranking position and remain so until the battery
is disconnected.
(3) Push the drive assembly (25) back towards the
commutator end to eliminate slack.
(4) Measure the distance between the pinion and
the interior nose housing wall with a feeler
gauge. Distance shall be within the 21/64 to
25/64 inch range (see figure 13-8).
Figure 13-7. Circuit for Checking Pinion Clearance
(Code A)
(5) Adjust clearance by removing plug (17) and
turning shaft nut (19). Turn nut clockwise to
increase clearance and counterclockwise to
reduce clearance.
Replace plug after
adjustment.
(6) Disconnect test set up.
n. Installation.
(1) Install three screws through housing (37, figure
13-4) to secure starter to engine assembly.
(2) Attach battery cable connections and connect
wires to the pilot relay (6, figure 13-4).
Figure 13-8. Checking Pinion Clearance (Code A)
13-11
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(3) Secure bypass oil filter assembly bracket to
engine with six screws.
20v DC on voltmeter.
(4) Attach bypass oil filter.
(3) Using rpm indicator and ammeter, at 95 amps
rpm should be at 5500. At a maximum current
draw of 120 amps rpm should be at 7500.
(5) Install ether lines with the six support clamps
and screws.
13-6.
(4) To check pinion clearance connect as shown in
figure 13-11.
STARTER ASSEMBLY (Code B) To service
the components of the starter assembly,
proceed as follows:
CAUTION
CAUTION
To prevent overheating damage to windings,
do not energize hold-in windings longer
than 30 seconds. If adjustment cannot be
made in this time, disconnect battery and
allow windings to cool .
Remove negative battery cable first and tape
cable terminal.
a. Removal.
Remove starter motor by removing
battery cable connections to starter and three
screws which secure housing (21, figure 13-9) to
engine. Tag and remove wires to the pilot relay (6,
figure 13-4).
(5) Energize hold-in windings in electrical solenoid
by connecting a 24V DC battery to the G and S
terminals. Momentarily energize pullin windings
by flashing a jumper lead from the G to the
MTR terminal ((A} figure 13-11). Do not leave
jumper lead connected. Hold-in windings will
keep solenoid plunger in operating position as
long as battery is connected between G and S
terminals.
b. Inspection. Remove inspection plug (1, figure 13-9).
If any brush is less than 3/8 inch (9.5 mm) long, the
complete set of brushes should be replaced, para.
13-6 d (21).
c.
Test. Testing of the starter motor and electrical
solenoid assembly consists of a no-load test of the
complete unit followed by a pinion clearance check
and adjustment. Before conducting the no-load test,
check armature for freedom of rotation. Use a
screwdriver to turn the pinion on the exposed drive
assembly in the drive housing. Tight bearings, bent
armature shaft, or a loose pole shoe screw will
cause armature binding. If armature does not turn
freely, disassemble the unit. If armature rotates
freely, conduct the no load test before
disassembling the motor.
(6) Push drive assembly toward commutator end of
starter to remove slack.
Measure pinion
clearance ({B) figure 13-11).
(7) Turn plunger rod nut (10, figure 13-9) clockwise
to reduce clearance and counterclockwise to
increase clearance as necessary to achieve a
pinion clearance of 0.328 to 0.390 inches (8.33
to 9.9 mm). Apply pressure on stud to prevent
turning while adjusting.
(8) After completing adjustment, disconnect battery
from G and S.
CAUTION
d. Disassembly
Do not allow starter motor to operate more than
30 seconds. Allow it to cool at least 2 minutes
before reenergizing. Overheating will damage
motor.
(1) Remove four brush inspection plugs (1, figure
13-9) and gasket (2) from lever housing (3).
Discard gasket.
(1) Connect the starter assembly as shown in figure
13-10
(2) Use power supply to obtain
13-12
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 13-9. Starter Assembly, Exploded View (Code B)
13-13
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND FOR FIGURE 13-9
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.
Brush inspection plug
Inspection plug gasket
Lever housing
Bolt
Solenoid
Starter housing
Plunger
Protector bellows
Terminal lead
Plunger rod nut
Shift lever
Plunger spring
Snap ring
Recessed washer
Recessed washer
Spring retainer washer
Snap ring
Shift lever shaft
Preformed packing
Preformed packing
Stator housing
Bolt
Bolt
Gasket
Rubber ball
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
Dust cap
Oil wick
Drive housing bushing
Drive assembly
Brake washer
Protective dust cap
Oil wick
Lever housing plug
Machine bolt
Lever housing bushing
Armature
Spacer washer
Preformed packing
Oil seal
Plain external nut
Plain hexagon nut
Lockwasher
Flat washer
Electrical holder
assembly
Braided strap
Electrical parts kit
Insulator washer
Machine bolt
(2) Disconnect terminal lead (9) from solenoid.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
Starter housing
mounting plate
Insulator washer
Preformed packing
Brush plate insulator
Sleeve bearing
Flat washer
Machine screw
Brush plate screw
Electrical brush
Helical spring
Terminal stud
Terminal lug
Flat washer
Field terminal washer
Field coil insulator
Field coil
Terminal stud bushing
Pole shoe screw
Pole rotor shoe
Field coil screw
Insulator plate
Protective dust cap
Pilot relay
Bracket
(9) Remove six bolts (23) securing stator housing
(21) to lever housing (3).Separate housings and
remove gasket (24).Discard gasket and remove
six rubber balls (25).
(3) Remove four bolts (4) securing solenoid (5) to
starter housing (6). Slide solenoid off plunger
(7) and free of bellows (8).
(10)
Remove dust cap (26) and oil wick (27)
from stator housing (21). Discard oil wick.
(5) Remove nut (10) securing plunger.(7) to shift
lever (11) from inside of lever housing (3).
(11)
Remove bushing (28), drive assembly (29)
and brake washer (30) from lever housing (3).
(6) Compress spring (12) and remove snap
rincg:(13) from plunger (7). Remove washer
(14), spring (12) and-washer (15), bellows (8)
and washer (16). Discard snap ring.
(12)
Remove dust cap (31), oil wick (32) and
plug (33) from lever housing (3).Discard oil
wick.
(13)
Remove seven bolts (34) securing lever
housing (3) to starter housing (6).
(14)
Remove bushing (35) from lever housing (3)
and slide lever housing off armature (36) and
away from starter housing (6).
(4) Remove cap (1) from lever housing (3).
(7) Remove snap ring (17) from shift lever shaft
(18). Remove shaft and shift lever (11) from
lever housing (3) Discard packings (19) and
(20).
(8) Matchmark stator housing (21) to lever housing
(3) and lever housing (3) to starter housing (6).
(15)
13-14
Remove washer (37), packing
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 13-10. No-Load Test Circuit (Code B)
(38) and oil seal (39) from lever housing (3).
Discard packing and oil seal.
(16)
Remove nuts (40 and 41) and washers (42
and 43) from electrical holder assembly
(44). Remove braided strap (45), electrical
parts kit (46) and washer (47).
(17)
Remove inspection plug (1) and gasket (2)
from starter housing (6).
(18)
Remove four bolts (48) securing starter
housing mounting plate (49) to starter
housing (46).
Remove mounting plate
washer (50), packing (51) and insulator (52)
from electrical holder (44). Discard packing.
(19)
Slide armature (36) from housing (6).
(20)
Remove sleeve bearing (53) and washer
(54) from armature (36).
(21)
Remove two screws (55) and screw (56)
and then remove electrical brush (57) and
spring (58) from electrical holder assembly
(44).
(22)
Remove nut (40) from terminal stud (59)
and then remove terminal lug (60).
(23)
Remove nut (41), washer (61) and washer
(62) securing field coil insulator (63) to field
coils (64).
(24)
Remove insulator (63), washer (62), bushing
(65) from terminal stud (59)
(25)
Remove two screws (66) from each of four
pole rotor shoes (67) and remove shoes.
(26)
Remove screw (68) and insulator plate (69).
e. Cleaning.
WARNING
P-D-680, TYPE II, IS FLAMMABLE (WHEN
ATOMIZED) AND IS MODERATELY TOXIC TO EYES,
SKIN, AND RESPIRATORY TRACT. SKIN AND EYE
PROTECTION IS REQUIRED. AVOID REPEATED OR
PROLONGED CONTACT.
USE IN WELLVENTILATED AREA. COMPRESSED AIR USED FOR
CLEANING OR DRYING CAN CREATE AIRBORNE
PARTICLES THAT MAY ENTER THE EYES.
PRESSURE SHALL NOT EXCEED 30 PSI (207 kPa).
WEARING OF GOGGLES IS REQUIRED TO AVOID
INJURY TO PERSONNEL.
13-15
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
CAUTION
Do not immerse the drive assembly (29) in solvent.
This would wash the lubricant from the overrunning
clutch, and result in premature wear and failure of
the drive assembly.
(2) Clean drive assembly
dampened cloth.
(29)
with
solvent
(3) Clean windings and insulated parts with a dry
brush and dry compressed air to remove loose
dust and dirt.
(4) Remove oily caked deposits from windings and
insulated parts with a brush and solvent and
blow dry. Do not immerse or soak insulation.
(5) Dry armature (36) or field coils (64) in an oven
at 175°to 200°F (29°to 93°C) for 2 hours.
(6) Wipe brushes (57) with clean dry cloth to
remove dirt or oil. Do not use solvent. Replace
any oilsoaked brushes.
(A) ENERGIZING SOLENOID WINDINGS
CAUTION
Do not use emery cloth or paper for the following
operation. Emery dust could cause electrical shorts
in the starter motor.
(7) If commutator is in good condition, polish it with
00 grade sandpaper P-P-105 to obtain a bright
surface .Blow off with compressed air after
sanding. Do not use emery cloth or paper. If
commutator slots are filled with dirt, clean with
toothpick or narrow piece of wood soaked in
solvent and blow dry.
f.
Inspection and Checks
(1) Visually inspect starter
(B) MEASURING PINION CLEARANCE
Figure 13-11. Adjusting Starter Pinion Clearance
(1) Clean all parts except armature (36, figure 13-9),
field coils (64), electric al solenoid (5), and drive
assembly (29) in cleaning solvent P-D-680, Type II
and blow dry with compressed air.
13-16
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
housing (6, figure 13-9) and stator housing (21)
for cracks or other damage.
Drive housing bushing (28), lever housing
bushing (35), and sleeve bearing (53) must be
lubricated and installed properly to achieve long
service life.
(2) Check all threaded parts for crossed, deformed,
or stripped threads.
(2) Replace worn bushings (28 and 35) and bearing
(53) as follows:
(3) Drive housing bushing (28), lever housing
bushing (35), and sleeve bearing (53). are
pressfit into their respective bores, with
clearance of -0.0005 to -0.0020 inch (-0.013 to
-0.051 mm). Check that they are tight fit and
cannot be rotated in bores.
(a) Remove bushings using bushing driver.
(b) Remove sleeve bearing (53) using a blind
hole bushing puller or a bushing cutter. Do
not cut into starter housing (6).
(4) Check drive housing bushing (28), lever housing
bushing (35), and sleeve bearing (53) for
scoring and proper fit on armature (36).
Clearance shall not exceed 0.006 inch (0.15
mm).
(c) With clean hands, place a new bushing on
the palm of the hand and fill it with SAE 20
lubricating oil. Place thumb of free hand
over open end of bushing and push hard to
pressurize oil in bushing.
Bushing is
properly lubricated when oil seeps through
entire outside diameter of bushing.
(5) Visually inspect armature (36) for the following
defects:
(a) Scored or grooved bushing surfaces.
(d) Check that bore into which bushing is to be
inserted is clean and grit free.
(b) Damaged laminations due to rubbing on
pole rotor shoes (67).
CAUTION
(c) Burned or scored commutator bars.
Do not drill, ream, or machine bronze
bushings. Machining will seal or plug
bushing pores and prevent proper
lubrication.
(d) High insulation between commutator bars.
(e) Loose commutator bars.
NOTE
(f) Damaged splines.
If new lubricated bushing is not going
to be installed immediately, store in a
clean plastic bag.
(g) Damaged or loose windings due to thrown
solder.
g. Armature Test.
Check armature per paragraph 13-5g.
(e) Using correct size bushing driver, install
new lubricated drive housing and lever
housing bushings
h. Field Coil Test.
Check field coil per paragraph 13-5h.
i.
Repair/Overhaul.
(1) Replace starter housing (6, figure 13-9), stator
housing (21), and lever housing (3) if cracks or
other damage have been found.
13-17
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(28 and 35) or sleeve bearing (53). Ensure
that bushing is started square and driven
straight into housings (21, 3 and 6) until
level with, or slightly below, thrust surface.
Bushings are sized to be a correct fit on
armature shaft when installed.
Do not
ream, drill, or machine bushing.
WARNING
LATHE OR MILLING OPERATIONS
CREATE METAL PARTICLES WHICH
MAY ENTER THE EYES. WEARING
GOGGLES IS REQUIRED TO AVOID
INJURY TO PERSONNEL.
(f) Check fit of bushings or bearing on
armature (36). Correct clearance is 0.0015
to 0.003 inch (0.038 to 0.08 mm).
If
bushing fits too tightly, it was incorrectly
installed; remove damaged bushing and
install a new one. If fit is too loose, check
armature shaft for wear.
(a) Resurface commutator using armature and
undercutting lathe MIL-L-14576.
(b) After
machining,
undercut
insulation
between commutator bars to a depth and
width of 0.031 inch (0.79 mm).
CAUTION
(3) Replace armature (36) for any of the following
defects:
Do not use emery cloth or paper for
the following operation. Emery dust
could cause electrical shorts in the
starter motor.
(a) Thrown solder due to overheating.
(b) Loose windings.
(c) After machining and undercutting, remove
any burrs from commutator using sandpaper
P-P105; do not use emery cloth. After
deburring, remove any sanding or copper
dust from slots between commutator bars.
(c) Loose commutator bars.
(d) Bushing surface worn to the extent that
clearance between bushing exceeds 0.0015
to 0.003 inch (0.038 to 0.08 mm).
WARNING
(e) Bushing surface scored to depth of more
than 0.003 inch (0.08 mm).
AVOID
BREATHING
FUMES
GENERATED
BY
SOLDERING.
REMOVE RINGS AND WATCHES. EYE
PROTECTION IS REQUIRED TO AVOID
INJURY TO PERSONNEL.
(f) Damaged or uneven wear of splines.
(g) Shaft runout exceeds 0.005 inch (0.13 mm)
TIR.
(5) Resolder any field coil leads as required, in
accordance with MIL-S-6872, using solder QQS-571, Type SN 60, and rosin flux.(F) Refer to
TO-00-25-234.
(h) Presence of electrical opens, shorts, or
grounds.
(4) If commutator runout is over 0.005 inch (0.13
mm) or it is scored, uneven, or burned, repair as
follows:
(6) If frayed field coil windings are present, wrap
with insulating tape and paint with insulating
varnish MS355632.
13-18
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(7) If field coils have electrical shorts, opens,
grounds, oil soaking, or insulation obviously damaged
beyond repair, replace as follows:
(h) Check that insulators (69) are properly
placed and pole rotor shoes are not pinching
field coils (64). Tighten pole shoe screws
(66) using an ordinary screwdriver.
(a) Place a pole shoe spreader between
opposite pole rotor shoes (67, figure 13-9)
and tighten in place.
(i) Place a pole shoe spreader between
opposite pole rotor shoes (67) and tighten in
place.
(b) Using a pole shoe screwdriver and an arbor
press, remove pole shoe screws (66).
Remove pole screw spreader with pole rotor
shoes (67).
(j) Using a pole shoe screwdriver and an arbor
press, tighten pole shoe screws (66) and
remove pole shoe spreader.
(c) Repeat steps (1) and (2) for other two rotor
pole shoes.
(k) Repeat steps (7) through (10) for other two
pole shoes.
(d) Push in on field coil terminal stud (59) and
slip field coils (64) out of starter housing (6).
(l) Ensure that terminal bushings (65) and field
terminal washer (62) are properly positioned
on terminal stud (59). Install another field
terminal washer (62), flat washer (61), and
plain hexagonal nut (41) on terminal stud.
(e) Remove field coil insulators (63), insulator
plate (69), field terminal washer (62), and
terminal bushings (65) and discard.
(m) Install terminal lug (60) and plain external
nut (40) on terminal stud (59). Do not
tighten nut at this time.
(f) Insert new field coil (64) into starter housing
(6) with new field coil insulators (63),
insulator plate (69), field terminal washer
(62), and terminal bushings (65).
(8) Replace defective electrical holder assembly
(44) and insulators as follows:
NOTE
(a) Remove brush plate screws (56) and
electrical holder assembly (44) with brush
plate insulator (52) and insulator washer
(47).Discard insulators if defective.
If pole rotor shoes (67) have a long lip
on one side, lip must face in direction
of armature rotation (clockwise when
viewed from the drive end).
This
locates lip as trailing edge of pole
rotor shoe.
(b) Install new brush plate insulator (52) and
insulator washer (47) on new electrical
holder assembly (44) and insert stud
(g) Insert pole rotor shoes (67) into position in
field coils and retain with pole shoe screws
(66). Do not tighten screws at this time.
13-19
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
through hole in starter housing (6) and
preformed packing (51).
j.
(1) Check that all parts are clean before starting
assembly procedure.
(c) Install insulator washer (50) terminal stud
bushing (65) braided strap (45), flat washer
(43), lockwasher (42), and hexagon nut (41).
Do not fully tighten nut at this time.
(2) Lubricate spacer washer (37, figure 13-9) and
flat washer (54) with a thin film of petrolatum VV-P236 and install on armature (36).
(d) Install brush plate screws (56) and tighten.
(3) Soak new oil wicks (27 and 32) in SAE 20 motor
oil and install in lever housing (3) and stator
housing (21). Secure wicks with protective dust
caps (26 and 31).
(e) Tighten hexagon nut (41) to 20 to 25 footpounds (27 to 34 newton-meters).
(9) Replace oil soaked or cracked electrical brushes
(57) or brushes which are less than 0.656 inch
(16.66 mm) in length.
(10)
Replace helical springs (58) if tension is
under 2 pounds (0.9 kg).
(11)
Remove nicks or accumulated dirt from
plunger (7) or bore of electrical solenoid (5).
(12)
Replace electrical solenoid (5) if tests show
it to be defective.
(13)
Replace plunger spring (12) if warped or if
free length is less than 2.296 inches (58.32
mm).
(14)
Replace shift lever shaft (18) if worn or
grooved.
(15)
Replace shift lever (11) if shaft holes are
worn or elongated or if pads are worn or
deformed.
(16)
Assembly.
NOTE
To aid in installation of starter
housing
and
electrical
holder
assembly on armature do not attempt
to install starter housing and electrical
holder
assembly
with
electrical
brushes loaded by helical springs.
(4) Position electrical brushes (57) in electrical
holder assembly (44) so that tangs of helical
springs (58) rest against side of electrical
brushes and hold electrical brushes in retracted
position. Once starter housing (6) and electrical
holder assembly (44) have been installed on
armature (36), tangs of helical springs (58) may
be placed in their normal positions on electrical
brushes (57), tensioning electrical brushes
against commutator.
(5) Install protective dust cap (70) and new
preformed packing (51) on starter housing (6).
Install assembled housing and electrical holder
assembly (44) over commutator of armature
(36).
Remove slight nicks or burrs from pinion
teeth of drive assembly (29).Replace drive
assembly if teeth are cracked or excessively
worn or if overrunning clutch is defective.
(6) Thread field coil brush leads through inspection
holes in field frame. Install armature (36, figure
13-9) into field frame.
13-20
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
NOTE
Hold the field frame securely on the
armature (36) when placed into the
starter housing (6) so that the field
frame does not slip off. Otherwise
brushes (37) will have to be removed
and re-installed as per step j(4).
(7) Put starter housing (6) in place on field frame.
Ensure that matchmarks are lined up. Secure
starter housing to field frame using machine
bolts (34).
(8) Attach brush leads to brush holders using brush
plate screws (56).
(9) With lip facing lever housing brushing (35),
install a new spacer washer (37) in lever
housing (3).
(10)
(11)
(13)
Using new gasket, put stator housing in
place on lever housing.
Ensure that
matchmarks are lined up. Install drive housing
bolt (22) and internal housing bolts (23) Crosstighten bolts to 13 to 17 footpounds (18 to 23
newtonmeters).
(16)
Install electrical solenoid (5) over plunger
(7) and into protector bellows (8).Secure
electrical solenoids to starter housing (6)
with machine bolts (4).
(17)
Place terminal lug (60) on field terminal of
electrical solenoid (5). Install external nut
(40) and tighten it with other hexagonal nut
(41) to 20 to 25 footpounds (27 to 34
newtonmeters).
(18)
Check and adjust pinion and clearance per
paragraph 13-6 (4).
Installation
(2) Attach battery cable connections and connect
wires to pilot relay (6, figure 13-4).
Install brake washer (30) over shaft of
armature (36), tilt shift lever (11), and install into
lever housing (3). Ensure that shaft lever is
properly positioned in collar of drive assembly
(29).
Install shift lever shaft (18) with preformed
packings (20 and 19) and secure with new snap
ring (17).
Install plunger (7) through shift lever (11).
Install plunger rod nut (10) on shaft until
several threads are engaged.
(1) Install three bolts through housing (21, figure
13-9) to secure starter to engine assembly.
Install a new preformed packing (38) on
lever housing (3) and put lever housing in place
on field frame. Ensure that matchmarks are
lined up.
(12)
(14)
k.
(15)
13-7. TACHOMETER DRIVE ADAPTER (Code A).
To replace the tachometer drive adapter, code A,
proceed as follows:
a. Remove the speed switch in accordance with
the Operator/ Crew and Organizational
Maintenance manual.
b. Unscrew the adapter (6, figure 13-12) from the
tachometer drive housing.
c.
Replace with a new adapter, if required.
d. Replace the speed switch in accordance with
the Operator/ Crew and Organizational
Maintenance manual.
Place spring retainer washer (16), protector
bellows (8), recessed washer (15), plunger
spring (12), and recessed washer (14) over
plunger (7) and secure with snap ring (13).
13-8. TACHOMETER DRIVE (Code A). To inspect,
replace, and repair the tachometer drive, refer to figure
13-12
13-21
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Capscrew
Lockwasher
Gasket
Screw
Lockwasher
Adapter
Seal
Spacer
Shaft
Drive
Bushing
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Gear
Weight and carrier assy
Ring
Bushing
Weight and carrier assy
Tachometer drive and
cover
Coupling
Gear
Ring
Bearing
Coupling
23.
24.
25.
26.
27.
28.
29.
30.
31.
Screw
Lockwasher
Washer
Coupling
Shaft
Gear
Key
Seal
Cover
Figure 13-12. Mainshaft-Cover and Tachometer Drive,
Exploded View, Code A
and proceed as follows:
(2) Remove the fuel pump.
a. Removal.
(3) Remove the main shaft cover assembly by
removing the four capscrews and washers
securing it to the engine assembly.
(1) Remove the speed switch and tachometer drive
adapter in accordance with paragraph 13-7,
13-22
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(4) Check governor weight carrier shaft (16) in its
bushing (15) before removal. Excessive wear
can be felt by moving shaft from side to side in
the bushing.
(2) Visually inspect gears for cracked, broken, or
worn teeth.
(5) Observe gear backlash between weight shaft
gear and drive gear (19). Normal backlash is
0.005 to 0.009 inch (0.13 to 0.23 mm).
c.
(3) Inspect all shafts for wear or scoring.
Repair. Repair by replacing any worn or damaged
parts.
d. Assembly.
(6) To remove the governor weight and carrier
assembly (16) from the drive cover (31) use a
puller to pull weight shaft assembly from front
cover. The bushing (15) is locked on the shaft
with snap ring (14) and will usually come out of
the cover with weight shaft assembly; however,
if snap ring pulls off shaft leaving bushing in
front cover, use an internal engaging puller to
pull bushing.
(7) Remove screw (4), lockwasher
tachometer drive housing.
(5),
(1) Clean all parts thoroughly with mineral spirits.
(2) Press first oil seal (30) into drive cover with lip
toward outside of pump, and press second oil
seal into drive cover with sealing lip toward
inside of fuel pump. Seals must be spaced so
the "telltale" hole is not covered.
(3) Lubricate oil seal assembly tool and install tool
over main shaft (27). Place snap ring (20)
between drive gear (19) and bearing (21).
Press main shaft into front cover and through
seals. Secure snap ring (20) in cover groove.
Remove oil seal assembly tool and install
coupling (18).
and
(8) Use a dowel puller to remove tachometer drive
shaft (9), seal (7), spacer (8), bushing (11), and
gear (12).
(9) Remove snap ring (20) with hose clamp pliers.
(10)
Remove coupling (18), gear (19), and
bearing (21).
(11)
Remove spider coupling (22), screw (23),
lockwasher (24), washer (25), and coupling
hub (25A). Press drive shaft (27) from
cover.
(12)
Press gear (26) from shaft (27).
(13)
Press oil seals (30) from cover.
(4) Line up oil groove in top of tachometer drive
bushing (11) with fuel pump drive shaft. Press
gear (12), bushing (11), and shaft (9) into cover
until bushing bottoms.
(5) Install spacer (8) on top of bushing with slotted
edge down.
(6) Install new oil seal (7) with spring side down.
Spacer (8) must bottom on bushing.
CAUTION
Do not overpress
become flattened
effectiveness.
b. Inspection.
(1) Inspect bushing (15); if worn larger than 0.504
inch (12.80 mm), replace bushing.
spacer; it can
eliminating its
(7) Cover top of seal with a thin coat of lubricating
oil. Secure tachometer adapter (6) to cover with
13-23
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
a. Removal.
washer (5) and screw (4).
(8) Install key (29), press gear (26) and coupling
(25A) into position on drive shaft (27). Press
slow and straight. Be certain tachometer gear
teeth are aligned.
(1) Remove the speed switch and tachometer drive
connector in accordance with paragraph 13-9.
(9) Install Washer (25), lockwasher (24), screw (23),
and spider coupling (22). Hold coupling (25A)
or main shaft (27) in a copperjawed vise while
tightening.
(3) Remove the main shaft cover assembly by
removing the four cap screws and washers
securing it to the engine assembly.
(10)
(4) Check the governor weight carrier shaft (24,
figure 13-21) in its bushing before removal.
Excessive wear can be felt by moving shaft
from side to side in the bushing.
Coat governor bushing (15) with highpressure lubricant and press governor weight
and carrier assembly (16) into front cover.
Mesh gears to avoid gear tooth damage. The
bushing must seat against housing. Rotate
weight assembly, with weights opened out, to be
sure it will turn completely in housing. Install
snap ring (14).
(11)
Install mainshaft cover assembly to engine
assembly with the four washers and capscrews.
(12)
Replace the fuel pump, speed switch and
tachometer drive adapter.
13-9.
(2) Remove the fuel pump.
(5) Observe gear backlash between weight shaft
gear and drive gear (22, figure 13-13). Normal
backlash is 0.005 to 0.009 inch (0.13 to 0.23
mm).
(6) Remove carrier (24, figure 13-21).
(7) Remove drive shaft (9, figure 13-13), seal (8),
bushing (10), and gear (11).
(8) Remove screw (13), hub (14).key (15),
spacer (16) and gear (17). Pres drive shaft (25)
from cover.
TACHOMETER DRIVE CONNECTOR (Code
B). To replace the tachometer drive adapter,
code B, proceed as follows:
(9) Press gear (22) from cover
a. Remove the speed switch in accordance with
the Operator/ Crew and Organizational
Maintenance manual.
(10) Press oil seals (19) from cover.
b. Inspection.
b. Unscrew the connector (7, figure 13-13) from
the tachometer drive housing.
c.
(1) Visually inspect gears for cracked, broken, or
worn teeth.
Replace with a new connector if required.
(2) Inspect all shafts for wear or scoring.
d. Replace the speed switch in accordance with
the Operator/ Crew and Organizational.
Maintenance manual.
c.
Repair. Repair by replacing damaged parts.
d. Assembly.
13-10. TACHOMETER DRIVE (Code B). To inspect,
replace, and repair the tachometer drive refer to figure
13-13, and proceed as follows:
(1) Clean all parts thoroughly with mineral spirits.
13-24
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(6) Cover top of seal with a thin coat of lubricating
oil. Secure tachometer connector (7) to cover.
(2) Press first oil seal (19) into drive cover with lip
toward outside of pump, and press second oil
seal into drive cover with sealing lip toward
inside of fuel pump. Seals must be spaced so
that the "tell tale" hole is not covered.
(7) Install key (15), press gear (17), hub (14,) and
spacer (16) into position on drive shaft (25).
Press slow and straight. Be sure tachometer
gear teeth are aligned.
(3) Lubricate oil seal assembly tool and install tool
over main shaft (25). Place snap ring (23)
between drive gear (22) and bearing (24).
Press main shaft into front cover and through
seals. Secure snap ring (23) in cover groove.
Remove oil seal assembly tool and install
adapter (21).
(8) Secure with screw (13).
(9) Install carrier (24, figure 13-4) into front cover.
Mesh gears to avoid gear tooth damage. Rotate
weight assembly, with weights opened out to be
sure it will turn completely in housing.
(4) Line up oil groove in top of tachometer drive
bushing (10) with fuel pump drive shaft. Press
gear (11), bushing (10), and shaft (9) into cover
until bushing bottoms.
(10)
(11)
Install main shaft cover assembly to engine
assembly with four capscrews and washers.
Replace the fuel pump.
(5) Install new oil seal (8)
Section III. OIL FILTER AND SENSORS
13-11. LUBRICATING OIL COOLER. To test and
repair the lubricating oil cooler, refer to figure 13-14 and
13-15 and proceed as follows:
and apply 1 to 4 psi (7 to 28 kPa) air pressure to
water side.
(4) Inspect for air leaks and porosity in castings.
NOTE
(5) Apply 35 to 45 psi (241 to 176 kPa) to oil side.
Figure 13-15 is given for informational
purposes only, since older models
may not contain removable cores.
(6) Inspect for air leaks and porosity in castings.
b. Repair and Reassembly. To repair the lubricating
oil cooler, refer to figure 13-14, and proceed as
follows:
a. Test.
(1) Refer to the Operator/Crew Organizational
Maintenance manual for inspection and removal
procedures.
(1) Remove screws (33), cover (36), and gasket
(38). Then remove screws (26), washer (27),
screw (25), connection (28) and gasket (29).
(2) Clamp cooler assembly in fixture and assemble
air connection.
(3) Place unit in water tank with spring side down.
13-25
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 13-13. Mainshaft Cover and Tachometer Drive,
Exploded View, Code B
13-26
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(3) Fill element with proper lubricating oil. Refer to
table 3-1 of the Operator/ Crew and Organizational
Maintenance manual.
NOTE
To prevent hardening and drying of
foreign substances, clean cooler
assembly immediately after removing
end cover plates. Use approved
cleaning solvent that will not harm
non-ferrous metal. Finish cleaning by
blowing
through
core
with
compressed air.
(4) Install new top gasket, position filter case, and
tighten clamps securely.
(5) Run engine, check for leaks, recheck engine oil
level; add oil as necessary to bring oil level to FULL
mark on oil level gauge (dipstick).
NOTE
(2) Repair damaged tubes, by inserting a smaller
OD tube inside damaged tube. Cut and flare
ends, then solder securely. Do not restrict more
than 5 percent of total number of tubes in this
manner. If more than 5 percent of tubes are
defective, discard cooler.
Always allow oil to drain back to oil
pan before checking level. This may
require several minutes.
13-12. BYPASS VALVE. To inspect, test, replace, and
repair the lubricating oil filter bypass (relief) valve, refer
to figure 13-14, and proceed as follows:
(3) To assemble the lubricating oil cooler, install
new gasket (38), cover (36), new washers (27),
new gasket (38), new gasket (29), connection
(28), and new screws (25), (26) and (33).
c.
a. Removal.
(1) Drain the engine oil and remove the oil filters
(13) in accordance with the Operator/Crew and
Organizational Maintenance manual.
Bypass Oil Filters. The bypass oil filters are located
on a bracket mounted over the starter motor
assembly on the right side of the engine. Service
the bypass oil filters by replacement as follows:
(2) Remove oil transfer tube (3) and discard O-ring
(4).
(1) Clean filter case. Handle or store in a manner
to prevent out-of-round.
(3) Remove capscrews (1) and washers (2).
(2) Insert new element in filter case, seating it
securely on bottom.
(4) Remove capscrews (5), capscrews (6), and
washers (7); discard gasket (11).
LEGEND FOR FIGURE 13-14
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Screw
Washer
Tube
O-ring
Screw
Screw
Lockwasher
Tube
O-ring
Connection
Gasket
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Lubricating oil
filter assy
Filter
Adapter
Lockplate
Plug
Plug
Retainer
Spring
Disc.
Screw
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
13-27
Lockwasher
Head
Gasket
Screw
Screw
Lockwasher
Connection
Gasket
Tube
O-ring
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
Lubricating oil
cooler assy
Screw
Screw
Lockwasher
Cover
Cover
Gasket
Cooler
Screw
Bracket
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 13-14. Lubricating Oil Cooler, Exploded View, Code A
13-28
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(5) Remove retainer (18), spring (19), and disc
(20).
(6) Plug fuel inlet port using plug provided with
spray angle tester.
b. Inspection and Test. Visually examine springs
and disc for cracks and other damage.
c.
(7) Install injector into leakage tester and clamp
into position. Support plate may be tilted for
easier installation of injector.
Repair. Repair by replacing any damaged or
defective parts.
(8) Operate retraction lever and read air
flowmeter at top of ball float.
d. Reassembly.
(9) Rotate plunger by small increments to find
the highest reading on flowmeter. The
maximum readings should not exceed 4.5
(worn limit).
(1) Replace disc (20), spring (19), and bypass
spring (18).
(2) Replace gasket (11) and install washers (7),
capscrews (6), and capscrews (5).
(10)
If maximum readings exceed 4.5 worn
limit, repair injector.
(11)
With this test completed, place
retraction lever to "A" position;
disconnect transfer line; exhaust the air
cylinder, and remove injector.
(12)
Remove plunger and reinstall spring
and plunger.
(3) Install washers (2) and capscrews (1).
(4) Replace O-ring (4) and install oil transfer
tube (3).
(5) Replace the oil filters and refill the engine
oil in accordance with the Operator/Crew
and Organizational Maintenance manual.
13-13. INJECTORS. The following paragraphs contain
test, adjustment, and repair procedures for the
injectors.(See figure 13-16.) Refer to Operator and
Organizational Maintenance manual for removal
procedures and proceed as follows:
b. Cup Spray Pattern Check. The cup spray
pattern check is conducted using a spray angle
tester. Refer to paragraph h, and proceed as
follows:
a. Leakage Test. The leakage test is conducted
using an injector leakage tester (see figure 1317). Refer to paragraph g. and proceed as
follows:
(1) Insert injector into adapter.
(2) Remove plunger (7) and spring (4) from
injector.
(1) Oil injector O-rings (10).
(3) Install plunger bore plug and rubber seal in
injector plunger bore.
Protect injector
plunger from dirt or damage during tests.
(2) Install plunger extension on plunger (7) and
remove spring (4).
(3) Align injector delivery orifice with locating
screw hole or bushing hole in adapter pot.
(4) Place injector into special seat and adjust
holddown bracket into position required,
then tighten thumb screw.
(4) Using hand pressure, press injector into pot
until it bottoms.
(5) Tighten knob against plug and seal in
plunger bore so it seals thoroughly.
(5) Insert and tighten locating screw.
13-29
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Screw
Washer
Oil transfer
tube
Packing
Screw
Screw
Washer
Oil transfer
tube
Packing
Connection
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Gasket
Lube oil filter
Filter element
Adapter
Lockplate
Plug
Plug
Retainer
Spring
Disc
Screw
Washer
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Filter head
Gasket
Screw
Screw
Washer
Connection
Gasket
Tube
Packing
Lube oil
cooler
Screw
Figure 13-15. Lubricating Oil Cooler, Exploded View, Code B
13-30
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
Screw
Washer
Cover
Cover
Gasket
Plug
Draincock
Core
Packing
Cooler
Screw
Bracket
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(6) Jet fuel source pressure to 22 psi (152 kPa).
(7) If leakage is observed, the ball (8) must be
replaced. Slight seepage is harmful.
(7) Shift the target ring in base of tool so one
spray stream hits center of No. 1 or index
window. This window provides ±3 degrees
tolerance on injector spray stream location.
d. Disassembly. Proceed as follows:
(1) Lift out injector link (3), plunger (7), and
spring (4). Remove spring (4) from adapter
(15).
(8) Check that spray stream hits a window in
the target ring. No more than one stream
must require the increased tolerance of the
No. 1 window.
(2) If required, store plunger (7) by standing on
coupling end.
(9) After testing, assemble plunger with spring in
body adapter and store in clean place until
ready for next test.
c.
NOTE
Injector barrels and plungers are class
fit. Do not interchange.
Flow Test. The flow test is accomplished using the
injector test stand (see figure 13-19).Refer to
paragraph i, and proceed as follows:
(3) Remove O-rings (10) from injector adapter
(15) and discard.
(1) Seat injector in body so injector inlet aligns
with body inlet hole. Tighten locating screw.
(4) Remove filter screen clip (11) and remove
screen (12). Check screen and discard if
damaged.
(2) Remove spring (4) and plunger (7) from
injector adapter. Leave spring (4) off and
install plunger (7).
NOTE
(3) Attach test stand inlet pressure line to drain
connection of test stand.
Do not remove orifice plug (13) from
inlet groove.
(4) Hold injector plunger down against its seat
in injector cup with injector in a vertical
position. Assembly may be held in hand; do
not place in test stand holding device.
(5) Insert injector into holding fixture.
(6) Slide body wrench, over flats on injector.
(7) Place retainer wrench on injector.
(5) Turn on test stand and adjust pressure to
150 psi (1034 kPa).
(8) Activate air cylinder on holding fixture to
hold injector in place. Loosen cup retainer
(5) but do not remove.
(6) Check orifice plug inlet opening or injector
for leakage past ball valve.
(9) Deactivate air cylinder.
NOTE
(10) Remove injector clamp and retainer wrench
from fixture.
Make certain that plunger is seated in
the cup.
(11)
Screw off cup retainer (5) and remove
injector cup (6) and barrel (7).
NOTE
Do not lose check ball (8)
13-31
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND
1.
2.
3.
4.
Screw
Clamp
Link
Spring
5.
Retainer
6.
Cup
7.
Barrel and
plunger
8.
9.
10.
11.
Ball
Pin
O-ring
Clip
Figure 13-16. Injector, Exploded View
13-32
12.
13.
14.
15.
Screen
Plug
Gasket
Adapter
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(12)
Remove check ball (8) from top of
barrel (7).
(9) Use strong magnifying glass to check for
burrs, carbon, and distorted radii in orifice
(13). If metering orifice shows signs of
damage, replace orifice.
e. Repair. Proceed as follows:
(1) Replace injector link (3) if worn excessively.
f.
(2) Check closely for metal seizure. As a rule
this is the only true indication of scuffing or
scoring.
Adjustment and Reassembly. Proceed as
following using any new parts required for
repair:
(1) Drop check ball (8) into top of barrel (7).
(3) Narrow streaks running the length of the
plunger (7) usually are the result of the
varying thickness of penetrant treatment
used to prevent rusting.
Plunger is
satisfactory for reuse unless surface
disruption is evident.
CAUTION
Be certain all mating surface parts are
clean and free of burrs or other
imperfections which could result in
incorrect flow or torque. Lap to repair.
(4) Test spring tension, on spring tester device
that is capable of very accurate
measurements of spring lengths and applied
load by means of standard and dial indicator
gauge. Load required to compress spring to
1.663 inches (42.2 mm) is 143.25 pounds
(65 kg) minimum to 158.75 pounds (72 kg)
maximum. Worn limit is when 138 pounds
(63 kg) is required to produce the spring
length. If spring does not compress at right
load limit, replace spring.
(2) Hold barrel (7) with check ball (8) up and
place new adapter spiral pins (9) into barrel
(7).
(3) Turn adapter (15) and barrel (7) with barrel
up and place cup (6) on barrel (7).
(4) Lubricate cup retainer threads (5) and cup
flange contact area with 20 or 30W lube oil
and assemble to adapter. Screw retainer
(5) down finger tight and loosen 1/4 turn.
(5) Inspect injector spray holes and tip with
magnifying glass. Compare with new cup.
Discard cup if cup shows abrasive wear,
corrosion damage, or enlarged or distorted
spray holes.
(5) Immerse injector plunger (7) in clean
injector test oil and install in adapter without
spring (4).
(6) Insert injector into fixture.
(6) Using a flat steel plate and "bluing" check
injector cup barrel surface for flatness.
(7) Slide body wrench over flats on injector
adapter.
(7) Check cup retainer for nicks or burrs which
could prevent proper seating with sleeve in
head.
(8) Place retainer wrench on injector retainer.
(9) Activate air cylinder on holding fixture to
align cup and plunger.
(8) Inspect injector barrel plunger bore for
scoring. If injector will pass leakage test,
barrel is usable. If leakage was too high,
barrel and plunger must be replaced.
13-33
(10)
Tighten cup retainer (5) with crowfoot
wrench and retainer wrench to 50
footpounds (68 joules).
(11)
Remove injector from loading fixture
being careful not to hit cup on stud.
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(12)
Hold injector in vertical position (cup
down) and allow plunger to drip a few
drops of test oil into cup.
(13)
Insert plunger about 1/2 inch (12.7 mm)
into barrel to be certain plunger is started
straight.
the ball float will fluctuate slightly during
opening and closing of the door. Other than
not being able to obtain an accurate reading
during actual swinging of the door, such a
room has no adverse effects and is
desirable.
(14)
Jam coupling with palm of hand to seat
plunger in cup and rotate 90 degrees
while holding plunger firmly against cup
seat.
(b) A work bench of standard height which is not
subject to pounding or other heavy work. The
bench must not have a vise or other shop
equipment which is generally subject to impacts.
(15)
Hold injector with cup up and plunger
should slide out when injector is lifted
quickly.
(16)
If plunger does not slide out, remove
plunger, coat tip with test oil, and repeat
test.
(c) An air supply of 80 psi (552 kPa) minimum
pressure. The air line to the injector leakage
tester should not be in a location where
intermittent. pressure drops are caused by
actuation of other shop air equipment.
(17)
(18)
(19)
(20)
(21)
(2) Mount rubber isolation pads to feet with
capscrews provided.
If
plunger
sticks
because
of
misalignment, loosen cup retainer, rotate
cup 1/4 turn, and retorque. Repeat as
necessary.
(3) Mount feet to panel. When feet-to-panel
capscrews are snug, panel must be installed
in a vertical position to ensure proper
operation of air flowmeter.
Remove plunger from adapter and
lubricate plunger with test oil. Install
spring on plunger and insert into adapter.
Test plunger in accordance
paragraphs a, b, and c above.
(4) Fill air cylinder oiler 1/3 to 1/2 full of injector
test oil. Make sure sealing ring is in place
before tightening bowl retainer.
with
(5) Fill bubble checker bowl with injector test oil
to oil level marker. To more easily fill bowl
to specified level, it may be filled
approximately 3/4 full and then drained to
proper level through valve at bottom of
bowl.
Install new screen (12) and clip (11).
Refer to the Operator/Crew and
Organizational Maintenance manual for
replacement procedures.
g. Installation,
Assembly,
and
Operating
Instructions for the Injector Leakage Tester (See
figure 13-17).
(1) The following facilities are necessary for
installation of the injector leakage tester:
(a) A clean area with good lighting. An
enclosed fuel systems area is preferred.
When a tightly enclosed room is used,
due to the extreme sensitivity of the air
flowmeter,
13-14
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(6) Use a vise-grip wrench while connecting air
supply line to prevent disturbance to
threads.
(7) Install T-handle clamping mechanism
backed out approximately 1/2 thread turn
from snug position.
(8) Install retraction handle and lock intoposition with jam nut.
(9) Set pressure regulator at 60 psi (414 kPa).
(10)
Operate air cylinder a few times and set
final pressure at precisely 60 psi (414 kPa).
The air pressure must be held at 60 psi (414
kPa) during all tests.
(11)
The velocity of air cylinder piston rod
may be adjusted as desired with small valve
at rear of panel. Loosen locknut and screw
valve stem in to decrease piston speed or
back screw out to increase piston speed.
Lock the nut on the stem when desired
piston speed is attained.
(12)
With retraction lever in "A" position,
install load cell and clamp into position.
(13)
Adjust knurled knob until load cell reads
200 psi (1379 kPa). The psi (kPa) reading
on load cell is a direct reading in pounds
(kg) load, since load cell piston area equals
1 square inch (6.45 sq cm). Adjust knurled
knob to obtain 200 lbs. (90.7 kg) load
during several clamping cycles.
(14)
LEGEND
1.
2.
3.
4.
5.
Gauge
Air cylinder
Injector
T-handle clamp
Retraction
lever
6. Feeler gauge
With load cell clamped at 200 lbs. (90.7
kg) load, use the feeler gauge to adjust
locknuts into position and tighten.
Clamping
mechanism
should
be
checked daily with load cell and
locknuts adjusted if necessary,
7.
8.
9.
10.
11.
Load cell
Pressure
regulator
Cylinder actuation valve
Bubble checker
Flowmeter
Figure 13-17. Injection Leakage Tester
h. Installation,
Assembly,
and
Operating
Instructions for the Spray Angle Tester. The
spray angle tester (figure 13-18) is used with the
injector test stand which is described in
paragraph i.
(1) Locate Spray angle tester on or near the
injector test stand so injector inlet
connection of test stand will reach injector to
be spray checked. Use injector test oil or
fuel oil to perform test.
13-35
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(3) Fill cambox with SAE 30 non detergent
lubricating oil to top of sight glass. Refill
when oil level gets low in sight glass.
(4) Plug electrical connection into receptacle
carrying the necessary voltage to operate
the test stand.
(5) A motor driven shaft and cam are housed in
the cambox. The cam actuates the vertical
push rod at the bottom of the housing.
(6) The push rod is connected to the injector by
a link so the injector plunger will be actuated
by cam action just as it is in the engine.
Figure 13-18. Spray Angle Tester
(7) Injectors are clamped in the test stand by
hydraulic pressure from the cylinder, piston
rod, and injector seat. The injector seat
contains a removable orifice to restrict the
metered fuel flow and cause a back
pressure simulating compression pressures
as found in the engine.
(2) Attach drain hose to spray angle tester base
and place loose end in injector test stand
drain pan.
(3) Assemble cup seat spacer H-10 to seat
bracket bore.
(4) Place H-2 seat in seat spacer and bracket
bore.
(8) Before clamping the injector in the test
stand, the cam must be timed by rotating
the timing wheel so the wheel mark and
pointer are aligned.
(5) Place target ring in base of spray angle
tester.
i.
(9) Shop air pressure regulated by air regulator
is used to apply a balanced force on the
hydraulic system. The air gauge at top of
hydraulic reservoir is used as a reference
indicating that pressure has not changed.
Installation,
Assembly,
and
Operating
Instructions for the Injector Test Stand . The
injector test stand must be located near hot and cold
water connections. Water temperature, controlled by
a mixing valve, is used to maintain test oil at a 90 to
95°F (32 to 35°) temperature range. If temperature
exceeds 135°F 57°C) drain and replace with new
test oil. (See figure 13-19.)
(1) Fill test oil tank 3/4 full of test oil and
maintain this level or higher during test. Test oil
capacity is approximately 5 gallons. It is available
as Part No.99011-68.
(2) Fill the hydraulic fluid reservoir to half level
in sight bulb with clean Type A automatic
transmission fluid. Be careful not to allow
oil to enter the standpipe in center of
reservoir.
13-36
(10)
When the air valve is opened, air
travels up the pipe in the center of the tube
type hydraulic reservoir and exerts a
downward pressure against the column of
hydraulic fluid.
(11)
When both the air valve and the
hydraulic valve are opened, hydraulic fluid
is admitted under the piston in the cylinder
and lifts the injector into clamped
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(14)
Fuel is delivered to the vial during a
measured number of strokes as recorded by the
counter.
13-14. FUEL INJECTION PUMP. To test, adjust,
replace, repair, overhaul, and rebuild the fuel injection
pump for Code "A" or Code "B", refer to figure 13-20
through 13-25 and proceed as follows:
a. Test and Calibration. The fuel pump should be
tested using the fuel pump test stand; refer to
paragraph b then proceed as follows:
(1) Remove the fuel pump and mainshaft cover
from the assembly as follows:
(a) Remove the speed switch in accordance
with the Operator/ Crew and Organizational
Maintenance manual.
(b) Disconnect the fuel pump line from the
pump shut-off valve.
LEGEND
1.
2.
3.
4.
5.
Air gag
Fuel pressure gaug
Vial graduate
Start/stop switch
Temperature gauge
6.
7.
8.
9.
10.
11.
Counter
Inbt
Yoke
Air alve
Pressure Regulator
Sight glass
(c) Disconnect the throttle lever linkage from
the throttle lever.
(d) Disconnect the shut-off valve electrical
connections.
(e) Disconnect the pump cooling line to the
check valve elbow (1, figure 13-24) on the
gear pump.
LEGEND
1.
2.
3.
4.
5.
Air Gauge
Fuel pressure
gauge
Vial graduate
Start/stop
switch
Temperature gauge
6.
7.
8.
9.
10.
11.
Counter
Inlet
Yoke
Air valve
Pressure
regulator
Sight glass
(f) Remove the capscrews securing the
mainshaft cover to the engine assembly.
(2) Install the fuel pump in the fuel pump test stand
mounting bracket leaving about 1/16 inch
(0.0625 mm) between fuel pump coupling and
test stand drive coupling.
Figure 13-19. Injector Test Stand
(3) Squirt some clean test oil into the gear pump
inlet hole, so pump will pick up faster, then
connect suction line.
position. Any leak in the hydraulic
clamping system will directly affect
injector loading and must not be
permitted.
(4) Fill the fuel pump housing with clean test fuel oil
through the plug hole on
(12)
Fuel is delivered to the injector through
the inlet connector. Fuel pressure is controlled at this
point by a connecting line and pressure regulator.
(13)
The second connection with the clean
plastic line is the injector drain connection which carries
drain fuel from the injector back to the tank.
13-37
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Ball
Screw
Lockwasher
Cover
Ring
Plunger
O-ring
O-ring
Plug
Cap
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Seal
Spring
Screen assy
Nut
Lockwasher
Washer
Screw
Lever
Screw
Cover
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Ball
Shaft assy
Screw
O-ring
Ring
O-ring
Shaft
Nut
Screw
Plug
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
O-ring
Screw
Plunger
Plunger
Shim
Spring
Pin
Driver
Washer
Spacer
Figure 13-20. Fuel Injection Pump, Exploded View, Code A
13-38
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
Sleeve
Barrel
Spring housing
Clip
Plug
Screw
Nameplate
Dowel pin
Bushing
Housing
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 13-21. Fuel Injection Pump, Exploded View, Code B
13-39
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND FOR FIGURE 13-21
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Barrel assy
Screw
Plate
Gasket
Ring
Seal
Seal
Plug
Cap
Spring
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Seal
Connector
Screen
Plug
Adj. nut
Seal
Valve
Nut
Nut
Plug
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Screw
Dowel
Bushing
Carrier assy
Spring
Shim
Plunger
Plunger assy
Driver
Spacer
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
Plunger
41.
Bearing
42.
Shim
43.
Plunger
44.
Barrel
45.
Housing
46.
Screw
47.
Cover
48.
Ball
49.
Throttle shaft assy
Screw
Stop
Shaft
Adj.screw
Seal
Seal
Ring
Ball
Body
top of the pump. Reinstall plug.
(8) Completely open the fuel pump shut-off valve
by turning knob clockwise (12, figure 13-22),
and the flow control valve.
(5) Connect line to fuel pump shut-off valve.
(6) Connect a No. 4 hose to the cooling bleed
check valve on the gear pump. Drain into
splash tray under pump.
(9) Open throttle to wide open position (secure
open with a spring), and start and run pump at
500 rpm.
CAUTION
(10)
Never operate gear pump with the
drain plugged.
If pump is newly rebuild or has been
opened, run at slightly over rated speed for 5
minutes to flush,
(7) Never remove fuel pump damper either during
testing or operation as it will cause erratic pump
performance and accelerate wear.
LEGEND
1.
2.
3.
4.
Screw
Lockwasher
Washer
O-ring
5.
6.
7.
8.
Screw
Coil
Shield
O-ring
9.
10.
11.
12.
Washer
Valve
Housing
Knob
Figure 13-22. Fuel Shut-off Valve, Exploded View
13-40
13.
14.
15.
16.
O-ring
Shaft
Plug
Housing
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND
1.
2.
3.
4.
5.
Plug
Seal
Screw
Washer
Lockwasher
6.
7.
8.
9.
10.
Screw
Lockwasher
Cover
Gasket
Ring
11.
12.
13.
14.
15.
Retainer
Spring assy
Spring
Shim
Pack assy
16.
17.
18.
19.
20.
Screw
Spring
Washer
Guide and clip
Plunger
15.
16.
17.
18.
19.
Shaft
Gear
Gasket
Cover
Housing
Figure 13-23. Governor Spring Pack, Exploded View
LEGEND
1.
2.
3.
4.
Elbow
O-ring
Screw
Lockwasher
5.
6.
7.
8.
9.
Gasket
Screw
Lockwasher
Washer
Elbow
10.
11.
12.
13.
14.
Plug
Dowel
Ring
Gear
Shaft
Figure 13-24. Gear Pump, Exploded View
13-41
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
allow bearings to seat-, and to purge all air
from the system.
(d) If you cannot obtain 8 inches (203 mm)
of vacuum, check for restriction in test
stand filter or fuel supply line.
(11) Before starting calibration, check pump
fuel flow-in the flowmeter for air. If air is
present, correct leak before continuing test.
(e) Close the fuel manifold orifice valve
until the flowmeter shows 168 psi (1159
kPa) at 1800 rpm. There must be no air
visible in the flow- meter. Disregard
change in vacuum readings at this
setting.
(12) The test fuel oil must be 90 to 100°F (32 to
38°C).
(13) Set gear pump at 8 inches (203 mm) Hg.
vacuum during run-in.
(f) If flow cannot be obtained and held,
check idle plunger and governor break.
Inspect pulsation damper diaphragm.
(14) Calibration Procedure.
(g) Open fuel pressure gauge valve. With
throttle in full fuel position, increase
pump speed until point at which fuel
pressure just begins to decrease (peak
point). This should occur at 2090 rpm.
(a) Close idle, leakage, and pressure
valves. Open flow control or needle
valve wide open.
(b) Increase pump speed to engine rated
speed.
(h) If speed is lower than specified, add
shims between governor spring and
retainer. To reduce speed, remove
shims.
(c) Adjust vacuum valve in fuel pump
suction line to obtain 8 inches (203 mm)
Hg on vacuum gauge.
Figure 13-25. Fuel Pump Damper, Exploded View
13-42
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
NOTE
CAUTION
When pump is open to make
adjustments, open main control valve to
flowmeter wide open and move throttle
lever back and forth until flowmeter
shows no air, so air may be expelled
more rapidly from system.
Weight assist plunger must be installed
with the smallest end to the governor
plunger.
(17) Check Pressurizing Valve. Loosen the
plug (1, figure 13-23) in the governor
spring pack housing cover. Fuel should
leak around the plug if the pressure valve
is properly pressurizing the housing.
(15) Setting Idle Speed.
(a) Close test stand main flow control valve
and open idle orifice valve.
(18) Checking Pump Seals.
(a) With the test stand operating at 500
rpm, close vacuum valve in fuel pump
suction line until vacuum gauge reads
15 inches vacuum.
The fuel flow
control valve should be open during this
check.
(b) Set throttle shaft in idle position (toward
gear pump) and hold firmly against stop.
(c) Run test stand at 168 psi (1159 kPa).
(d) Check pressure on fuel manifold
pressure gauge; it should be 168 psi
(1159 kPa). If pressure is low, screw
idle adjusting screw (16, figure 13-23) in
with the spring adjusting tool. To lower
pressure, back out screw.
(b) Put a small amount of light cup grease
over the vent hole at the mainshaft seal
bore of the mainshaft cover (30, figure
13-20).
(c) If lubricant is sucked into the hole at the
15 inch vacuum setting, this is an
indication that the seals will not permit
proper engine performance and should
be replaced.
(16) Weight Assist Pressure Check.
(a) Decrease pump speed to 800 rpm.
Adjust flowmeter if not as specified.
(b) The fuel manifold pressure should be
129 to 135 psi (890 to 931 kPa) at'1500
rpm.
(d) During the above check, observe the
flowmeter for air in the meter which may
or may not indicate air leakage into the
pump.
Air may be entering lines
between tank and pump. A slow leak
may not show up promptly as air in the
meter. Observe fuel level in tank for
possibility of low fuel causing air
bubbles.
(c) If fuel pressure is low, add shims behind
the governor weight assist plunger in
the governor weight carrier (16, figure
13-12) or (24, figure 13-21).
To
decrease pressure, remove shims. If
adjustments are required, recheck entire
pump calibration. Shims are available
in 0.007 to 0.016 inch (0.178 to 0.406
mm).
(e) Leakage may occur at the gear pump to
housing gasket if gear pump is not
positioned correctly.
(f) Tighten all capscrews,
13-43
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
pump and fuel pump body.
screws, hose connections, pipe plugs,
and filter screen cap.
(c) Remove fuel pump damper from gear
pump and connect copper line from
orifice block to gear pump pressure tap.
(19) Housing Porosity Check.
(a) Fill fuel pump with clean fuel or test oil.
(b) Remove suction fitting at gear pump
and install fittings so an air pressure
hose may be attached.
(d) Connect the fuel suction line to the
suction side of the gear pump. Run a
line from the gear pump bleed
connection to the fuel supply tank.
(c) Air supply.hose line must be equipped
with a valve and gauge to control air
pressure at a maximum of 20 psi.
(e) Shut off the fuel manifold pressure
gauge to prevent damage from over
pressure.
(d) Apply 20 psi air pressure; do not exceed
20 psi or damage to seals may result.
(f) The valve in the suction line and the
valve controlling the main flow orifice
are to be fully open. All other valves
must be completely closed. With the
valves in this position, fuel will be
routed through the manifold orifice.
(e) Pour fuel oil over pump and examine
carefully for air bubbles, indicating
leaks. Alternately wipe pump or specific
area dry and check for wet seepage.
Do not use this check for seals.
(g) Start the pump drive and run the pump
at 400 to 450 rpm. The gear pump
must pick up at this speed without the
aid of priming. Any gear pump which
fails to pick up fuel must be rebuilt or
replaced in accordance with paragraph
13-10f.
(20) Gear Pump Test.
(a) Use a fuel pump build up with only the
parts required to drive the gear pump,
minimum
of
pump
body,
with
tachometer drive and a complete
mainshaft cover assembly. If desired, a
complete fuel pump can be used if the
governor plunger and weight assist
plunger and spring assembly are
removed and pump housing is filled with
fuel; this will prevent any possible
damage to governor plunger or
governor barrel. Gear pump may be
mounted directly to test stand with
adapter bracket.
b. Instructions for the Fuel Pump Test Stand. The
fuel pump test stand, figure 13-26, is required
for accurate testing and calibration of the feel
injection pump. Pump speeds may be varied
continuously from 475 to 4750 rpm. Correct
calibration of the fuel injection pump is one of
the most important procedures to satisfactory
engine operation.
(1) Test Oil. The fuel pump test stand must be
filled with clean test oil No. 99011-68 or
equivalent.
(b) Install gear pump block plate, with
gasket on each side, between gear
13-44
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 13-26. Fuel Pump Test Stand
NOTE
nonharmful to personnel. The chemical
and physical requirements must be as
follows:
Hydraulic oils are not suitable to use as
test oils. The test oil shall be a straight
oil or blend of oils containing parafinic,
aromatic, or naphthenic compounds, but
not olefinic compounds, which show
little or no change in physical properties
during storage or use.
The use of
various additives and/or inhibitors to
stabilize the oil is left to the discretion of
the supplier. The additives must be
antifoaming,
anticorrosive,
and
antigumming. The fuel, additives, and
color dye must be nontoxic and
Kinematic Viscosity
at 100°F (38°C) Centistokes
ASTM D445 ........................................... 2.5 to 3.3
Viscosity at
100°F (38°C) Saybolt
Universal (SUS),
ASTM D2161 .....................................34.4 to 37.0
Specific Gravity
at 60°F (15.5°C),
ASTM D287 ..........................................820 to 830
13-45
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
properly adjusted.
Gravity, Degrees, API,
60°F (15.5°C,
ASTM D287 ............................................. 41 to 39
Flash Point, P.M.,
closed cup,
ASTM D93 160°F (71°C)
min. color, ASTM D1500........................... 2 max.
Water, ASTM D1796 ...................................... 0.005
Corrosion,
ASTM, D130 ..............................Must pass class I
Galvanic
corrosion,
ASTM 5322-1 ....................................... Must pass
Sulphur percent
weight,
ASTM P 129, D1552 ........................................ 0.4
Distillation at
20 percent point,
ASTM D86 ............................. 440°F (226°C) min.
(c) Throttle control linkage is adjusted so
full throttle is obtained, and when released throttle is stopped by front
throttle leakage adjusting screw.
(2) Remove the speed switch in accordance
with the Operator/Crew and Organizational
Maintenance manual, and connect a high
accuracy tachometer to the fuel pump
tachometer drive connection.
(3) Operate the engine a sufficient period of
time to bring engine up to operating
temperature (at least 165° F (74°C) oil
temperature.
(4) Remove pipe plug (1, figure 13-23) to
provide access to the idle adjusting screw
(16).
Sediment - Using a 10-micron filter, 22,260
particles per milliliter are permissible. Using
a 40-micron filter, 195 particles per milliliter
are permissible. Using a 50-micron filter, 5
particles per milliliter are permissible.
(5) Turn the idle adjusting screw (16) in to
increase or out to decrease the speed using
the fuel pump spring pack adjusting tool.
The recommended idle speed is 550 ± 20 to
30 rpm.
Mobil Oil Company Type MCL-41 is one
source that meets the above requirements.
d. Replace. Tolreplace the fuel pump, proceed as
follows:
(2) The instruments on the fuel pump test stand
must
be
periodically
checked
and
maintained.
(1) Disconnect the fuel pump line from the
pump shut-off valve.
(2) Disconnect the throttle lever linkage from
the throttle lever.
(3) Refer to paragraph 13-14a for detailed
procedures for connecting a fuel pump to
the test stand, and operating the test stand.
c.
(3) Disconnect the shut-off valve electrical
connections.
Adjustment on Engine. To adjust the fuel pump,
refer to figure 13-23 and proceed as follows:
(4) Disconnect the pump cooling line to the
check valve elbow, (1, figure 13-24) on the
gear pump.
(1) Before making fuel pump adjustments, be
certain the following initial conditions are
observed:
(5) Remove the seven capscrews securing the
fuel pump to the gear cover.
(a) Engine is at operating temperature.
Fuel temperature is not above 110°F
(43°C).
(b) Timing,
valves,
and
injectors
(6) Install a new gasket (3, figure 13-12) or (12,
figure 13-13) and attach a new or repaired
fuel pump with the
are
13-46
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
seven capscrews.
lockwashers
(5),
screws
(6),
and
lockwashers (7).
Lift off governor and
discard gasket (9).
(7) Attach the pump cooling line to the check
valve elbow (1, figure 13-24) on the gear
pump.
(8) Connect the
connections.
shut-off
valve
NOTE
electrical
Steps (9) thru (25) are rebuild
instructions for the fuel pump housing
assembly, code A. Steps (26) thru (41)
are rebuild instructions for the fuel pump
housing assembly, code B.
(9) Connect the throttle lever linkage.
(10) Connect the fuel pump line to the pump
shut-off valve.
(9) Remove filter screen cap (10, figure
13-20), cap seal ring (11), filter spring
(12), and fuel filter screen assembly
(13).
e. Repair. Repair the fuel pump by replacing
defective or worn parts as determined in paragraphs a
and f.
(10) Remove pin (37), driver (38), washer (39),
spacer (40), plunger (34), shim (35), and
spring (36).
f. Overhaul and Rebuilding. Refer to figures 1320 through 13-25 and proceed as follows:
(1) Remove the fuel pump in accordance with
paragraph d.
(2) Clean outside of fuel
approved solvent that
aluminum surfaces.
(11) Heat housing in oven to 300°F (149°C) and
press out governor sleeve and barrel (41,
42).
pump with an
will not harm
(12) Remove three screws (2), lockwashers (3),
fuel control cover (4), snap ring (5), and
barrel plunger (6).
(3) Mount the fuel pump in holding fixture and
swivel vise.
(13) Remove and discard O-rings (7 and 8).
(4) Remove elbow (9, figure 13-24) and the
orifice elbow assembly (1); clean parts in
fuel oil and dry with compressed air blown
through bottle ends.
(14) Remove nut (14), lockwasher (15), washer
(16), screw (17), and throttle lever (18).
(15) Remove two screws (19), and throttle shaft
cover (20).
(5) Remove the pulsation damper (figure 13-25)
from the gear pump and discard O-ring (4).
CAUTION
(6) Remove the gear pump (figure 13-24) from
the main housing by removing capscrews
(3), lockwashers (4), screws (6), washers
(8), and lockwashers (7). Tap lightly with a
plastic hammer to loosen dowel; remove
gear pump and discard gasket (5).
Use extreme care when removing throttle
shaft cover (20) to avoid dropping ball
(21).
(16) Remove ball (21), unscrew fuel adjusting
screw (23), and remove and discard O-ring
(24).
(7) Remove the fuel shut-off valve by removing
screws (1, figure 13-22) from the top of the
main housing and discard O-ring (4).
(17)
(8) Remove the governor spring pack (figure
13-23) by removing screws (3), washers (4),
(18)
13-47
Remove snap ring (25), throttle shaft
(27), and discard O-ring (26).
Visually inspect throttle
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
shaft (27) and fuel adjusting screw (23) for
signs of wear or damage; replace if
necessary.
(d) Visually check governor sleeve and
barrel (41 and 42) and plunger (34) for
wear; replace if worn or damaged.
NOTE
(22) Governor Barrel Replacement.
Do not attempt to remove the throttle
shaft sleeve; it is honed to size after
assembly to housing and due to close
tolerances, the housing and sleeve must
be replaced if damaged or worn
excessively.
(a) To locate a new governor sleeve and
barrel (41 and 42, figure 13-20), scribe a
center- line on the barrel and sleeve (41
and 42) and spring pack housing (43)
lining up the fuel passages so fuel flow
will not be restricted.
(19) Visually inspect filter screen assembly (13)
for holes or imbedded metal particles in
mesh. Replace if damaged, otherwise,
clean in fuel oil and dry with compressed
air.
(b) Heat housing (50) in oven to 300° F
(149°C).
(c) Coat new governor barrel with highpressure lubricant.
(20) Check drive shaft bushing (49) for signs of
seizure or burrs. Replace if damaged.
(d) Place governor sleeve and barrel (41
and 42) in housing bore with chamfered
end first and location pin hole on bottom
side, lining up scribe marks, then press
barrel in housing with arbor press until it
bottoms against spring pack housing.
This is important to align barrel retaining
pin holes.
(21) Check drive shaft bushing (49), XD with
inside micrometers; if worn beyond 0.7525
inch (19.11 mm) replace bushing as
follows:
(a) Remove worn bushing using a gouge
chisel or half inch pipe tap.
After
tapping bushing, screw a half inch pipe
cap on a close nipple and screw the half
inch nipple into the bushing. Insert a
punch through the rear of the housing
and drive out the bushing.
(e) Install spring (36), shim (35), plunger
(34), spacer (40), washer (39), driver
(38), and secure with pin (37).
NOTE
The chamfered side of washer (39) must
be installed next to driver (38). There
must be at least 0.002 to 0.005 inch (0.05
to 0.13 mm) clearance between washer
face and driver so washer will float.
(b) Apply a thin coat of high-pressure
lubricant to a new front drive shaft
bushing, press bushing into housing
flush with housing bore using an arbor
press.
(c) Line ream bushing to 0.7495 to 0.7505
inch. (19.04 to 19.06 mm) with the ream
fixture, and a well-oiled 0.750 inch (3/4
inch {19.05 mm}) reamer.
Check
bushing ID.
(23) Air Fuel Control Replacement.
(a) Lubricate new barrel O-rings (7 and 8,
figure 13-20) on plunger (6).
13-48
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(b) Secure plunger in housing with snap
ring (5).
(31) Remove two screws (37), and throttle shaft
cover (38).
(c) Install cover (4) with lockwashers (3)
and screws (2).
CAUTION
(24) Throttle Shaft Replacement.
Use extreme care when removing throttle
shaft cover (38) to avoid dropping ball
(39).
(a) Lubricate new O-ring (24, figure 13-20)
and slide on fuel adjusting screw (23).
(32) Remove ball (39), unscrew fuel adjusting
screw (44), and remove and discard O-ring
(45).
(b) Insert fuel adjusting screw (23) into
throttle shaft (27) about six turns. Do
not restrict throttle shaft fuel port.
(33) Remove snap ring (47), throttle shaft (43),
and discard O-ring (46).
(c) Lubricate new O-ring (26) and slide on
throttle shaft (27).
(34) Visually inspect throttle shaft (43) and fuel
adjusting screw (44) for signs of wear or
damage; replace if necessary.
(d) Insert throttle shaft (27) in housing (50)
with throttle stop up.
(e) Replace ball (21), cover (20), screws
(19), lever (18), screw (17), washer (16),
lockwasher (15), and nut (14).
NOTE
Do not attempt to remove the throttle
shaft sleeve; it is honed to size after
assembly to housing and due to close
tolerances, the housing and sleeve must
be replaced if damaged or worn
excessively.
(25) Filter Screen Replacement.
(a) Install fuel filter screen assembly (13,
figure 13-20) in housing (50).
(b) Install filter spring (12), cap seal ring
(11), and filter screen cap (10).
(35) Visually inspect filter screen assembly (13)
for holes or imbedded metal particles in
mesh. Replace if damaged, otherwise,
clean in fuel oil and dry with compressed
air.
(26) Remove filter screen cap (9, figure 13-21),
cap seal ring (11), filter spring (10), and
fuel filter screen assembly (13).
(36) Check drive shaft bushing (23) for signs of
seizure or burrs. Replace if damaged.
(27) Remove spring (25), shim (26), plunger
(27) and plunger assembly (28).
(37) Check drive shaft bushing (23), ID with
inside micrometers; if worn beyond 0.7525
inch (19.11 mm) replace bushing as
follows:
(28) Heat housing in oven to 300°F (149°C) and
press out governor sleeve and barrel (35,
36).
(29) Remove three screws (2), fuel control
cover (3), snap ring (5), and barrel plug (8).
(a) Remove worn bushing using a gouge
chisel or half inch pipe tap.
After
tapping bushing, screw a half inch pipe
(30) Remove and discard O-rings (5 and 6).
13-49
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(e) Install spring (25), shim (26), plunger
(27), and plunger assembly (28).
cap on a close nipple and screw the half
inch nipple into the bushing. Insert a
punch through the rear of the housing
and drive out the bushing.
(39) Air Fuel Control Replacement.
(b) Apply a thin coat of high-pressure
lubricant to a new front drive shaft
bushing, press bushing into housing
flush with housing bore using an arbor
press.
(a) Lubricate new barrel O-rings (5 and 6,
figure 13-21) on plunger (8).
(c) Line ream bushing to 0.7495 to 0.7505
inch. (19.04 to 19.06 mm) with the
ream fixture, and a well-oiled 0.750 inch
(3/4 inch (19.05 mm)) reamer. Check
bushing ID.
(c) Install cover (3) with screws (2).
(b) Secure plunger in housing with snap
ring (5).
(40) Throttle Shaft Replacement.
(a) Lubricate new O-ring (45, figure 13-21)
and slide on fuel adjusting screw (44).
(d) Visually check governor sleeve and
barrel (35) and plunger (31) for wear;
replace if worn or damaged.
(b) Insert fuel adjusting screw (44) into
throttle shaft (43) about six turns. Do
not restrict throttle shaft fuel port.
(38) Governor Barrel Replacement.
(c) Lubricate new O-ring (46) and slide on
throttle shaft (43).
(a) To locate a new governor sleeve and
barrel (35, figure 13-21), scribe a
centerline on the barrel and sleeve and
spring pack housing (36) lining up the
fuel passages so fuel flow will not be
restricted.
(d) Insert throttle shaft (43) in housing (49)
with throttle stop up.
(e) Replace ball (39) and cover (38) with
screws (37).
(b) Heat housing (49) in oven to 300° F
(149°C).
(41) Filter Screen Replacement.
(c) Coat new governor barrel with highpressure lubricant.
(a) Install fuel filter screen assembly (13,
figure 13-21) in housing (49).
(d) Place governor sleeve and barrel (35) in
housing bore with chamfered end first
and location pin hole on bottom side,
lining up scribe markes, then press
barrel in housing with arbor press until it
bottoms against spring pack housing.
This is important to align barrel retaining
pin holes.
(b) Install filter spring (10), cap seal ring
(11), and filter screen cap (9).
(42) Gear Pump Overhaul.
(a) Drive against dowels (11, figure 13-24)
with flat end punch to remove gear
cover from dowels in gear body.
13-50
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Discard gasket (17).
washer (9).
(b) Lift drive and driven gears and shafts
from gear pump body.
(c) Check for corrosion, excessive wear, or
cracks in cover or diaphragm. Replace
if necessary.
(c) Check pump shafts (14 and 15) for wear
or scoring; discard if damaged.
Replace shaft if worn smaller than
0.4998 to 0.5001 inch (12.695 to 12.703
mm) diameter.
(d) Install new O-rings (6 and 8) in grooves
and new nylon washer (9).
(e) Coat the diaphragm (7) with 10W or
20W oil and lay in cover (10).
(d) If gears are scored or worn badly, the
gears must be replaced.
(f) Assemble cover to housing, and attach
to fuel pump; replace O-ring (4) and
torque capscrews to 11 to 13 footpounds (15 to 18 joules).
(e) Check gear body and cover for scoring
or wear; replace parts as needed.
(f) Check lubrication holes in cover and
body; they must be clean.
(44) Fuel Shut-Off Valve Overhaul.
(g) Lubricate and slide shafts and gears into
cover.
(a) Remove four screws (5, figure 13-22),
coil (6), fuel shield (7), O-ring (8), spring
(9), and valve (10). Discard O-ring (8).
(h) Position new gasket (17) and install
body to cover. Align locating notches
together.
(b) Remove manual override knob (12) and
unscrew override shaft (14). Remove
and discard O-ring (13).
(i) Secure cover and body with dowels,
tighten capscrews to 11 to 13 footpounds (15 to 18 joules). Check to see
that pump turns freely with finger
pressure.
(c) Clean all parts except the coil assembly
(6) in mineral spirits.
NOTE
Do not wet the coil with solvent; instead,
wipe it with a clean lint-free cloth.
(j) Install a gear pump to fuel pump with
screws (3), lockwashers (4), screws (6),
washers (8), and lockwashers (7).
(d) Visually check valve and valve seat for
wear, bonding, failure, or corrosion.
Replace if necessary.
Valve seat
should have a minimum seat 0.015 inch
(0.38 mm) wide.
(k) Install elbow (9) and orifice elbow (1).
(43) Pulsation Damper Overhaul.
(a) Remove body (5, figure 13-25) from
cover (10).
(e) Check
coil
resistance
with
an
ohmmeter; replace if coil resistance is
below 30 ± 2 ohms.
(b) Remove spring steel diaphragm (7);
discard O-rings (6 and 8) and nylon
13-51
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(b) Remove high-speed spring (13), spring
retainer (11), and ship (14).
CAUTION
Be sure starting switch is in
position when checking coil.
OFF
(c) Remove idle spring plunger (20), idle
spring (17), plunger (19), and washer
(18).
(f) Install a new O-ring (13) on override
shaft (14) and coat with 10W or 20W
oil.
(d) Examine
governor
spring
pack
components for any worn or damaged
parts.
(g) Screw override shaft (14) into housing
until it reaches bottom of its bore. Use
a depth micrometer set at 0.118 inch
(2.997) mm) and check distance from
face of valve housing to tip of shaft. If
necessary, screw override shaft (14) out
until it is 0.118 inch (2.997 mm) below
housing face. Do not move shaft, or
press on knob until it contacts valve
housing which will act as a stop.
(e) Assemble idle screw (16) into plunger
guide (19), place washer (18) over
screw point inside guide.
(f) Place small idle spring (17) into plunger
guide (19) and place idle plunger (20)
against spring in guide.
(h) Place valve (10) into valve housing (16)
with rubber side toward housing.
(g) Install the spring pack (15) into spring
pack housing (43, figure 13-20) or (36,
figure 13-21)..
(i) Apply lubricant to new housing O-ring
(8) and seat in groove.
(h) Install spring (13, figure 13-23), shim
(14), retainer (11), and snap ring (10).
(j) Drop spring washer (9) on valve with
concave side up and piloted around
valve locator.
(i) Install new gasket (9), cover (8),
lockwashers (7), screws (6), wash- ers
(4), lockwashers (5), screws (3), and
new seal (2).
(k) Place fuel shield (7) on valve housing
(16) and tighten screws (5) to 25 to 30
inch-pounds (2.8 to 3.4 joules) torque.
(46) Mainshaft Cover assembly Overhaul.
Refer to paragraphs 13-8 and 13-10.
(47) The reassembled fuel pump should be
tested and calibrated in accordance with
paragraph a and replaced in accordance
with paragraph d.
(l) Install fuel shut-off valve to fuel pump
with capscrews (1), lockwashers (2),
washers (3), and new O-ring (4).
Torque to 25 to 30 inch-pounds (2.8 to
3.4 joules).
13-15. TURBOCHARGER (Code A). To repair the
turbocharger, refer to figure 13-27 and proceed as
follows:
(45) Governor Spring Pack Overhaul.
(a) Remove snap ring (10, figure 13-23)
which holds governor spring pack in
sleeve with a pair of snapring pliers.
a. Refer to the Operator/Crew and Organizational
Maintenance manual for removal instructions.
13-52
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 13-27. Turbocharger, Exploded View, Code A
13-53
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND FOR FIGURE 13-27
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Screw
Lockwasher
Washer
Support
Hose
Adapter
Adapter
Clamp
Hose
Clamp.
Hose
Clamp
Elbow
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25..
Nut
Clamp
Tube
Hose
Elbow
Elbow, R.B.
Elbow, L.B.
(not shown)
Nut
Gasket
Stud
Screw
'Washer
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
b. Remove screws (24), washers (25), nuts (26),
and clamps (27).
c.
Nut
Clamp
Clamp
Exhaust elbow
Case
Screw
Lockwasher
Housing
O-ring
Nut
Impeller
Seal
Sleeve
39.
40.
41.
42.
43.
44.
45.
46.
47'.
48.
49.
Plate
O-ring
Insert
Bearing
Wheel
Ring
Shield
Packing
Housing
Screw
Nameplate
(3) Refer
to
the
Operator/Crew
and
Organizational Maintenance manual for
replacement instructions.
Remove case (30), screws (31), lockwashers
(32), nut (35), impeller (36), seal (37), sleeve
(38),. O-ring (40), insert (41), bearing (42),
housing (47), packing (46), shield (45), ring (44)
and wheel (43).
13-16. TURBOCHARGER, CODE B.
To repair
turbocharger, refer to figure 13-28, and proceed as
follows:
d. Inspect diffuser plate (39) for cracks, burrs, and
distortion. Discard and replace if damaged.
a. Refer to the Operator/Crew and Organizational
Maintenance manual for removal instructions.
e. Inspect wheel (43) for cracked or broken vanes.
Discard and replace if damaged.
b. Remove screws (14), washers (15), nuts (12),
and seals (13). Remove clamp (16).
f.
c.
Inspect impeller (36) for damage. Discard and
replace if damaged.
g. Check all bearings for wear, chips, and cracks.
Discard and replace if damaged.
d. Remove hose (11).
e. Disassemble turbocharger as shown in figure
13-28.
h. If slight scratches or nicks are present in the
compressor casing, they may be smoothed out
with a very fine polishing cloth. Discard and
replace casing if it is cracked or distorted.
i.
Reassemble the turbocharger, as
(replace any worn or damaged parts):
Remove clamps (5) and (8), fittings (6) and (7),
and remove hoses (9) and tubing (10) and (37).
f.
Inspect impeller (21) for damage. Discard and
replace if' damaged.
follows
g. Inspect wheel (28) for cracked or broken vanes.
Discard, and replace if damaged.
(1) Install wheel (43), new ring (44), shield (45),
new packing (46), housing (47), bearing
(42), insert (41), new O-ring (40), sleeve
(38), seal (37), impeller (36), nut (35),
lockwashers (32), screws (31), and case
(30).
h. If slight scratches or nicks are present in the
compressor housings, (32), (36), or (19), they
may be smoothed out with a very fine polishing
cloth. Discard any housing that is cracked or
distorted.
i.
(2) Install clamps (27), washers (25), screws
(24), and nuts (26).
13-54
Reassemble turbocharger as shown in figure 1328, being sure to replace any worn or damaged
parts.
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 13-28. Turbocharger, Exploded View, Code B
13-55
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND FOR FIGURE 13-28
1.
2.
3.
4.
5.
6.
7.
8.
Screw
Washer
Washer
Nut
Clip
Elbow
Coupling
Clamp
9.
10.
11.
12.
13.
14.
15.
Hose
Tube
Hose
Nut
Seal
Screw
Washer
16.
17.
18.
19.
20.
21.
22.
23.
Clamp
Screw
Dataplate
Housing
Nut
Impeller
Ring
Plate
24.
25.
26.
27.
28.
29.
30.
Sleeve
Insert
Bearing
Seal
Wheel
Seal
Shield
31.
32.
33.
34.
35.
36.
37.
Pad
Housing
Stude
Nut
Gasket
Housing
Tube
Section IV. WATER PUMP
13-17. REPAIR. There are two types of water pumps
used on the engine assembly, All generator sets after
engine serial number 10605201 are equipped with the
new style pump incorporating an idler assembly. This
section provides disassembly and repair instructions for
both types of water pumps.
(d) Press shaft (25) from bearings (22) and
spacer (23); only if damaged, remove
retaining ring (24) from groove in shaft.
(2) Repair. Proceed as follows:
(a) Inspect bearings for rough or worn
races, or damaged shield. Replace if
necessary.
a. Water Pump Without Idler Assembly.
(1) Disassembly. Prior to disassembly, remove
the water pump from the engine assembly
in accordance with the Operator/Crew and
Organizational Maintenance manual. Refer
to figure 13-29.
(b) Inspect impeller and cover for cracks or
corrosion that could interfere with
circulation. Replace if necessary.
(c) Measure internal clearances and press
fits in accordance with tabulated data in
Chapter 1. Replace parts as necessary.
(a) Disassemble the water pump by
removing five screws (13), lockwashers
(14), cover (41), and gasket (30).
(d) Inspect water pump mounting parts for
cracks. Replace as necessary.
(b) Pull impeller (29) with puller and pull
sheave hub (19) from pump drive shaft
(25). Remove three screws (16) and
washers (17) to disassemble sheave
hub assembly.
(3) Reassembly. Reassemble the water pump
as follows:
(a) Place bearing retaining ring (24) over
long end of water pump drive shaft (25);
press into first ring groove with a piece
of tapered steel tubing.
(c) Remove snap ring (21) from pulley end
of body (15) and press out shaft spacer
(23) and bearings (22). Remove carbon
face seal (26) and seat (28) from pump
body (15); discard seal and seat.
(b) Pack bearings (22) full of grease, MILG-3545.
13-56
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 13-29. Water Pump, Exploded View
13-57
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND FOR FIGURE 13-29
1. Hose assy
2. Elbow
3. O-ring
4. Water transfer
tube assy
5. Screw
6. Lockwasher
7. Connection
8. Gasket
9. Screw
10. Lockwasher
11. Plug
12. Drain cock
13. Screw
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
Lockwasher
Body
Screw
Lockwasher
Sheave
Sheave
Sheave
Ring
Bearing
Spacer
Ring
Shaft
Seal
Impeller assy
28. Seat
29 Impeller
30. Gasket
31. Screw
32. Lockwasher
33. Connection
34. Gasket
35. Plug
36. Plug
37. Bushing
38. Plug
39. Flange
40. Gasket
41. Cover
against bearing race. Support other end
of shaft during pressing operation;
mount front adjustable sheave (18).
Turn water pump body assembly over
and press in new carbon face seal (26)
with a section of 1-3/4 inch (44.5 mm)
inside diameter by 2 inch (50.8 mm)
outside diameter tubing until it seals.
(c) Press shielded bearing (22) with
shielded side to retaining ring (24) over
shaft until bearing seats against
retaining ring. Bearings go on "long"
end of shaft using the retainer ring as a
guide point.
NOTE
(j) Lubricate the inside diameter of the new
rubber seat (28) with a light coat of
permanent antifreeze.
Apply load to inner bearing race only.
(d) Slide bearing spacer (23) over shaft
(25) against bearing.
CAUTION
(e) Place bearing (22) with open side to
spacer, over water pump shaft and
press into place.
Do not allow any lubricant on the seal
face.
(f) Pack space between bearings 55 to 65
percent (0.84 to 0.99 ounces - 24 to 28
g) full of grease MIL-G-3545.
(k) Slide the seal seat assembly (rubber
and metal seat washer) over the water
pump shaft until the chrome oxide side
of the washer bottoms against the
carbon face of the pump seal.
(g) Press shaft and bearing assembly into
water pump body (15).
(h) Assemble large snap ring (21) to hold
bearing and shaft in position.
(l) Press impeller (29) onto shaft until there
is 0.022 to 0.031 inch (0.56 to 0.79 mm)
clearance between back of impeller and
water pump body (15).
(i) Place rear adjustable sheave (20) on
pulley hub (19); press pulley hub and
sheave onto drive shaft until hub seats
(m) Install water pump
13-58
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
cover (41) and new gasket (30) to water
pump body (15).
Check clearance
between impeller vanes and cover; it
should be 0.020 to 0.040 inch (0.051 to
1.01 mm).
assembly (8) from the water pump
body.
(h) Remove screw (22) and washer (23)
and take off idler pulley cover (24) and
gasket (25).
b. Water Pump With Idler Assembly.
(i) Remove locknut (26).
(1) Disassembly. Prior to disassembly, remove
the water pump and idler assembly in
accordance with the Operator/Crew and
Organizational manual. Refer to figure 1330.
(j) Remove idler pulley (29) and bearing
assembly (28) from idler shaft (31).
(k) Remove rear oil seal (30) from the idler
pulley (29).
(a) Remove screws (3) and washers (4) and
separate cover (21) from the body (52).
Remove and discard gasket (17).
(l) Remove inner bearing races (cones)
from the pulley.
(b) With a suitable puller, remove impeller
(11) and pulley (6). Remove front water
pump oil seal (7).
(m) With a suitable puller or punch, remove
the bearing races (cups) from the
pulley.
(c) Support water pump body (52) on
impeller end. Press the water pump
shaft (16) and bearing assembly (8)
from the body by applying pressure to
the pulley end of the shaft.
CAUTION
Exercise care
retaining ring.
pulley.
(d) Remove bushing (14), gasket (15) and
water pump seal (13) from the shaft
(16).
when removing the
Do not damage idler
(n) Remove the bearing retaining ring
inside the idler pulley.
(o) Remove the retaining ring (37) and
washer (38) from the pivot shaft (35).
(e) Remove the inner race (cone and
bearing) of the roller bearing assembly
(8) with a suitable puller.
(p) Remove the pivot arm bushing (40) and
O-rings (36) from the shaft.
(f) Remove the two bearing races of the
roller bearing assembly (8) from the
water pump body (52) with a suitable
puller.
(2) Repair. Proceed as follows:
(a) Inspect pump body and idler bearings
for rough or worn races, or damaged
shield. Replace if necessary.
CAUTION
Exercise care when removing the
retaining ring. Do not damage pump
body.
(b) Inspect impeller and cover for cracks or
corrosion. Replace if necessary.
(c) Measure internal clearances and press
fits in accordance with tabulated
(g) Remove large retaining ring of bearing
13-59
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 13-30. Water Pump with Idler Assembly
13-60
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND FOR FIGURE 13-30
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Screw/washer
Screw/washer
Screw
Washer
Sleeve
Pulley
Seal
Bearing
Spacer
Spacer
Impeller
Seal
Seal
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Bushing
Gasket
Shaft
Gasket
Plug
Plug
Plug
Cover
Screw
Washer
Cover
Gasket
Nut
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Belt
Bearing assy
Pulley
Seal
Shaft
Screw
Spring locator
Spring
Shaft
Seal
Ring
Washer
Idler pulley
bracket
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
Bushing
Idler arm
Clamp
Hose
Screw
Tube
Gasket
Screw
Washer
Retainer
Drain cock
Pin
Body
Replace parts as
on the shaft (16). Seat race on shaft
shoulder using a mandrel.
(d) Inspect spring locator rod (33) and
spring (34) for visible signs of damage
or wear. Replace as necessary.
(f) Insert shaft (16) with bearing into pump
body (52) from the impeller end.
data in Chapter 1.
necessary.
(g) Position the water pump pulley end up
and in- stall spacer (10) over water
pump shaft (16).
(e) Inspect water pump mounting parts for
cracks. Replace as necessary.
(h) Place small bearing cone spacer over
water pump shaft (16).
(3) Reassemble the water pump and idler
assembly (install replacement parts as
necessary) with new gasket (17), Figure 1330. Water Pump with Idler Assembly oil
seal (7) and bracket bushing (40 as follows:
NOTE
Water pump must be lubricated during
reassembly.
(a) Install large retaining ring from bearing
assembly in retaining groove inside the
front of the water pump body (52).
(i) Fill water pump cavity with 0.97 to 1.15
ounces (.025 to .030.1) of MIL-G-3545
grease.
(b) Install bearing race into front of water
pump body. Seat race or retaining ring
using a suitable mandrel.
(c) Insert bearing cup spacer (9) from the
rear of the pump body (52).
(j) Support the pump on its impeller end
and install the remaining race (bearing
and cone) in the shaft (16) using a
suitable mandrel.
(d) Install the other bearing race into the
rear of the pump body. Seat race on
spacer (9) using a mandrel.
(k) Check water pump shaft end play with a
dial indicator. End play must be 0.003
to 0.010 inch (0.08 to 0.25 mm).
(e) Apply MIL-T-3545 grease to one inner
race (bearing and cone) and install race
(l) Install front oil seal
13-61
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(37) on shaft (35).
(7) on the shaft (16). Seal shall be
installed flush to 0.020 inch (0.51 mm)
below chamfer in water pump body (52).
(v) Install retaining ring from bearing
assembly (28) in groove inside idler
pulley (29).
(m) Support the water pump on its pulley
end and install the rear oil seal (7).
Seal shall be installed flush to 0.020
inch (0.51 mm) below chamfer in the
water pump body (52).
(w) Install bearing races inside pulley (29)
and seat races against retaining ring.
Install gasket (15) and bushing (14)
from rear of water pump body (52).
(x) Apply MIL-G-3545 grease to inner race
(bearing and cone) and install race in
rear of idler pulley (29).
(o) Apply Locktite No. 3375066 to outside
diameter of water pump seal (13).
Press seal (13) into bushing (14). Make
sure seal bottoms on bushing.
(y) Install rear oil seal (30) in idler pulley
(29) using a suitable mandrel. Seat seal
flush to 0.020 inch (0.51 mm) below
chamfer in pulley.
(p) Press the seal seat (12) onto the shaft
(16) using a suitable mandrel.
(z) Install small spacer from bearing
assembly (28) into front of idler pulley
(29).
(n)
(q) Position the pulley (6) on the shaft (16)
and press the pulley until it bottoms on
the inner race (bearing and cone) of the
bearing assembly (8).
(aa) Apply MIL-G-3545 grease to remaining
inner race (bearing and cone) and
install race in front of the idler pulley
(29).
(r) Apply a thin coat of Locktite 601 to the
impeller bore. Support the pump on its
pulley end and press the impeller (11)
on the shaft. Clearance between the
impeller vanes and the housing shall be
0.020 to .031 inch (0.51 to 0.79 mm).
(ab) Place idler pulley assembly (29) on
idler shaft (31).
(ac) Install locknut (26) and torque nut from
70 to 75 foot-pounds (95 to 102 joules).
(ad) Check idler pulley end play with a dial
indicator. End play shall be 0.003 to
0.10 inch (0.08 to 0.25 mm).
(s) Install new gasket (17) and secure
pump cover (21) to the body (52) with
screws (3) and washers (4). Torque
screws from 30 to 35 foot-pounds (41 to
47 joules).
(ae) Fill idler pulley cavity with 0.4 to 0.5
ounces of MIL-G-3545.
(t) Install O-rings (36) on idler pivot shaft
(35).
(af) Install idler assembly on water pump
with four screws (1). Finger
(u) Install washer (38) and retaining ring
13-62
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
assembly either forward or backward.
Torque mounting screws from 30 to 35
foot-pounds (41 to 47 joules).
tighten mounting screws.
(ag) Retract idler assembly and install drive
belts (27). Align belt by moving idler
Section V. HOUSING
13-18. CRANKSHAFT PULLEY VIBRATION DAMPER.
To replace the crankshaft pulley vibration damper, first
remove the guard in accordance with Operator/Crew
Organizational Maintenance manual and proceed as
follows:
CAUTION
Do not use a gear puller that applies
pressure to pulley outside diameter. To
do so will result in damage to pulley.
a. Removal. To remove the crankshaft pulley
vibration damper, refer to figure 13-31, and
proceed as follows:
(4) Remove crankshaft pulley (6) using
universal puller kit with threaded
adapters that fit into tapped holes on
face of pulley.
(1) Remove crankshaft pulley retaining screw
(1) and washer (2).
b. Installation. Proceed as follows:
(2) Remove lockwires and six capscrews
securing vibration damper (3) to crankshaft
pulley (6).
(1) Install pulley (6) on crankshaft as far as
possible.
(3) Remove capscrews (4) and washers (5).
(2) Secure with washers (5) and capscrews
(4); torque capscrews 60 to 70 footpounds (81 to 95 joules).
Figure 13-31. Crankshaft Pulley Vibration Damper,
Exploded View
13-63
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(3) Install vibration damper (3) and fasten with
washer (2) and screw (1); torque screw to
450 to 500 foot-pounds (610 to 678 joules).
a. Inspection. Inspect the engine front support for
signs of cracking or other signs of damage.
Replace if necessary, as follows:
(4) Install six screws securing vibration damper
(3). Torque conical screws to 70 to 80 footpounds (95 to 108 joules). Torque hexagon
head capscrews to 100 to 120 foot-pounds
(136 to 163 joules).
b. Removal.
(1) Refer to Chapter 2, Section IV to remove
engine assembly.
(2) Remove screws (4), lockwashers (5), screws
(6), and lockwashers (7).
NOTE
Crankshaft must be kept to front or rear
limit of thrust clearance while wobble is
being checked.
(3) Remove screws
lockwashers (2).
c.
CAUTION
(1),
nuts
(3),
and
Installation.
(1) Install new engine front support screws (1),
lockwashers (2), and nuts (3).
Do not pry against or strike damper.
(4) With a dial gauge mounted to gear case
cover and arm resting on the inner
machined surface of the outer member,
check vibration damper eccentricity and
wobble at points (1) and (2) as show in
figure 13-32. Wobble must not exceed
0.009 inch (0.23 mm) per inch of radius.
Eccentricity must not exceed 0.030 inch
(0.76 mm).
(2) Replace engine assembly.
(3) Install lockwashers (7), screws
lockwashers (5), and screws (4).
(6),
13-20 OIL PAN ASSEMBLY. To replace or repair the
oil pan assembly, refer to figure 13-34, and proceed as
follows:
a. Removal.
(1) Drain oil in accordance with the
Operator/Crew
and
Organizational
Maintenance manual.
(2) Disconnect temperature sensor (34, figure
13-34) electrical connector. Remove screw
and washer securing temperature sensor
cable clamp, then move and secure cable
away from work area.
(3) Disconnect engine preheat hose coupling on
radiator line and two couplings on preheater
assembly, then remove three screws and
washers securing preheat hose support
brackets to engine.
Move and secure
preheat hoses away from work area.
Figure 13-32. Vibration Damper Wobble Check
Points
(4) Remove four nuts and washers from
preheater assembly V-bolts, then move and
secure preheater assembly away from work
area.
13-19. ENGINE FRONT SUPPORT. To inspect and
replace the engine front support, refer to figure 13-33,
and proceed as follows:
13-64
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 13-33. Engine Front Support, Exploded View
13-34) from generator end of oil pan by
removing screws (1), lockwashers (2),
washers (3), screws (29), and lockwashers
(30).
(5) Disconnect fuel inlet hose coupling at fuel
filters, then move and secure hose away
from work area.
(6) Remove six screws securing ether line
support clamps to engine, then loosen ether
line fittings from manifolds and solenoid
valve (located on upright support) to
remove ether lines. Store ether lines in a
safe place to avoid damaging them.
(10) Remove two screws and washers securing
battery cable clamps to engine. Using a
suitable rope or cord, tie battery cables to
upper engine block out of the way of the
work area.
(7) Disconnect two bypass oil
couplings from tee on oil pan.
hose
(11) Remove 45 screws (24), lockwashers (25),
and washers (26), and drop oil pan (32).
(8) Disconnect bypass oil filter inlet hose
coupling at top of rear bypass oil filter, then
remove six screws securing bypass oil filter
support bracket to engine block to remove
bypass oil filter assembly.
(12) Remove three screws (8), lockplate (9),
screws (16), clamp (18), and tube
assembly (22), and remove oil pan.
filter
(13) Remove all gasket material from oil pan
mating surfaces.
(9) Remove two support brackets (31, figure
13-65
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 13-34. Oil Pan Assembly, Exploded View
13-66
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND FOR FIGURE 13-34
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Screw
Lockwasher
Washer
Plug
Gasket
Bushing
Plug
Screw
Lockplate
Connection
Gasket
O-ring
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Tube
Support
Screen
Screw
Nut
Clamp
Screw
Lockplate
Bracket
Tube
Gasket
Screw
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
(14) Steam clean pan and all mounting parts.
Lockwasher
Washer
Gasket
Seal
Screw
Lockwasher
Bracket
Pan
Hose assy
Temperature
sensor
2. Tap hole with 1-1/4 inch by 12 tap.
Use fuel oil lubricant to prevent
tearing of metal.
CAUTION
3. Install new drain plug with a new
copper gasket. Torque to 60 to 70
foot-pounds (81 to 95 joules).
Do not use solvent that will harm nonferrous metal.
(15) Visually check oil pan for cracks, or if a
leak is suspected, check using dye
penetrant.
c.
(16) Spray suspected area with dye penetrant.
Allow penetrant to dry for 15 minutes. Do
not force dry.
When using Part No. 120349 (if drain plug has
previously been repaired with Part 62117)
proceed as in (a) above, except enlarge
damaged hole by drilling to 1-19/64 inch (33.94
mm) and tap hole with 1-3/8 inch by 12 tap.
d. Installation. Proceed as follows:
(17) Spray area with dye developer. Check for
crack indications. Check all holes for
damaged threads.
NOTE
Position oil pan prior to installing screen
assembly.
b. Repair.
(1) Install screen assembly (15, figure 13-34)
with clamp (18), screws (16), lockplate (9)
and screws (8).
(1) A cracked oil pan should be replaced.
(2) If oil plug drain hole is damaged, repair as
follows (two oversize plugs are available to
permit rethread of oil drain holes at least
twice):
(2) Check for proper location of oil gauge hole
in relation to oil gauge tube location.
(a) When using Part No. 62117 oil pan
drain plug, size 1-1/4 inch by 12 thread,
proceed as follows:
(3) Install new seal and gasket (28 and 27) in
groove at rear of pan. Use grease to hold
seal and gasket in place.
1. Enlarge damaged hole by drilling to
1-11/64 inch (27.76 mm).
(4) Assemble oil pan (32) to block with 45
screws (24), washers (26), and lockwashers
(25), but leave screws loose.
13-67
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(5) Snug tighten screws (24) at four corners.
pump must first be removed and disassembled.
Proceed as follows:
(6) Finish tightening oil pan screws. Torque to
20 to 25 foot-pounds (27 to 34 joules).
(1) Remove suction tube and discharge tube
from oil pump and lift off pump.
(7) Install two screws and washers securing
battery cables and clamps to engine.
(2) Remove screws (16, 20, and 21) and
lockplates (17) securing pump body (38) to
cover (25).
(8) Install support brackets (31) with screws (1),
lockwashers (2), washers (3), screws (29),
and lockwashers (30).
(3) Carefully drive cover (25) (with soft hammer
or brass punch) from body (38) and remove
gasket (32).
(9) Install six screws securing bypass oil filter
support bracket to engine block, then
connect bypass oil filter inlet hose coupling
at top of rear bypass oil filter.
(10) Connect two bypass oil
couplings to tie on oil pan.
filter
(4) Remove idler gears (29) from shafts (26);
remove shafts from pump body (38).
hose
(5) Remove nut (6), spacer (7), intermediate
drive gear (8) and thrust washer (11). Press
out shaft (14).
(11) Install ether lines with six clamps and
screws and attach ether line fittings at
manifolds and solenoid valve.
(6) Press drive gear (15) from drive shaft (30).
Remove drive shaft assembly from body.
(12) Connect fuel inlet hose coupling at fuel
filters.
(7) Press internal gear (31) from shaft (30), if
shaft or gear is worn or damaged.
(13) Connect engine preheat hose coupling on
radiator line and two couplings on preheat
assembly. Install preheat hose support
brackets, screws, and washers.
(8) Remove plunger cap (33); remove spring
(34) and plunger (35) from body (38).
(9) Inspect and replace all bushings and shafts
if worn or damaged.
(14) Install temperature sensor electrical
connector, then connect cable and secure
with clamp, screw, and washer.
(10) Replace cover, or body if finished surfaces
in gear pockets are scored or visibly worn.
(15) Refill engine with proper lubricating oil in
accordance with the Operator/Crew and
Organizational Maintenance manual.
(11) The drive and idler gears must be replaced
if worn, scored or damaged. Check all
hardware for worn or damaged threads.
Replace as necessary.
13-21. OIL PUMP. To inspect, test, replace, and repair
the oil pump, remove the oil pan in accordance with
paragraph 13-20, refer to figure 13-35, and proceed as
follows:
b. Test. Following reassembly, crank gears by
hand; they should turn smoothly and freely.
c. Reassembly and Repair. Repair by replacing
any worn or damaged parts and proceed as follows:
a. Disassembly and Inspection. To inspect the
components of the lubricating oil pump, the
13-68
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 13-35. Oil Pump, Exploded View
LEGEND
1.
2.
3.
4.
5.
6.
7.
8.
9.
19.
Screw
Screw
Lockplate
Dowel
Dowel
Nut
Spacer
Gear and bushing
Bushing
Gasket
10.
11.
12.
13.
14.
15.
16.
17.
18.
29.
Gear
Washer
Plug
Plug
Shaft
Gear
Screw
Lockplate
Connection
Gear
20.
21.
22.
23.
24.
25.
26.
27.
28.
Screw
Screw
Plug
Cover
Bushing
Cover
Shaft
Gear
Bushing
30.
31.
32.
33.
34.
35.
36.
37.
38.
Shaft
Gear
Gasket
Cap
Spring
Plunger
Body
Bushing
Body
(1) Place plunger (35) and spring (34) in body
and secure with cap (33).
shaft, leaving 0.061 to 0.063 inch (1.55 to
1.60 mm) end thrust.
(2) Press internal drive gear (31) onto short end
of drive shaft (30) until shaft extends
through gear 1.020 to 1.040 inch (25.91 to
26.41 mm).
(5) Press in intermediate drive gear shaft (14)
until it seats. Mount thrust washer (11),
intermediate drive gear (8), spacer (7) and
nut (6) Torque nut (6) to 70 to 80 footpounds (95 to 108 joules).
(3) Install drive shaft assembly in pump body.
(6) Place idler gears (29) in pump body. Install
shafts
(4) Press external drive gear (15) on drive
13-69
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(26) first. Press shafts in until they protrude
0.860 to 0.890 inch (21.84 to 22.61 mm)
above face of body.
CAUTION
Make sure that lubricating oil pump gear
is fully engaged before final tightening
of capscrews.
(7) Place a new gasket (32) on pump body (38).
Assemble cover (25) to body.
Press
together using pilot capscrew near each end
to pilot gasket.
(3) Attach a dial indicator to block.
indicator on gear teeth.
(8) Secure cover to body with lockplates (17)
and screws (16, 20, and 21). Check drive
shaft for freeness.
Place
(4) Rotate gear by hand to advance position;
"zero" indicator.
Back gear to retard
position and note reading; permissible
backlash is 0.006 to 0.15 inch (0.15 to 0.38
mm). If not within limits gear train must be
replaced.
(9) Lock screws in position with lockplate tangs.
d. Replacement. Proceed as follows:
(5) Assemble lubricating oil suction and
discharge lines, connections, and clamp,
using new O-rings, gaskets, and lockplates.
Torque screws to 30 to 35 foot-pounds (41
to 47 joules). Secure lockplates. Suction
screen must have 1/2-inch (12.70 mm)
clearance.
(1) Remove suction tube and discharge tube
from oil pump and lift off pump.
(2) Position lubricating oil pump to block and
secure with dowel pins, lockplates, and
capscrews.
Section VI. FLYWHEEL AND HOUSING
13-22. RING GEAR, FLYWHEEL, AND HOUSING. To
inspect and replace the ring gear, flywheel, and housing,
refer to figure 13-35, and proceed as follows:
(3) Insert two 5/8-18, 7-inch (178 mm) long
studs through two capscrew holes in
flywheel 180 degrees apart and screw into
crankshaft flange to support flywheel during
removal.
a. Inspection.
(4) In two holes provided, place two 1/2-13, 21/2 inch (63.5 mm) screws which are
threaded their entire length. Turn in screws
alternately to pull flywheel from crankshaft
dowels. Using a suitable hoist, lift flywheel
from guide studs.
(1) Check for cracks or other flaws in flywheel,
ring gear, and housing.
(2) Check ring gear teeth for excessive wear
and damage from improper starter gear
meshing.
(3) Replace any damaged or cracked parts.
WARNING
b. Removal.
(1) Refer to Chapter 2, Section IV and remove
the generator assembly to provide access to
the flywheel housing.
OVERHEAD
OPERATIONS
HAVE
INHERENT HAZARDS THAT CANNOT BE
MECHANICALLY SAFEGUARDED. HARD
HATS AND SAFETY SHOES ARE
REQUIRED.
(2) Remove lockwires, ten screws (1) and
lockwashers (2) securing flywheel to
camshaft flange.
13-70
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(5) Drive ring gear (5) from flywheel with a
blunt chisel.
(6) Install two 5/8-11 studs in block to guide
flywheel housing during removal.
(4) The crayon will leave a chalk mark until
temperature reaches 600°F (316°C). At
600°F (316°C), the crayon will leave a liquid
smear.
CAUTION
(7) Drive housing from dowels by tapping on
back side with a soft hammer or wooden
block. Using a suitable hoist, lift housing
from guide studs.
c.
Installation
(1) Install housing on dowels by tapping with a
soft hammer or wooden block.
(2) If an oven with heat control is not available,
heat ring gear (5) with a heating torch from
inside diameter so heat travels outward to
teeth.
(3) Use a Templistick crayon or equivalent to
determine amount of heat applied.
(a) Stroke gear with 600°F (316°C) crayon
several times while applying heat.
Overheating to temperatures
660°F (349°C) will soften gear.
above
(5) Place ring gear on flywheel and quickly
drive onto flywheel until gear is firmly
seated.
(6) Index the zero on crankshaft with the zero
on flywheel and assemble flywheel over
studs to crankshaft flange.
(7) Insert lockwashers (2) and screws (1).
Tighten screws alternately, a little at a time,
to pull flywheel up evenly. Continue until all
screws are tight.
(8) Attach indicator gauge to side of flywheel
housing to indicate bore of flywheel. The
total indicator reading must not be greater
than 0.005 inch (0.13 mm).
Figure 13-35A. Ring Gear, Flywheel, and Flywheel Housing
13-71
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND
1.
2.
3.
4.
5.
6.
7.
Screw
Lockwasher
Washer
Plate
Nut
Washer
Water pump
pulley assy
8. Sleeve
9. Pulley
10. Belt
11. Screw
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Lockwasher
Plate
Gasket
Screw
Lockwasher
Support
Shim
O-ring
Screw
Lockwasher
Plug
Plug
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
Seal
Seal
Pointer
Screw
Gasket
Dowel
Screw
Lockwasher
Screw
Lockwasher
Screw
Lockwasher
Figure 13-36. Gear Case, Exploded View
13-72
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
Dowel
Screw
Lockwasher
Dowel
Plug
Gasket
Housing
Cover
Bearing
Bushing
Cover
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
13-23. TIMING GEAR AND COVER. To inspect and
replace the timing gear and cover, refer to figures 1336, and 13-37, and proceed as follows:
(2) Inspect gear case for cracks, burrs, or
breaks. Replace if damaged.
a. Removal. Proceed as follows:
(3) Inspect screw threads and repair with helicoil inserts if found damaged.
(1) Remove 26 screws (27, figure 13-36) and
two screws (20) and lockwashers (21).
(4) Inspect dowels for damage; replace or bore
out for oversize if required.
(2) Install two 6-inch (152 mm) guide studs
through top of gear case into block to prevent gear case from falling during removal.
c.
Installation.
(1) Install thrust washer (5, figure 13-37) on
idler shaft (6) with oil grooves facing away
from shaft shoulder.
(3) With a soft hammer, tap case alternately
top and bottom, left and right, to drive from
dowels.
(2) Insert dowel pin (3) in drilled hole in end of
idler shaft (6), if removed.
(4) Lift gear case from guide studs and remove
studs from block.
(3) Install timing gear (7) on shaft (6) indexing
two "O" marks on gear astride single "O"
mark on crankshaft gear.
(5) Remove capscrew (1, figure 13-37)
lockwasher (2), front thrust washers (4 and
5), gear and bushing (7 and 8) and rear
thrust washer (5).
(4) Install outer thrust washers (5 and 4) over
shaft with oil grooves next to idler gear.
b. Inspection.
(5) Install lockwasher (2) and screw (1).
(1) Inspect gear for cracks, broken teeth, or
visible wear.
Replace if damaged or
excessively worn.
(6) Timing gear thrust limit is 0.001 to 0.016
inch (0.03 to
LEGEND
1. Screw
2. Lockwasher
3. Pin 6. Shaft
4. Washer
5. Washer
9. Gear
Figure 13-37. Timing Gear, Exploded View
13-73
7. Idler gear assy
8. Bushing
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(8) Install new gasket (28, figure 13-36).
0.41 mm); check clearance with feeler
gauge.
(9) Secure gear cover with capscrews (27),
lockwashers (21) and screws (20).
(7) Install guide studs in engine block.
Section VII. CYLINDER HEAD AND VALVE OPERATING MECHANISM
13-24. GENERAL. The following paragraphs contain
maintenance instructions for components comprising the
cylinder head.
(2) Rocker arm shaft bore inside diameter
should be 1.243 to 1.125 inches (28.577 to
28.558 mm). If lever shaft does not meet
these dimensions, replace shaft.
13-25. ROCKER ARM SHAFT AND ROCKER ARM
ASSEMBLY. To service the rocker arm shaft and
rocker arm assembly, refer to figure 13-38 and proceed
as specified in the following paragraphs:
c.
Reassembly.
(1) Install adjusting screws (20) and (24) and
locknuts (19) and (23) in rocker levers.
a. Removal. Proceed as follows:
(2) Coat rocker lever shaft with clean
lubricating oil. Start shaft (14) into housing
(8). Install levers on shaft as shaft is
pushed through housing.
(1) Refer
to
the
Operator/Crew
and
Organizational Maintenance manual for
inspection and cylinder head cover removal
instructions.
(3) Coat cup plug (11) contact surfaces with
Locktite sealer. Install new cup plug (11) in
rocker lever housing (8).
(2) Remove pipe plug (12).
(3) Remove pipe plug (13) from end of rocker
lever housing (8), and set screw in bottom
of housing that secures shaft.
(4) Install pipe plug (13) and shaft plug (15) in
end of rocker lever housing. Use sealing
tape or Locktite to prevent oil leakage.
(4) Use a flat or drift punch to force out shaft
(14) and cup plug (11).
(5) Check all levers for freedom of movement
on shaft.
(5) Locate shaft in V-block and remove shaft
plug (15).
(6) Install pipe plug (12).
(6) Remove rocker levers from housing. Tag
rocker levers for correct position as removed to ensure proper reassembly.
(7) Tighten shaft lockscrews (18) and (26) and
adjust so screws contact valve stem, then
advance 20 degrees and lock with nuts (17)
and (25).
NOTE
(7) Remove adjusting screw lock nuts (17) and
(25) and adjusting screws (18) and (26).
On worn crosshead and guide, it may be
necessary to advance 30 degrees to
straighten crosshead to guide.
b. Repair of Rocker Arm Shaft Assembly.
(1) If shaft outside diameter is not between
1.123 inches to 1.124 inches (28.52 mm to
28.55 mm) replace shaft.
(8) Hold adjusting screw in
13-74
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND
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.
Screw
Lockwasher
Washer
Cover
Gasket
Screw
Washer
Housing
Gasket
O-ring
Plug
Plug
Plug
Shaft
Plug
Pin
Locknut
Screw
Bushing
Rivet
Lever
Lever
Lever
Lever
Nut
Screw
Bushing
Socket
Lever
Figure 13-38. Rocker Arm Shaft and Rocker Arm Assembly,
Exploded View
position and tighten nut with torque wrench to 25 to 35
foot-pounds (34.6 to 41.5 joules).
a. Removal, Code A (Figure 13-39)
(1) Lift crossheads.
(9)
Using a wire gauge, check to make sure
there is a minimum of 0.020 inch (0.51
mm) clearance between crosshead and
valve spring retainer.
(2) Remove pushrods by lifting them from their
tappets.
(3) Remove lockwires (3) and (10) and copper
washers (17) holding tappet guides (16).
Discard copper washers.
(10) Refer
to
the
Operator/Crew
and
Organizational Maintenance manual for
adjustment and reassembly instructions.
(4) Lift tappets (8) and (15) from block with a
long wire hook or other suitable tool.
13-26. PUSHRODS AND TAPPETS. To inspect and
replace the pushrods and tappets, refer to figures 13-39
and 13-40, and proceed as follows:
13-75
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
b. Removal, Code B (Figure 13-40)
(3) Check injector and valve pushrod ball end
for wear.
(1) Lift crossheads.
(4) Check socket of pushrod with ball end of
new rocker lever adjusting screw.
(2) Remove pushrods by lifting them from their
tappets.
(5) Check pushrod for straightness.
(3) Remove lockwires (2) and (16), guides (6)
and (11), and sockets (1) and (15).
(6) Check pushrod for out-of-round condition.
13-27. CYLINDER HEAD ASSEMBLY. Refer to the
Operator/Crew and Organizational Maintenance manual
for injector, turbocharger, exhaust manifold, water
manifold, and cylinder head cover removal instructions.
Refer to figure 13-41 and proceed as follows:
(4) Lift tappets (7) and (9) from block with a
long wire hook or other suitable tool.
c.
Replacement, Code A (Figure 13-39). Replace
any defective parts (refer to paragraph c) and
reassemble as follows:
a. Replacement. Proceed as specified in the
following paragraphs:
(1) Insert 0.006 inch (0.15 mm) shim between
side of roller (5) and (11) and tappet (8) and
(15); press pin (4) and (12) through tappet
and roller with new lockwire (3) and (10) in
pin. Make sure lockwire seats in groove of
tappet.
(1) Remove screws (1) and washers (2). Install
guide studs to aid in removal of the cylinder
heads.
CAUTION
CAUTION
Do not crank engine with cylinder head
removed unless screws (1) have been
reinstalled to prevent movement of
cylinder lines.
Lubricating oil passage in pin and tappet
must index for adequate lubrication.
(2) Install new copper washers (17) and holding
tappet guides (16).
NOTE
Tag cylinder heads for position occupied
on engine so that they may be installed
in the same position.
d. Replacement, Code B (Figure 13-40). Replace
any defective parts (refer to paragraph e) and
reassemble as follows:
(2) Using a suitable hoist, remove cylinder
heads.
(1) Insert 0.006 inch (0.15 mm) shim between
side of roller (4) and (12) and tappet (7) and
(9); press pin (5) and (10) through tappet
and roller with new lockwire (2) and (16) in
pin. Make sure lockwire seats in groove of
tappet.
WARNING
OVERHEAD
OPERATIONS
HAVE
INHERENT HAZARDS THAT CANNOT BE
MECHANICALLY SAFEGUARDED. HARD
HATS AND SAFETY SHOES ARE
REQUIRED.
(2) Install new sockets (1) and (15) and guides
(6) and (11).
e. Inspection.
b. Installation.
(1) Using a fine wire, check indexing of pin and
body lubricating oil passage.
NOTE
(2) Check freeness of roller by rotating two or
three turns.
Cylinder heads should have valve
guides, valves, and springs assembled
in position before installation.
13-76
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
studs and dowels.
(1) Check that breather hole in cylinder head is
open.
(7) Remove guide studs.
(2) Clean mating surfaces of cylinder block and
cylinder head. Make certain that cylinder
walls are clean and well lubricated with
clean lubricating oil.
(8) Lubricate capscrew threads with clean
engine lubricating oil and allow oil to drain
from threads.
(3) Check head gasket to be sure all grommets
and seals are in position. Install gasket over
dowels so that the work "top" on gasket is
visible.
CAUTION
Excessive oil in capscrew holes in block
could cause an error in torque value
when cylinder head capscrews are
tightened.
(4) Position ferrule on O-ring into each
lubricating oil passage between cylinder
head and block.
(9) Lubricate washers and cap- screw head
washer mating surfaces with SAE 140-W
lubricant.
(5) Install guide studs into block.
(6) Carefully lower cylinder heads over guide
LEGEND
1.
2.
3.
4.
Pushrod
Pushrod
Lockwire
Pin
5.
6.
7.
8.
Roller
Sleeve
Socket
Tappet
9.
10.
11.
12.
Injector
Lockwire
Roller
Pin
Figure 13-39. Pushrods and Tappets, Code A
13-77
13.
14.
15.
16.
17.
Sleeve
Socket
Tappet
Guide
Washer
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND
1.
2.
3.
4.
Socket
Lock wire
Ring
Roller
5.
6.
7.
8.
Pin
Guide
Injector
Retainer
9.
10.
11.
12.
Valve
Pin
Guide
Roller
13.
14.
15.
16.
Rod
Rod
Socket
Lockwire
Figure 13-40. Pushrods and Tappets, Code B
(10) Tighten capscrews to 25 to 40 foot-pounds
(34 to 54 joules) in sequence shown in
figure 13-42.
with feeler gauge. Variance up to 0.016
inch (0.41 mm) is acceptable.
NOTE
(11) Continue tightening in sequence to 150 to
200 foot-pounds (203 to 270 joules) and to
275 to 305 foot-pounds (373 to 414 joules)
torque. Breakaway torque in direction of
tightening is 275 to 340 foot-pounds (373
to 461 joules).
Replace water manifold seals when
replacing water manifolds.
(13) Reinstall the injectors, cylinder head cover,
water manifold, exhaust manifold, and
turbocharger in accordance with the
Operator/Crew
and
Organizational
Maintenance manual.
(12) Place a straight edge on top of, and
parallel to, the cylinder head exhaust ports
to check port flatness across all six points
13-78
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 13-41. Cylinder Head, Exploded View
13-79
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 13-42. Head Capscrew Tightening Sequence
c.
Inspection.
e. Overhaul.
(1) Check valve seats and injector sleeve for
cracks. Discard cylinder head if cracked.
(1) Using a valve spring compressor, compress
valve springs (6), remove half collets (3),
retainers (5), spring (6), valve spring guides
(7), and guides (9).
(2) Check all valve springs for damage.
(3) Check for signs of metal erosion around
water holes.
NOTE
Perform the necessary tests to determine
the extent of overhaul or the scope of
rebuilding required to the cylinder head.
(4) Check cylinder head for worn or uneven
surface at point of contact with gasket.
(5) Examine fuse plug for signs of overheating.
If plug shows signs of overheating, check
for further damage and replace if necessary.
(2) Hydrostatic Testing
(a) Install injector sleeve holding tool or a
scrap injector assembly in each injector
sleeve. Tighten tool or injector holddown capscrews to 10 to 12 foot-pounds
(14 to 16 joules) torque to seal lower
end of injector sleeve and place cylinder
head in the hydrostatic tester or
equivalent.
d. Repair.
(1) Replace any damaged valve springs.
(2) Insert sleeves into water holes that have
become enlarged due to metal erosion.
Refer to paragraph 13-27 f.
WARNING
(3) Resurface head surface that is deeply
scratched or worn. Rework valve seat insert
counterbore by removing amount of stock
equal to that removed during head
resurfacing operations. Refer to paragraph
13-27 f.
OVERHEAD
OPERATIONS
HAVE
INHERENT HAZARDS THAT CANNOT BE
MECHANICALLY SAFEGUARDED. HARD
HATS AND SAFETY SHOES ARE
REQUIRED.
(4) If exhaust ports are not flat, resurface
exhaust ports. Exhaust ports should not be
more than 0.003 inch (0.08 mm).
(b) Use hoist to position head and tester
over
13-80
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(plugged fuel passages).
water tank, connect air line, and apply
30 to 40 psi (207 to 276 kPa) air
pressure.
Submerge head in water
deep enough to cover entire head.
(j) Block fuel outlet and attach an air
pressure gauge.
(c) Check carefully around valve seats and
injector sleeve for cracks. Discard head
if cracked.
(k) Install air fittings in fuel inlets and apply
air pressure of 90 to 100 psi (620 to 689
kPa).
(d) Test cylinder head for leaks at 75 to 85
psi (517 to 686 kPa) water pressure with
water at 17a to 200°F (79 to 93° C).
Check carefully around valve seats and
injector sleeves for cracks even though
such cracks may not show water
leakage. Discard head if cracked.
(l) Close air inlet valve
passage for leaks.
(m)
and
inspect
Check air gauge; there must be
no drop in pressure for 15 seconds;
discard an unserviceable head.
(3) Cylinder heads are equipped with fuse plugs
containing a metal-alloy center that melts if
the engine is over- heated. Examine fuse
plug for signs of overheating. If fuse plug
has melted, check carefully for further
damage to head and engine, and proceed
as follows:
(e) Open water outlet of test fixture; check
for free water circulation through
cylinder head. If restriction is evident,
remove all pipe plugs and fuse plugs;
clean water jackets of salt, lime, or
sludge.
WARNING
(a) Drill through center of melted plug.
THE USE OF ACID IS EXTREMELY
DANGEROUS TO WORKMEN AND
INJURIOUS TO MACHINER. ALWAYS
PROVIDE A TANK OF STRONG SODA
WATER AS A NEUTRALIZING AGENT.
(b) Tap hole with left-handed threads.
(c) Insert a screw and turn until plug breaks
loose; remove screw and melted plug.
(d) Install new fuse plug.
(f) Clean fuel passage with a brush and
flush passages with solvent to remove
deposits.
(4) Check for loose valve seat inserts by lightly
tapping head near inserts.
A slight
looseness may be found by tapping when
head is cold and covered with film of oil.
(g) Check water passage running full length
of head between valves for restrictions.
If plugged, open by rodding or drilling.
(5) If seat area width exceeds 0.125 inch (3.18
mm) at any point and cannot be narrowed
sufficiently, it is unlikely that seat can be
successfully reground.
(h) Check lubricating oil restrictor plug and
lubricating oil passages to be sure they
are open.
(i) Install
"dummy"
injectors
in
(6) Note results of hydrostatic test. Leaks
indicate need for replacement of injector
head
13-81
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
sleeves. Visually check sleeves which pass
pressure test, for scratches on cup seat
area. If seat area is scratched, mark for
replacement.
(7) Injector tip Protrusion Test. Cylinder heads
that have passed the above tests must be
checked further for injector tip protrusion
(seat depth) and seating pattern.
(a) Lightly coat injector cup with bluing,
install injector assembly into injector
sleeve of head and torque to 11 to 12foot-pounds (15 to 16 joules). Remove
and check seat pattern. Bluing band
must be 0.060 inch (1.5 mm) minimum
in width and located approximately
15.32 inch (11.9 mm) from bottom of
head surface.
Figure 13-43. Crosshead Dimensions
holes.
Do not use plug gauge for this
operation.
(b) Measure tip protrusion with dial indicator
or protrusion checking tool.
Tip
protrusion must be 0.045 to 0.055 inch
(1.14 to 1.40 mm).
(13) Visually check for excessive wear on
rocker lever (1) and valve stem contact
surface (2). Check adjusting screw and
crosshead threads (4) for wear or
distortion.
Mark for replacement, if
excessive wear is found.
(8) Check guide outside diameter with
micrometers. See tabulated data in Chapter
1 for worn replacement limits.
(14) Check reamed depth of crosshead bore,
minimum of 1.00 inch (25.4 mm) in depth,
valve stem counterbore depth on
underside of crosshead should be 0.120 to
0.140 inch (3.05 to 3.56 mm).
(9) Check guide for straightness. It should be
at right angles with milled surface of head.
Replace if not straight.
(10) Check crosshead guide protrusion above
cylinder head. Protrusion should be 1.860
to 1.880 inch (47.24 to 47.75 mm).
(15) Check valve guide inside diameter (bore)
using a small bore gauge set at 0.4545
inch (11.544 mm). Use bore gauge as "No
Go" gauge (refer to tabulated data in
Chapter 1).
(11) Check stem inside diameter (3, figure 1343) using a small bore gauge set at 0.4402
inch (11.181 mm). Use as a "No Go"
gauge to check for wear beyond
replacement limit.
(16) Check for out-of-round holes, gauge at
several points crosswise and endwise of
head full length of guide. Do not use a
plug gauge for this operation. Visually
check valve guides for chips, cracks, or
burrs. Mark for replacement any guides
showing excessive wear or damage.
(12) Check for out-of-round
f.
Rebuilding. Proceed as follows:
(1) Coat water passage sleeves with sealant,
align sleeve in top of water passage hole,
drive into position
13-82
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
edges.
using bushing driver and hammer.
(8) After resurfacing check head height, use
micrometer or vernier depth gauge. Do not
remove more than indicated as worn limit.
See tabulated data in Chapter 1.
(2) Use a flat mill file to file sleeve flush with
top of cylinder head. Do not damage head
surface.
Remove burrs from inside
diameter of sleeve, clean all cuttings and
filings from water passages.
(9) Check exhaust ports for flatness after head
has been resurfaced. Ports should not be
out of plane more than 0.003 inch (0.08
mm).
(3) If proper sleeve is not available, heavy wall
copper tubing may be used. Tubing must
provide 0.002 to 0.005 inch (0.05 to 0.13
mm) press fit. Overall length should be
approximately 1/2 inch (12.70 mm); inside
diameter must be 7/16 inch (11.11 mm) to
allow proper water flow.
(10) Install new injector sleeves to maintain
correct injector tip protrusion.
(11) Check overall height of assembled valve
springs to see if it is necessary to install
spacers (1/16 inch (1.59 mm) maximum)
under springs to obtain correct assembled
height.
(4) Resurface head if it has been scratched,
etched, or worn unevenly at point of contact
with gasket sealing areas. Check erosion
around water holes which could cause
failure of head gasket to seal. If eroded,
install bushings before resurfacing head.
CAUTION
(5) Remove 0.005 to 0.006 inch (0.13 to 0.15
mm) material at one time and no more than
0.030 inch (0.76 mm) total.
Refer to
tabulated data in Chapter 1.
Only 1/32 inch (0.79 mm) spacer can be
used if head has not been resurfaced.
(12) Drive out worn guides from underside of
cylinder head.
NOTE
(13) Install new guides with arbor press and
mandrel.
Waviness on mounting surface must not
exceed 0.0004 inch (0.010 mm) in depth
and distance between high and low
points must not be closer than 1.00 inch
(25.4 mm). Surface not to deviate from a
true plane more than 0.0003 inch (0.008
mm) within 0.250 inch (6.35 mm) of any
opening and entire surface must not
deviate from true plane more than 0.004
inch (0.10 mm) T.I.R.
(14) If proper valve guide mandrels are not
available, press guides into head to obtain
1.270 to 1.280 inch (32.26 to 32.51 mm)
protrusion above head surface.
(a) Ream valve guide from bottom side of
cylinder head using a drill press and
floating tool holder.
NOTE
(6) Rework valve seat insert counterbore by
removing amount of stock equal to that
removed during head resurfacing operation.
Use lubricating oil or soluble oil and
water solution for good finish.
(7) Sand surface of cylinder head with an
orbital sander. Do not use a disc sander.
Do not allow the sander to tilt or rock, since
this may result in rounding of the machined
(b) Ream valve guides with reamer to
dimensions 0.4525 to 0.4532 inch
(11.493 to 11.511 mm).
13-83
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
hold and drive cutters.
CAUTION
(21) Cut counterbore 0.006 to 0.010 inch (0.15
to 0.25 mm) deeper than insert thickness to
permit peening of head to hold insert. It is
important to allow cutter to dwell for
several revolutions upon reaching proper
depth in order to ensure a perfectly flat
surface at the bottom for the insert to seat
on.
Special care must be used to avoid
breaking carbide tips. Sharpen tipped
tools on a diamond-impregnated wheel.
(15) Remove crosshead guides marked for
replacement using a dowel puller.
(16) Using a crosshead guide mandrel, press
new guides into cylinder head to obtain
protrusion of 1.860 to 1.880 inch (47.24 to
47.75 mm).
(22) Install valve seat insert and peen around
insert at least five places with a 1/4 inch
(6.35 mm) diameter round end punch.
(17) If crosshead guide bore is worn or
mutilated, install oversized guides as
follows:
(23) After checking condition of grinding
equipment, grind valve seats holding
seating motor as nearly vertical as
possible.
(a) Drill guide bore in head to original depth
with a 29/64-inch drill.
(24) Check valve seat which should be 1/16 to
1/8 inch (0.159 to 3.17 mm).
(b) Lubricate and ream bore with a 15/32inch reamer.
(c) Install oversized guide until guide
protrusion is 1.860 to 1.880 inches
(47.24 to 47.75 mm).
(a) If seating area (2, figure 13-44) is wider
than 1/8 inch (3.175 mm) maximum,
stock can be removed from points "A"
and "B" with specially dressed valve
seat grinder stones.
(18) Remove loose or excessively worn valve
seat inserts by striking insert sharply with a
chisel, causing it to crack and release the
press fit. Remove all inserts if head has
been resurfaced.
(b) Narrowing should not extend beyond
chamfer on seat insert.
Chamfer
provides for peening metal.
CAUTION
Cover the valve seat with a rag to avoid
injury from broken pieces of the seat.
(19) Enlarge counterbore to next oversize using
valve seat insert cutter.
Inserts are
available in standard and oversizes as
tabulated in Chapter 1.
NOTE
If head was resurfaced and standard
inserts are to be used, deepen
counterbore only.
Figure 13-44. Valve Seat Insert, Cross Sections
(25) Dress wheel for final finish.
(20) A valve seat insert tool must be used to
13-84
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NAVFAC P-8-631-34
TO-35C2-3-463-2
shown, at less than load indicated under
worn limits above, valve springs should be
discarded and replaced.
(26) Finish grind with light touches of stone
against face.
(27) Check valve seat concentricity with valve
seat indicator.
(32) Remove worn sleeves with a muffler
sleeve cutting tool using extreme caution
to prevent damage to head surfaces.
(a) Use valve guide as center.
(33) Remove all foreign material from injector
sleeve sealing area. Clean O-ring groove
to remove all foreign material.
(b) Total run out should not exceed 0.002
inch (0.05 mm).
(c) The gauge must be a perfect fit on pilot
mandrel.
(34) Clean thoroughly and dry with compressed
air.
(28) Check seat with mating valve to ensure
proper sealing.
CAUTION
(29) Test valve spring on spring tester that is
capable of accurate measurements of
spring lengths by means of standards listed
below.
Avoid use of cleaning compounds
containing ammonia which may react
with the brass sleeves.
NOTE
Valve spring part no. ............................ 211999
Approx. free length ........................... 2.685 in.
(68.2 cm)
Assemble height ............................... 1.724 in.
(42.8 cm)
Pounds (kilograms) required
to compress
Machine head in sleeve seat area of head
if mutilated.
(35) Install seat cutter holder and position with
pilot in a drill press. Set drill press speed
at not more than 75 rpm. Cutter may be
turned by hand using a tap wrench.
New min. ....................................... 147.25
(66.3)
(36) Place cylinder head on drill press table,
allowing clearance for end of heat cutter to
protrude below head surface into a pilot. A
pilot can be made by recessing a 1/2-inch
(12.7 mm) drill bushing in a plate which is
centered below drill spindle and secured in
place.
New max. ...................................... 162.75
(73.2)
Worn limit ....................................... 142.0
(63.9)
(37) Before starting drill press motor, insert
cutter, adapter, and pilot into injector bore
to ensure proper alignment.
(30) Spacers may be used under valve spring
when insert and valve have been refaced
to make valve spring check within load
limit.
(38) Lift cutter, adapter, and pilot, lubricate
cutter with cutting oil and start cutting
operation; apply a steady, moderate
pressure.
NOTE
A maximum of 1/16 inch (1.59 mm)
spacers may be used under valve spring
when head has been resurfaced and
valve and seat have been refaced.
CAUTION
Do not cut more than 0.010 inch (0.25
mm) deep.
(31) If valve springs compress to dimension
13-85
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NAVFAC P-8-631-34
TO-35C2-3-463-2
(39) When proper depth has been obtained,
allow cutter to dwell for approximately 10
seconds to ensure a good seat and clean
grooves.
protrusion of injector cup tip beyond milled
face of cylinder head, as specified in
Chapter 1 under Injector Tip Protrusion,
when injector is installed.
(40) Coat new O-ring with clean engine
lubricating oil. Install O-ring into groove of
injector sleeve bore in head.
(46) Sleeve must "blue in" with Prussian Blue
360 degrees around injector seat when
injector is installed in cylinder head. Bluing
band must be 0.060 inch (1.52 mm)
minimum width.
(41) Using an injector sleeve driver, push new
injector sleeve into bore of cylinder head
until it bottoms. Do not strike mandrel with
hammer during this step.
Remove
mandrel.
(47) Perform the hydrostatic test of paragraph
13-27 e (2).
(48) Using the adapter wrench, remove spark
plug adapters from heads.
(42) Install an injector sleeve holding tool and
tighten nut to 35 to 40 foot-pounds (47 to
54 joules) torque.
(49) Clean and lubricate spark plug adapter
threads in the cylinder head by "chasing"
with a 7/8-14 UNF tap or cap- screw coated
with lubricating oil. Clean the machined Oring seating surface in the cylinder head
with fine emery paper to remove scale
build-up, etc., and to ensure proper seating
of the adapter O-ring.
(43) Insert mandrel into sleeve bore, strike
mandrel two moderate blows with hammer
to ensure that injector sleeve is properly
seated. Retighten injector sleeve holding
tool to 35 to 40 foot-pounds (48 to 55
joules) torque.
(44) Roll top 1/2 inch (12.70 mm) area of
sleeve with expanding roller. Use inchpound torque wrench to turn mandrel until
a 75 inch-pound (8.5 joules) maximum
torque reading is obtained on torque
wrench.
(50) Clean spark plug adapter seating areas.
(51) Clean threads and gasket seating area of
the adapter.
(52) Lubricate O-rings and O-ring seating areas
in bores of heads with clean engine oil.
Position new gaskets and O-rings on spark
plug adapters.
Screw adapters into
cylinder heads and tighten to 70 to 80 footpounds (95 to 105 joules).
CAUTION
Over-rolling of injector sleeve will cause
deformation of sleeve into O-ring
groove.
g. Assembly and Testing. Proceed as follows:
(45) Cut injector seat to provide proper seat and
injector tip protrusion. Use the injector
sleeve cutter in a drill press with pilot,
using a solid stream of good cutting oil to
allow cutter to cut freely without grabbing,
etc. To determine amount of cut, insert
injector, and torque to specifications, then
measure tip protrusion (see tabulated data
in Chapter 1). Depth of cut must provide
(1) Clean cylinder head, valves, springs, etc.
Before assembling.
(2) Lubricate valve stem with clean engine oil
and insert valves in valve guides.
(3) Place cylinder head face
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NAVFAC P-8-631-34
TO-35C2-3-463-2
down on a wooden bench or protective
surface to prevent marring milled surface.
injectors and secure with capscrews torqued
to same value.
(4) Assemble lower valve spring guide over
valve guides.
(10) Test cylinder heads for leaks at 35 to 85
psi (241 to 586 kPa) using the hydrostatic
tester and, if possible, at 175 to 200xF (79
to 93xC) water temperature.
Check
carefully around valve seats and injector
sleeve seats for any cracks.
(5) Assemble springs, reground valve heads
seat deeper in cylinder head causing valve
stem to protrude further above the guide.
This allows spring to extend beyond length
limits and causes weak spring action.
There- fore, up to 1/16 inch (1.59 mm) of
spacers may be used to reduce valve spring
length. See tabulated data in Chapter 1.
(11) Open water outlet valve of test fixture;
check for free water circulation through
cylinder head.
13-28. INTAKE AND EXHAUST VALVES AND
SPRINGS. To service the intake and exhaust valves
and springs, refer to figure 13-41, and proceed as
follows:
CAUTION
Too many spacers will cause the
compressed spring to become a solid
sleeve.
a. Removal. Proceed as follows:
(1) Using a valve spring compressor, compress
valve spring, remove half collets, retainers,
springs, valve spring guides, and valves.
(6) Assemble upper valve spring retainer and
use a valve spring compressor stand and
compressor plate to compress valve
springs. Insert new half collets.
(2) Place valves on a numbered board for
inspection.
(7) Replace all pipe plugs. Use sealing tape or
lead sealer to prevent leakage. Torque plug
as follows: (Torque values are given in footpounds followed in parentheses by the
metric equivalent in joules.)
PLUG
1/8 inch
Fuse plug
3/8 inch
1/2 inch
3/4 inch
1 inch
MINIMUM
5
5
35
60
65
135
(7)
(7)
(47)
(81)
(88)
(183)
b. Inspection.
(1) Clean valves with buffer and polish with
crocus cloth.
MAXIMUM
10
10
45
70
75
145
(2) Inspect, then discard if heads are cupped,
cracked, pitted, or worn too thin to regrind
within limits.
Check valve head rim
thickness (1, figure 13-45). Discard valve if
rim is less than 0.105 inch (2.67 mm).
(14)
(14)
(61)
(95)
(102)
(197)
(3) Inspect then discard if stem is scored or
worn beyond worn limits; new dimensions
are 0.450 to 0.451 inch (11.43 to 11.45
mm).
(8) Install pipe plugs in fuel inlet and drain
fittings in same position, as removed, in
each cylinder head. Position and secure
water header plates with new gaskets.
(4) Inspect then discard if collet recesses are
worn so new collets will not fit securely in
recesses.
(9) Install an injector sleeve holding tool or a
scrap injector and cup assembly in each
injector sleeve. Tighten sleeve holding tool
to 7 to 8 foot-pounds (9 to 11 joules) to seal
lower end of injector sleeve, or install
c. Testing.
spring testing.
13-87
Refer to paragraph 13-27 f (29) for
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NAVFAC P-8-631-34
TO-35C2-3-463-2
d. Repair.
Repair by replacing any worn or
damaged valves and springs, as determined in
paragraph b and c above.
(4) Assemble springs. Install, if required, up to
1.16 inch (1.59 mm) of spacers to reduce
valve spring length.
(5) Assemble upper valve spring retainer.
Compress valve springs and install new half
collets.
13-29. INTAKE AND EXHAUST VALVE SEATS. Refer
to paragraph 13-27 for procedures covering inspection
and replacement of the intake and exhaust valve seats.
13-30. CYLINDER HEAD. Refer to paragraph 13-27
for procedures covering inspection, replacement,
overhaul, and rebuilding of the cylinder head.
13-31. VALVE LIFTERS. Refer to paragraph 13-25 for
inspection and replacement of the valve lifters (levers).
Figure 13-45. Minimum Valve Head Rim Thk.
13-32. CAMSHAFT. Refer to figure 13-46 and proceed
as follows:
e. Installation.
(1) Lubricate valve stem with 140W lubricating
oil and insert valve into valve guide.
a. Removal.
(1) Remove push rods and tappets as specified
in paragraph 13-26.
(2) Place cylinder head face down on a wooden
bench or protective surface to prevent
marring of milled surface.
(2) Remove gear cover
paragraph 13-23.
(3) Assemble lower valve spring guide over
valve guide.
LEGEND
1.
2.
3.
4.
Plug
Gear
Gear
Washer
5. Key
6. Camshaft
7. Camshaft
Figure 13-46. Camshafts, Exploded View
13-88
as
specified
in
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(3) Lift and rotate camshaft slightly while pulling
from block.
(1) Apply clean engine lubricating oil to
camshaft journals and lobes.
Carefully
rotate camshaft through bores into position.
(4) Tag camshaft to identify left-bank or rightbank.
(2) Slide the camshaft into position with two "0"
marks on camshaft gear aligned with "0"
marks on side of timing gear.
b. Inspection.
(1) Check camshaft bushing journals with
micrometer. Replace camshaft if journals
are worn beyond 2.120 inches (53.85 mm).
(3) Attach a dial indicator to gear case. Place
indicator to gear case. Place indicator arm
on camshaft gear teeth.
(2) Replace camshaft that has scuffed, scored,
or cracked injector valve lobes.
c.
(4) Rotate gears by hand to advance position;
"zero" indicator. There must be a minimum
of 0.003 inch (0.08 mm).
Installation.
Section VIII. PISTON AND.RINGS
13-33. PISTON CONNECTING RODS, CONNECTING
ROD BEARINGS, PISTON PINS, AND RINGS. To
inspect and replace the pistons and connecting rods,
refer to figure 13-47 and proceed as follows:
holding pistons so they will not be lost or
damaged.
(7) Reassemble each connecting rod cap to
assembly as it is removed; the rod caps are
not interchangeable. Label each assembly
by cylinder number.
a. Removal.
(1) Clean all carbon from upper inside wall of
each cylinder liner with ridge reamer and
fine emery cloth.
NOTE
Rods and caps are matched assemblies;
as removed make sure parts are
stamped, so they can be reassembled
correctly. Phase 3 rods are stamped 1/4
inch (6.4 mm) either side of the bolt hole
centerline. If a new assembly is used, be
sure to stamp before installing in engine.
(2) Remove connecting rod bolt nuts (2) and
washers (3).
(3) Pull caps (7) and bearing shells (5) from
connecting rods.
(4) Tape bearing shells together and label each
pair by cylinder number for later reference.
(8) Remove piston snap rings (9).
(5) Using a soft hammer, drive rod bolts (4)
from rods.
(9) To facilitate removal of piston pins (10), first
heat piston in boiling water, then push pin
from piston, using finger pressure. Do not
drive or otherwise force pin from piston.
CAUTION
Do not mutilate inner walls of cylinder
liners.
(10) Remove piston rings (13, 14, 15, and 16).
(11) Remove cylinder liners from
(6) Push connecting rod and piston assembly
from cylinder liners with a wooden stick,
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NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND
1.
2.
3.
4.
5.
Connecting rod assy
Nut
Washer
Bolt
Bearing
6.
7.
8.
9.
10.
Bushing
Connecting Rod
Piston assy
Ring
Pin
11.
12.
13.
14.
15.
16.
Piston
Ring set
Ring
Ring
Ring
Ring
Figure 13-47. Piston and Connecting Rod, Exploded View
block using a cylinder liner puller and a puller
bridge.
lapping.
(c) Check worn liners with dial bore gauge.
Replace if worn more than worn limit
specified in Chapter 1.
b. Inspection. Proceed as follows:
(1) Cylinder liners.
(d) Deglaze cylinder liner walls. Used liners
only.
(a) Check for cracks just under top flange,
at bottom of liner, and above top seal
ring groove.
(2) Connecting rod bearing.
(a) Gauge shell with ballpoint micrometer,
dial indicator thickness gauge, or
comparator. Discard shells if they are
worn more than
(b) Discard and replace any liner with
excessive corrosion or erosion and pits
1/16 inch (1.59 mm) deep or more, or if
dents, pitting, or fretting on underside of
liner flange cannot be removed by
13-90
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
0.001 inch (0.03 mm) or if chipped,
flaked, or scored. See tabulated data in
Chapter 1 for shell thickness.
only 700 amperes need to be applied
with DC equipment, or, 850 amperes with
AC equipment.
(b) Total worn maximum oil clearance
should not vary more than 0.001 inch
(0.05 mm) between adjacent main
bearings. Refer to tabulated data in
Chapter 1.
(d) Apply 1.5 percent wet solution while
current is on. Make visual inspection
after each application of current.
(e) Assemble cap to rod and alternately
tighten nuts to operating tension by
torque method as specified in Chapter
1.
NOTE
Under no circumstances should an
attempt be made to scrape bearing
shells, nor should they be lapped or filed
to increase oil clearances. A properly
fitted bearing will appear dull gray after a
reasonable period of service, indicating
it is running on an oil film. Bright spots
indicate metal-to-metal contact and black
spots indicate excessive clearance.
(f) Check crank pin bore with a dial bore
gauge or inside micrometers. Correct
size is important to provide correct
bearing crush. New dimension after rod
separations are 4.0018 to 4.0028 inch
(101.646 to 101.671 mm).
(g) Check piston pin bushing diameter with
plug gauge or with inside micrometers.
Refer to tabulated data in Chapter 1.
(3) Connecting rods.
(h) Use rod checking fixture and locating
mandrel to check rod alignment.
(a) Magnaflux all connecting rods, caps and
bolts; discard if cracks are detected.
NOTE
NOTE
Be sure rod and cap are mated at all
times.
Difference in reading should not exceed
0.015 inch (0.38 mm).
(i) Check connecting rod bolts, bolt holes,
and bolt pads. The bolt head must rest
squarely on milled surfaces of the rod.
(b) Check rods for cracks with 1800-ampere
current AC equipment or 1500-ampere
current DC or rectified AC equipment
longitudinally between plates.
(j) If connecting rod bolts have been
tightened excessively, they may be
permanently stretched, in which case
they must be discarded. Discard bolt if
smallest diameter is less than 0.540
inch (13.72 mm).
(c) Check rods for cracks with 3000 to 3400
ampere-turns with AC equipment or
2600 to 2800 ampere-turns with DC or
rectified AC equipment in a coil.
NOTE
(k) Check bolt pilot OD; discard bolt if pilot
is smaller than 0.6242 inch (15.855
mm).
Ampere-turns is defined as the amperage
flowing through the coil, multiplied by
the number of turns in the coil. Most
coils contain four turns and therefore
(l) Discard all bolts and
13-91
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
nuts that have distorted threads.
more than indicated in Chapter 1.
(m) Check bolt hole diameter. If diameter
exceeds 0.6249 inch (15.872 mm),
discard rod.
(c) Pistons should be checked at room
temperature of 70 to 90°F (21 to 32°C);
refer to tabulated data in Chapter 1.
(n) Check bolt pad radius.
(d) Piston pin bore check at 70°F (21°C)
should fall within limits specified in table
13-2; add 0.005 inch (0.013 mm) per
10°F (-12°C) up to 90°F (32°C).
(4) Piston rings.
(a) New rings should be checked in cylinder
liner in which they are to be used to
make sure the gaps are correct.
(b) Insert each ring in mating cylinder liner;
position with head of piston so it is
seated squarely in ring travel area of
liner.
(c) Measure ring gap with a feeler gauge.
Gap should fall within limits specified in
Chapter 1.
Figure 13-48. Piston Check Points
(d) Do not file or stone chrome-plated rings;
be certain top and intermediate rings
are installed in chrome plated cylinder
liners.
(e) Check piston pin outside diameter with
micrometer. Pins should not be reused
if out-of-round more than 0.001 inch
(0.03 mm) or worn smaller than
indicated in Chapter 1.
(5) Piston and piston pin.
(a) Check top and second piston ring
grooves with a segment of new ring and
a feeler gauge. Hold ring in groove,
flush with land and insert 0.006 inch
(0.15 mm) feeler gauge; if gauge enters
groove without forcing or disengaging
ring, wear is excessive and piston
should not be used.
c. Installation. Refer to figure 13-47 and proceed
as follows:
(1) Insert one snap ring (9) in piston pin bore.
(2) Heat piston in water or an oven to 220°F
(104°C) for 5 minutes.
(3) Insert piston pin (9) through piston and rod
by hand. Lock pin in place with second
snap ring.
(b) Measure piston skirt diameter with a
micrometer at right angle to piston bore
(A, figure 13-48 for the barrel-ground
pistons), measure straight or tapered
ground pistons at point B, 1 inch (25.4
mm) below ring groove and C, 1 inch
(25.4 mm) above bottom of piston.
Pistons should not be reused if worn
(4) Assemble rings to pistons
13-92
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
with word "top" at top.
CAUTION
(5) Lubricate pistons, rings, and cylinder liners
with clean lubricating oil.
If liner is difficult to push down, the
packing rings may be twisted or have
slipped. Remove liner to check rings;
use extreme care to avoid twist or cut of
O-rings.
(6) Using a standard hand-type ring compressor
to compress rings, insert piston and rod
assembly in liner from bottom of liner.
(10) Drive liners to seat with cylinder liner
driver; when liner is near seat, tap gently to
prevent bouncing off seat as liner is driven
in place.
(7) Assemble new O-ring packings and crevice
seals on cylinder liner as follows:
NOTE
(11) With piston at lowest possible point, check
liner bore for roundness at several points
within range of piston travel. See figure
13-49.
To prevent swelling of O-rings, lubricate
lightly with clean engine lubricating oil,
just prior to installation.
(a) Roll black O-ring with one yellow mark
into position in upper groove. Install the
red silicone O-ring with two blue marks
in lower groove.
(a) Check with precision dial bore gauge.
(b) Micrometer readings to be taken as
near points C, D, E, F, and G along axis
A-A and B-B.
(b) Check for twisted O-ring in grooves
using mold mark on rings as guide,
straighten as required.
(c) At point C, approximately 1 inch (25.40
mm) below top of liner, it is permissible
to have up to 0.003 inch (0.08 mm) of
out-of-round.
(c) Install new crevice seal on liner.
(8) Lubricate machined portions of block, on
which packing rings seat, with clean lubricating oil.
(d) At other points, each about 2 inches
(50-80 mm) lower than preceding depth,
out-of-round must not exceed 0.002
inch (0.05 mm).
CAUTION
Never use white lead for lubricant. White
lead will harden and make cleaning
difficult at next engine teardown.
(12) Check liner protrusion at four equidistant
points with a gauge block to determine if
protrusion is uniform and 0.004 to 0.006
inch (0.10 to 0.14 mm) above block.
(9) Lift liner, piston and rod assembly and slide
into cylinder liner bore.
Numbers on
connecting rods must be toward outside of
engine. Connecting rods and caps are
numbered to correspond with their
respective cylinders; numbers on rods and
caps must be matched. Two rods are
assembled on each crank journal.
(13) Lubricate crankshaft side of bearing shells
with a thin coat of clean engine lubricating
oil. Slide upper connecting rod bearing
shells into position between the crankshaft
journals and rods. Be certain bearing shell
locating tang makes firm contact with the
recesses in the rod.
(14)
13-93
Place lower connecting rod
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
bolts and install washers and nuts.
(a) Tighten connecting rod bolt nuts
alternately to 70 to 80 foot-pounds (95
to 108 joules).
(b) Tighten the nuts on each connecting rod
alternately to 140 to 150 foot pounds
(190 to 203 joules).
(c) Completely loosen both nuts on each
connecting rod to relieve all tension.
(d) Tighten the nuts on each connecting rod
alternately to 70 to 80 foot-pounds (95
to 108 joules).
(e) Tighten the nuts on each connecting rod
alternately to 140 to 150 foot-pounds
(190 to 203 joules).
Figure 13-49. Cylinder Liner Check Points
(f) The breakaway torque in tightening
direction should be 140 to 180 footpounds (190 to 244 joules).
bearing shells in connecting rod caps. The
locating tang on the shell must index with
milled recess in cap. Numbers on rod and
cap must match (1 to 1, 2 to 2, etc.) and
must be toward outside of their respective
banks and must indicate proper position in
cylinder block: IL for left bank, IR for right
bank, etc. Stamp if new rod is being used.
This provides proper clearance between rod
crankpin end chamber and crankshaft rod
journal fillet.
(17)
Check for clearance of 0.008 to 0.022 inch (0.20
to 0.56 mm) between rod assemblies located on same
journal. Rods should move freely sideways with hand
pressure. Also check position of rod on piston pin and
make sure there is visible clearance between rod and
piston boss. This is extremely important to prevent
scoring or seizing of piston and liner.
(15) Completely lubricate bolt threads with
engine lubricating oil. Lubricate hardened
washers and bolt head mating surface with
SAE 140-W lubricant.
(18)
Turn crankshaft as each piston and rod
assembly is added to gauge additional drag. Increase
will be perceptible but must not be excessive for any
one rod assembly.
(16) Assemble caps and bearing shells over rod
Section IX. CRANKSHAFT AND BLOCK
13-34. CYLINDER
LINERS,
MAIN
BEARINGS,
CRANKSHAFT,
CAMSHAFT
BUSHINGS,
AND
CYLINDER BLOCK. To replace and inspect these
components, refer to figure 13-50 and 13-51, and
proceed as follows:
13-94
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
a. Removal.
NOTE
(1) Refer to paragraph 13-33 for cylinder liner
replacement and inspection instructions.
Replace bearing caps in same position
as removed. Main bearing caps are not
interchangeable.
Tape corresponding
upper and lower bearing shells together
and number by position removed.
(2) Remove 14 side bolts (33, figure 13-50) and
washers (34) from each side of block (39)
securing main bearing caps (38) to side of
block.
(8) Using a camshaft bushing drive remove the
camshaft bushings (23, figure 13-50).
(3) Remove main bearing capscrews (35 and
36) and remove and discard lockplates (37).
b. Inspection.
(4) With a small prybar, loosen each main
bearing cap (38). When caps are free, lift
caps from block.
(1) Cylinder Liners. Refer to paragraph 13-33
for cylinder liner inspection procedure.
(2) Main Bearings. Gauge shell with a ballpoint micrometer, dial indicator thickness
gauge, or comparator. Discard shells that
are worn more than 0.001 inch (0.03 mm) or
if chipped, flaked, or scored. Refer to
tabulated data in Chapter 1.
(5) Remove lower thrust washers (19, figure 1351) from each side of rear main bearing.
(6) Remove lower bearing shells (11, 13, 15,
and 17) from crankshaft or cap and remove
upper thrust washers (19). Tag and tape
thrust ring halves together to prevent
damage.
(3) Crankshaft. Proceed as follows:
(a) If crankshaft gear is chipped, cracked,
broken, or worn, replace gear.
(7) Using a chain hoist with rubber-covered
hooks to protect bearing surfaces, lift
crankshaft from cylinder block. Remove
upper bearing shells (12, 14, 16, and 18).
NOTE
If
crankshaft
gear
condition
satisfactory, do not remove gear.
WARNING
OVERHEAD
OPERATIONS
HAVE
INHERENT HAZARDS THAT CANNOT BE
MECHANICALLY SAFEGUARDED. HARD
HATS AND SAFETY SHOES ARE
REQUIRED.
is
(b) Attach a circular-type puller behind the
crankshaft gear.
(c) Apply 75 to 100 foot- pounds (102 to
136 joules) on puller screw.
LEGEND FOR FIGURE 13-50
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Liner
O-ring
Seal
O-ring
Drain cock
Coupling
Tube
Elbow
Valve
Elbow
Tee
Nipple
Bushing
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Shaft
Screw
Screw
Plug
Plug
Bypass spring
Disc
Drain cock
housing
Bushing
Plug
Dowel
Dowel
13-95
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Plug
Screw
Lockwasher
Washer
Nozzle
Plug
Bolt
Washer
Capscrew
Capscrew
Lockplate
Cap
Block
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 13-50. Cylinder Block, Exploded View
13-96
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(d) Heat gear with heating torch (not a
8utting torch) to 400°F (205°C). The
gear will expand, making it easier to
pull. Remove gear key.
Clean suspected defective area with
kerosene or other grease-removing
cleaner.
(b) Apply dye penetrant allowing time for it
to dissolve or enter in the defect. Allow
approximately 15 minutes for dye to act.
Do not "force" dry. Remove all excess
penetrant and apply developer so defect
will stand out. Cracks usually show up
as a solid or dotted line. Porosity
usually shows up as dots in local area.
(e) Inspect
crankshaft
visually
for
scratches, nicks, cracks, and obvious
wear pattern.
(f) Measure crankshaft journals with
micrometers. Refer to tabulated data in
Chapter 1.
(g) Check crankshaft for out-of-round
condition.
Crankshafts should be
replaced if main bearing or crankpin
journals are worn out-of-round more
than 0.001 inch (0.05 mm).
(c) Check for signs of corrosion. Corrosion
most frequently occurs on portions of
block nearest cylinder liners and is
evidenced by pitting.
c.
(h) Measure
and
carefully
examine
crankshaft thrust flange at No. 7 main
bearing; refer to tabulated data in
Chapter 1. If surfaces are scored or
scratched,
crankshaft
should
be
replaced.
Repair. To repair the cylinder block, proceed as
specified in the following paragraphs:
(1) Tappet Bores.
(a) Measure tappet bores with a small bore
gauge.
(4) Camshaft Bushings.
(b) If worn beyond limit specified in Chapter
1 or out-of-round more than 0.0015 inch
(0.038 mm), replace cylinder block.
(a) Use inside micrometers or dial bore
gauge to measure camshaft bushing
inside diameter. Mark bushings for
replacement if worn larger than worn
limit specified in Chapter 1.
(2) Idler Gear Shaft.
(a) Replace idler gear shaft if worn smaller
than 1.9965 inch (50.711 mm).
(b) Check for chipped, scored, or scratched
surfaces.
(b) Remove outer screw (16, figure 13-50)
from left side of idler shaft boss; then
remove screw (15) which secures shaft
in cylinder block.
(c) If bushings show signs of turning, in
block bore, check block bore sizes.
Refer to tabulated data in Chapter 1.
(c) Using a suitable puller, pull idler shaft
(14) from block.
(5) Cylinder Block.
(a) Use dye penetrant method for locating
cracks, porosity, leaks and other faults.
(d) Place new idler shaft in block bore and
drive
13-97
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND
1.
2.
3.
4.
5.
Screw
Washer
Damper
Screw
Washer
6.
7.
8.
9.
10.
Pulley
Gear
Key
Plug
Bearing
11.
12.
13.
14.
15.
Shell
Shell
Shell
Shell
Shell
16.
17.
18.
19.
20.
Shell
Shell
Shell
Washer
Crankshaft
Figure 13-51. Crankshaft, Exploded View
shaft into cylinder block until it seats on
shoulder.
(a) If camshaft bushing bore in block is
damaged, first determine cause of
damage and correct. Bore may then be
repaired installing a sleeve as follows:
(e) Install screw (15) to secure idler shaft in
cylinder bloc; install screw (16) in boss.
(b) Pilot boring bar in two good camshaft
bushing
(3) Camshaft Bushing Bore in Block.
13-98
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
bores either fore or aft of one being
repaired.
Hole Repair.
NOTE
(c) Cut piece of 2-1/2 inch (63.50 mm) OD
seamless steel tubing with 1/8 inch
(3.17 mm) wall to length of bore in
block. Chamfer one end to facilitate
installation.
This procedure cannot be followed in
off-centered holes due to thin-wall
construction.
(a) Drill out stripped or damaged threads
with a 53/64 inch drill (0.83 mm) to
1.000 to 1.150 inch (25.40 to 29.21 mm)
deep.
(d) Measure OD of tubing.
(e) Perform boring operation. Bore must be
0.002/0.005 inch (0.05/0.13 mm)
smaller than tubing OD to provide press
fit.
(b) Countersink 0.885 to 0.895 inch (22.48
to 22.73 mm) diameter by 86-degree
angle.
(f) Remove boring bar and carefully clean
block to remove all shavings.
(c) Tap hole with 7/8-14 UNF-2B tap to
0.800 to 0.900 inch (20.32 to 22.86 mm)
deep.
(g) Apply a thin coat of Permatex to tubing
OD and block bore ID to prevent galling
during installation and to provide a
tighter press fit.
(d) Install heli-coil insert.
(e) Screw in insert finger tight; locking
tangs will automatically stop insert.
(h) Install tubing with short mandrel to
prevent collapsing. Mandrel must have
shoulder on drive end.
(f) For proper engagement, visually check
insert flush or below surface of cap.
(i) Pin sleeve with 1/16 inch-27NPTF x 1
inch pipe plug or soft steel pipe plug
through side wall of block or through
camshaft bushing bore. Stake plug.
(g) Secure in position by driving heli-coil
insert down flush with cap surface by
lightly tapping.
(j) Reinstall boring bar and bore sleeve to
2.2535/2.2545 inch (57.239/57.264 mm)
ID. Remove bar and clean all shavings
from block.
(6) Top Surface Refinishing.
NOTE
If necessary, a cylinder block may be
salvaged by removing a maximum of
0.010 inch (0.25 mm) of material from the
top surface.
(k) Install bushings.
(4) Tappet Guide Screw Holes. Tappet guide
screw threads may be repaired using helicoil inserts.
(a) Use either a milling machine or large
surface grinder; locate block on main
bearing pads.
(5) Main Bearing Cap Sidebolt
(b) Remove dowels from head mounting
surface and make light cuts of 0.001 to
0.003 inch (0.03 to 0.08 mm) deep,
13-99
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
removing only enough material to make
block usable.
(1) Cylinder Liner Counterbore.
(a) Check upper liner counterbore and
remove burrs and dirt so liner will enter
cylinder block without distortion.
If
counterbore exceeds limits listed in
Chapter 1 for the top 0.400 inch (10.16
mm) depth, mark block for counterbore
repair. The counterbore ledge must be
smooth and perpendicular to the liner
bore to within 0.005 inch (0.13 mm)
total
indicator
reading.
Use
straightedge to check flatness of top of
block.
(c) Check distance from centerline of main
bearing to top of block (1, figure 13-52).
Refer to tabulated data in Chapter 1 for
dimensions.
(d) Finish surfaces to 125 rms.
(e) Resurface counterbore to obtain proper
linear protrusion. Check liner to block
contact in crevice seal area.
(b) Check counterbore depth so installed
liner will be assembled to correct
protrusion and to determine if refinish of
counterbore surface is necessary.
Depth of counterbore in a new block is
listed in Chapter 1. If worn to or beyond
limit, the cylinder block must be
salvaged. If worn less than worn limit,
the surface can be refinished and shims
installed under the cylinder liner to
restore proper protrusion. Refinished
counterbore radius must be 0.025 to
0.30 inch (0.63 to 0.76 mm).
Figure 13-52. Cylinder Block Height
Checking Location
(c) Installed cylinder liners must protrude
0.003 to 0.006 inch (0.08 to 0.15 mm)
above block.
To check for proper
protrusion without installing a liner,
proceed as follows:
(7) Cylinder Head Capscrew Threads.
(a) Drill out old threads with 23/31 inch drill
to a depth of 1-7/8 inch drill to a depth
of 1-7/8 inches (47.63 mm) from the
cylinder block top surface.
1. Measure liner flange outside bead
with micrometer. Do not include
bead on top of liner flange in taking
measurement.
(b) Tap drilled hole to a depth of 1-3/4 inch
(44.45 mm).
2. Measure block counterbore
(c) Install heli-coil insert with inserting tool
until it is 1/2 inch (12.70 mm) below top
surface. Break off insert tang using a
punch and hammer, not an inserting
tool.
d. Overhaul and Rebuilding of Cylinder
Block. Proceed as follows:
13-100
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
depth with dial indicator depth
gauge. Always measure counterbore
depth on ledge at the edge of liner
bore.
Add or remove shims beneath the liner
flange as needed to reach 0.004 to 0.006
inch (0.10 to 0.15 mm) protrusion.
3.
3. Check depth at four equidistant locations.
Ledge must not be "cupped" more than 0.
0014 inch (0. 036 mm). Depth must not
vary more than 0. 001 inch (0. 03 mm)
throughout counterbore circumference.
(2) Cylinder Liner Lower Bore.
(a) Install a new cylinder liner in the block without
packing rings or crevice seal.
4. Counterbore must always be resurfaced if
it slants downward toward the center or if
dimensions do not meet standards.
5.
(d)
With lines installed, check for out-ofround.
(b)
Subtract counterbore depth from liner
flange thickness to determine amount of
shims and depth of counterbore cut that
must be used to provide 0.004 to 0.006
inch (0.10 to 0.15 mm) liner protrusion;
0.007 inch (0.18 mm) shims are thinnest
available.
Desirable clearance between liner and block
should be as listed, but liner contact with block
is permissible as long as it does not cause liner
out-of-round.
(c) If clearances do not fall within limits, recheck
after counterboring; limits do not apply with
cylinder head installed and tightened to
operating torque. If clearance is not correct,
check lower block packing ring bore inside
diameter.
The most accurate method of checking
protrusion is as follows:
(d)
1. Install liner in block with proper number of
liner shims beneath the flange. Shims
are available from 0.007 to 0.068 inch
(0.18 to 1.73 mm). Use cylinder liner
hold-down tool. Tool should be spaced
so even load is applied.
Lower liner bore concentricity should be
checked with concentricity gauge. If a piston
seizure has occurred or after counterboring the
cylinder block, check the counterbore to lower
cylinder liner bore concentricity. Liner bore
should be concentric within 0. 005 inch (0. 13
mm) total indicator reading.
(3) Main Bearing Bore.
2.
Use gauge block and check liner
protrusion above the cylinder block at
four equidistant points outside the bead.
13-101
(a) Assemble main bearing caps to block in
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
operating position.
operating tension.
Tighten capscrews to
(b) Gauge main bearing bores horizontally,
vertically, and diagonally with dial bore
gauge or properly adjusted micrometers.
Refer to tabulated data in Chapter 1 for
dimensions.
2. The 20-degree chamfer (5) in block
is 0.010 to 0.020 inch (0.25 to 0.51
mm).
(b) Clean all chips from block.
(c) Mix sealer of three parts glycerine to one
part litharge to a smooth paste.
(d) Wipe bore with a clean cloth and apply
sealer.
NOTE
A boring tool may also be used to
check main bearing bore alignment. If
it is definitely determined that a main
bearing cap has been distorted, mark
block for reaming.
(e) Sleeve is larger than top bore. Place OD
of sleeve against top of bench and press
out-of-round just enough to push through
bore.
(4) Installation of Brass Sleeve using Boring Bar.
Proceed as follows:
NOTE
The OD of brass sleeve 163401 is
approximately 0.012 inch (0.30 mm)
larger than recommended bore. This
press fit is sufficient interference to
hold sleeve in place.
(f) Turn sleeve in cylinder bore so OD
chamfer is down.
(g) Provide a driver which closely pilots
sleeve and with clearance flats on
outside diameter.
(a) Bore block as shown in figure 13-53 and
to dimensions as follows:
1. Bottom of block bore (11) is 6.361 to
6.363 inch (161.57 to 161.62 mm)
diameter, to block deck (1) is 8.565
to 8.585 inch (127.55 to 228.06
mm).
(h) Index driver so flats will allow it to pass
through top bore and place driver on
sleeve.
(i)
Turn so driver is on bottom and press
sleeve over driver by using a wooden
hammer handle or equivalent. This is
slightly difficult due to limited space.
(j) Coat OD of sleeve with sealer.
(k) Position driver and sleeve in chamfered
edge of bore.
(l)
Place driver extension in driver; make
sure sleeve is centered in bore and tap
lightly on extension to seat driver in
sleeve and start sleeve into bore.
(m) Drive sleeve into bore of block until it
Figure 13-53. Sleeve and Block Boring
Dimensions 13-102
13-102
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
with compressed air and coat machined
surfaces with engine lubricating oil.
bottoms in bore with a heavy hammer or use
a hydraulic ram.
(n)
(r) After boring and sleeve installation check
alignment as described in paragraph d(2).
Should driver stick in sleeve due to
interference, a cylinder liner puller can
be used to pull driver.
(5) Cylinder Liner Counterbore. Resurface cylinder
liner counterbore if block has been resurfaced,
ledge is uneven or where liner protrusion is
incorrect.
(o) Bore sleeve inside diameter as shown in
figure 13-53 and to dimensions as
follows:
(6) Oil Control Valve. If oil control valve housing
has been removed from bore, located between
oil drillings in front center of block, install
housing as follows:
1. Bottom of sleeve (8) 20-degree
chamfer to (2) block deck 7.314 to
7.326 inch (185.78 to 186.08 mm).
2. Top of sleeve 20degree chamfer to
(3) block deck is 7.265 to 7.285 inch
(184.53 to 185.04 mm).
3. Bottom of sleeve (7) 0.040 to 0.060
inch (1.02 to 1.52 mm) radius to
block (4) deck 7.187 inch (182.55
mm) maximum.
4. Top of sleeve (7) radius is 0.040 to
0.060 inch (1.02 to 1.52 mm) (6)
diameter 6.250 to 6.260 inch
(158.75 to 159.00 mm).
(q)
Scribe a centerline on the boss
perpendicular to the bored hole, using
the capscrew holes as locators.
(b)
Align the scribe-line on the oil control
valve housing; align the two oil passage
holes with those in cylinder block. Press
housing into the bore until it is flush to 0.
020 inch (0. 51 mm) below the cylinder
block face.
(c) Insert oil control bypass disc and spring
into valve control housing.
5. Sleeve (9) bore diameter is 6.124 to
6.126 inch (155.55 to 155.60 mm)
to a (10) depth of 8.850 to 8.875
inch (224.79 to 225.42 mm).
(p) Remove boring bar from bore. Use fine
emery cloth to break sharp corners in
entrance of bore so rubber packing rings
will not be damaged when liners are
installed.
(a)
(d) Position expansion plug over spring and
into bore.
(e) Drive expansion plug into housing bore
with plug driver until flush with housing
surface.
e. Reassembly. To reassemble the cylinder block and
components, refer to figures 13-50 and 13-51 and
proceed as follows:
Clean bore thoroughly to remove all
emery dust and boring chips. Blow dry
13-103
(1) Refer to paragraph 13-33 for
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
cylinder sleeve installation.
of engine). Lubricate lockplates (37), and
capscrews (35 and 36) with clean engine
lubricating oil.
(2) Be certain crankshaft, main bearing shells, and
block main bearing bore are clean. Place all
upper main bearing shells in position in block;
locate in place with tang. Upper shells have oil
holes in center that align with oil passages in
block leading to oil header.
(3) Lubricate crankshaft journals and upper main
bearing shells with a thin coat of clean engine
lubricating oil.
CAUTION
All main bearing capscrews on right bank
(fuel pump side) except No. 7 are dowel
fit.
(9)
Torque each capscrew in alternate steps as
follows, and secure lockplates.
(a) Start capscrews by hand.
(4)
Using a suitable chain hoist and hooks
protected by rubber hose, carefully lower
crankshaft into position.
(b)
Tighten both capscrews on each cap
alternately to 200 to 210 footpounds
(271 to 285 joules).
(5) Slide upper thrust washers (19, figure 13-51) in
position around No. 7 journal. Lower thrust
rings are dowelled to main bearing caps and
hold upper rings in position.
(c)
Tighten both capscrews on each cap
alternately to 410 to 420 foot-pounds
(556 to 570 joules).
(d)
Loosen both capscrews to remove all
tension.
(e)
Tighten both capscrews on each cap
alternately to 200 to 210 footpounds
(271 to 285 joules).
(f)
Tighten both capscrews on each cap
alternately to 420 to 460 footpounds
(271 to 285 joules).
NOTE
Thrust rings are available in 0. 01 inch
(0. 25 mm) and 0. 020 inch (0. 51 mm)
oversizes
for
reconditioned
crankshafts.
(6) Place lower main bearing shells (11, 13, 15,
and 17) in caps and engage locating tangs.
Lubricate with a thin coat of clean engine
lubricating oil.
(g) The breakaway torque in the tightening
direction is 420 to 490 foot-pounds (570
to 666 joules).
(7) Install main engine bearing caps so numbers
stamped on cap correspond with numbers
stamped on block.
NOTE
The cylinder block is precision
machined for the cap to fit into its
correct position. Never file caps to
reduce bearing clearance.
Main
bearing caps are not interchangeable.
(8) Install new lockplates (37, figure 13-50) (base
"L" of lockplate down over cap to outside wall
13-104
(10)
Test crankshaft for free turning. Operation
must be free enough so it can be hand
cranked easily.
(11)
Attach a dial indicator gauge securely to
cylinder block with contact point of gauge
resting on crankshaft flange and face.
(12) Move crankshaft toward front
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
of engine, taking up all end play, and set
gauge at zero. The crankshaft must move
freely.
(13) Move crankshaft toward rear of engine. The
gauge should indicate 0.006 to 0.013 inch
(0.15 to 0.33 mm) end clearance for a new
engine, or an engine with new crankshaft and
new bearings.
(17)
Install camshaft bushings (23, figure 13-50)
using a bushing driver. Make certain that oil
passages between bushings and block oil
holes are properly aligned.
13. 35. INJECTION TIMING. After repair or overhaul,
the engine should be timed as follows:
(14) If end clearance is less than stated in step
(13), loosen capscrews slightly and shift
crankshaft toward front of engine, then toward
rear of engine. If capscrews have been
loosened, retighten as described in step (9).
Recheck end clearance.
NOTE
When an engine is being rebuilt,
always bring crankshaft end clearance
to 0.006 to 0.013 inch (0.15 to 0.33 mm)
by using standard new parts or by
using oversize thrust rings and a
reconditioned crankshaft.
NOTE
Timing No. 1 cylinder on right and left
bank will accomplish complete engine
timing. Repeat following steps for
each of the two cylinders.
a. Injector push tubes should be installed in their
sockets for timing operation.
b. Check No. 1 cylinder on each bank with injector
timing tool at 19 degrees before top center
firing position.
(15) Bend in ear of each lockplate (37) against the
main bearing capscrew to lock it in place.
c. Install timing tool in place of injector with one rod
in push tube socket and with other rod resting
on piston. Follow procedures as shown on
figure 13-54 and steps e(1) through e(4), below.
The numbers on the diagram show check points
corresponding to numbered instruction steps.
(16) Install and torque main bearing capscrews on
engines to the following values:
(a) Torque all right side capscrews to 70 to
75 foot-pounds (95 to 102 joules).
(b) Torque all left bank side capscrews to 70
to 75 foot-pounds (95 to 102 joules).
(c)
(d)
(e)
Return to right bank and torque side
capscrews to 135 to 145 foot-pounds
(183 to 197 joules).
Return to left bank and torque side
capscrews to 135 to 145 footpounds
(183 to 197 joules).
Breakaway torque is 135 to 190 footpounds (183 to 258 joules) in tightening
direction.
13-105
Figure 13-54. Engine Injection Timing
Procedure Diagram
d. When indicator gauges are set at "0", they must
be near fully
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
compressed position. Gauges should have at
least 0. 25 inch (6. 35 mm) travel range.
e. Engine must be barred accurately to each check
point as specified for the gauge above piston.
(1) Bar engine in direction of rotation to No.
1 top center firing position (highest point
of piston travel). Set indicator above
piston at "0".
(2) Advance engine to 90 degrees after top
center. Top of tool rod above piston will
be 90-degree mark on tool scale. Set
indicator above push tube to "0".
13-106
(3)
Bar engine opposite rotation to 45
degrees before top center. This is to take
up gear lash. Top of tool rod will be at
45-degree mark.
(4) Bar engine forward until piston is 0. 2032
inch lower than at top center position
which results in a minus reading on
indicator (-0.2032 inch) (-5.161 mm).
This is 19 degrees before top center.
Indicator above push tube should read
within fast and slow limits as follows: 0.050 inch (-1.27 mm) and -0.555 inch (1.40 mm).
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
CHAPTER 14
MAINTENANCE OF BASE ASSEMBLY
14-2. MAINTENANCE. All maintenance functions for the
base
assembly
are
performed
at
the
Operator/Organizational levels. Refer to Operator and
Organizational Maintenance manual.
14-1. GENERAL. The base assembly, figure 14-1,
mounts major assemblies of the generator set. It is
constructed of steel beams, strips, and plates welded into
one rigid skid base. The base contains the generator set
fuel tank assembly at the front end of the generator set.
LEGEND FOR FIGURE 14-1
1. Nut
2. Washer
3. Nut
4. Washer
5. Terminal
6. Hose assembly
7. Hose
8. Fitting
9. Elbow
10. Coupling
11. Nipple
12. Cock
13. Nipple.
14. Nut
15. Washer
16. Strap
17. Screw
18. Washer
19. Nut
20. Screw
21. Washer
22. Brace
23. Webbing
23A. Webbing
24. Fuel tank
25. Screw/washer
14-1
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
Nut/washer
Clamp
Screw
Washer
Plate
Screw
Washer
Plate
Screw
Washer
Angle
Screw
Washer
Angle
Screw
Washer
Washer
Plate
Adapter
Plug
Coupling
Nipple
Plug
Base
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 14-1. Base Assembly, Exploded View
14-2
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
CHAPTER 15
MATERIEL USED IN CONJUNCTION WITH THE GENERATOR SET
automatic control system. When the automatic system
requires one to four generator sets to support the load,
one automatic control module is required. The housing kit
encloses the generator set with shutters and access
doors. It is attached to the generator set support frame
assembly and the base assembly. The housing kit
assembly louvers are automatically controlled by a
mechanical linkage, motor-driven system.
Auxiliary
equipments also include a fuel hose, two electrical male
connectors, and two sling assemblies.
15-1.
GENERAL.
Auxiliary equipment used in
conjunction with the generator set includes the remote
control module and cable, the automatic control module,
and the housing kit. The. remote control module allows
remote start, stop, monitoring and control of single or
parallel operation of generator sets. Control devices on
the remote control panel are similar to the control panel
on the generator set control cubicle. It is connected to the
generator set by a 1000 foot (300 m) cable. The
automatic control module provides an unattended
Section I. MAINTENANCE OF REMOTE CABLE ASSEMBLY
jacket and two connectors P2 (2) at each end. Cable (5)
is a 37-conductor, AWG 14 wire with two connectors P1
and P4 (1 and 3) at each end. The cable is assembled
with self-locking tie wraps (4) approximately 6 inches (152
mm) apart. Refer to Chapter 10 for detail interconnection
data and wire list.
15-2. REMOTE CONTROL CABLE. The remote control
cable assembly is used to connect the remote control
module to the generator set. The cable assembly may be
of any length up to a maximum of 1000 feet (300 m).
15-3.
INSPECTION.
Inspect cable assembly for
damaged connectors, loose pins, poor and loose electrical
connections, and damaged cable.
15-5. REPAIR. Test each parallel wire for continuity. Be
sure wire is not shorted either to the connector, or to
another wire. Wire routing is common between like pins
of connectors: E to E, D to D, etc. Wires are AWG 14,
1000 feet long (300 m), and color coded. When replacing
connectors, solder in accordance with requirements 5 of
MIL-STD-454.
15-4. REPLACEMENT. The remote cable assembly is
connected from J2, J1, and J4 connectors at the rear of
the generator set control cubicle to the rear of the remote
control module at connectors J2, J1, and J4. Cable (6,
figure 15-1) is a 25-conductor, AWG 14 wire with PVC
Section II. MAINTENANCE OF REMOTE CONTROL MODULE
electrical connections, damaged case, or scratched
glass.
b. Testing.
15-6. GENERAL. This section contains maintenance
information on the synchroscope, relays, circuit card, and
flashing circuit.
The troubleshooting procedures
contained in tables 5-2 and 5-3, of the Operator and
Organizational Maintenance manual completely isolate
any faults that may occur. For maintenance of other
remote control module components, refer to the Operator
and Organizational Maintenance manual.
15-7. SYNCHROSCOPE.
(1) Connect the synchroscope as shown in
figure 15-2 test setup.
Frequency
generators used should be capable of
providing minimum 50 volts, maximum
240 volts. Frequency 0 to 60 Hz. For
testing, the pull-in frequency is 47 Hz.
a. Inspection. Inspect the synchroscope for loose
(2) The synchroscope axial
15-1
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 15-1. Remote Cable Assembly
polarizing coils are energized from the
'incoming' frequency, while the radial
field coils are connected to the 'running'
circuit.
If there is no difference
between the two circuits either in phase
angle or frequency, the pointer will
remain motionless at the 12 o'clock
position on the dial. With no frequency
difference, any phase angle difference
will cause the pointer to take up a
position away from the point.
If,
however, there is a difference in
frequency, this phase relationship will
be constantly changing and the pointer
will consequently rotate continuously in
one direction or the other at a speed
corresponding to the difference in
frequency. If 'incoming' is at a higher
speed than the 'running', the pointer
rotates clockwise, and counterclockwise
if its speed is lower.
(3) When the lamps turn off together, the two
sources are synchronized. When the
'incoming' frequency has been adjusted
to equal that of the 'running' frequency,
the pointer will come to rest at a point on
the scale depending on the phase
displacement of the two voltages. The
speed of
15-2
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 15-2. Synchroscope, Test Setup
the ‘incoming' must then be inched up or down until the
pointer takes a steady position at 12 o'clock.
S2 to terminals 3 and 4, also with
terminals 7 and 8 (DS2).
c. Replacement. The synchroscope is mounted on
the remote control module control panel.
Disconnect and tag wires and remove attaching
hardware to remove the synchroscope from the
control panel.
(d)
Adjust AC power supply to 120
volts, 60 Hz. With Sl and S2
closed, lamp DS1 should extinguish
and DS2 should light.
(e) Reduce voltage slowly to 104 volts
and hold for 2 minutes. Lamp
DS1 and DS2 shall maintain
states.
15-8. RELAYS. Test and replace undervoltage relay
K115 and underfrequency relay K116 as follows:
a. Test.
(f) Reduce voltage to 99 volts. DS1
and DS2 shall transfer states
within 4 to 8 seconds.
(1) Undervoltage relay K115 (2, figure 15-3).
(a)
Connect relay as shown in test
setup figure 15-4.
(b) Connect a variable 0 to 160V AC
source and variable frequency (50
to 60 Hz) source to terminals 1
and 2 with switch S1 in series.
(c)
Connect lamp DS1 and 24V DC
power supply in series with switch
15-3
(g)
Increase voltage slowly to 113
volts. Lamps DS1 and DS 2 shall
transfer states.
(h)
Reduce voltage to 48 volts.
Transfer of states of DS1 and DS2
shall be instantaneous
(i)
Reduce frequency to 50 HZ and
repeat the procedures in steps
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND
1. Screw
12. Bracket
22.
2. Undervoltage relay
13. Annunciator
23.
3. Screw
14. Resistor
24.
4. Underfrequency rely
15. Diode
25.
5. Screw
16. Jumper
26.
6. Nut
17. Screw
27.
7. Converter
18. Nut
28.
8. Screw
19. Terminal block
29.
9. Nut
20. Screw
30.
10. Screw
21. Nut
31.
11. Nut
Figure 15-3. Remote Control Module, Plate Assembly, Exploded View
15-4
Terminal block
Flasher
Screw
Nut
Transducer
Screw
Nut
Transformer
Plate
Terminal lug
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 15-4. Undervoltage Relay K115, Test Setup
(e) through (i) with the same results.
Lamp DS1 should light and DS2
should extinguish.
(2) Underfrequency relay K116 (4, figure
15-3).
(d) Lower frequency slowly until relay
contacts drop out (lights transfer).
Contacts should drop at 55 Hz
±0.1 Hz.
WARNING
HIGH VOLTAGES ARE PRESENT DURING TEST.
(e) Close switch S1 for 50 Hz test.
(a)
Connect relay to test setup as
shown in figure 15-5.
(f) Adjust the frequency to 50 Hz and
the input voltage to 120 volts.
Relay contacts should pick up.
Lamp DS1 should light and DS2
should extinguish.
(b) Open switch S1 for 60 Hz test.
(c) Adjust the frequency to 60 Hz and
the input voltage to 120 volts.
Relay contacts should pick up.
(g) Lower frequency slowly until relay
contacts drop out (lights transfer).
Contacts
15-5
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 15-5. Underfrequency Relay K116, Test Setup
should drop out at 46 ±0.1 Hz.
from the generator panel of the control
cubicle-
b. Replacement. Remove relay (2, figure 15-3) by
disconnecting and tagging wires and removing
four screws (1).
Remove relay (4) by
disconnecting and tagging wires. Remove four
screws (1) and remove-relay from plate
assembly (30).
WARNING
HIGH VOLTAGES PRESENT DURING TEST.
(a) Connect a test setup as shown in
figure 15-6.
15-9. TRANSDUCERS. Remove transducers A103,
A107, and A108 according to paragraph 15-9 b, and test
as follows:
(b)
a. Test.
(1) Transducer A103. This transducer and
generator set frequency meter are a
matched set, and must be tested as a
set. Refer to the Operator/Crew and
Organizational
Level
Maintenance
manual and remove frequency meter
15-6
Vary the frequency from lowest
scale reading to full scale reading
at 120 volts and at frequencies
between 48 and 53 Hz, the
generator set meter shall read
within 1 percent of the generated
frequency (to the left); at 120 volts
and at frequencies
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
between 57 and 62 Hz, generator
set meter shall read within 1
percent of the generated frequency
(to the right). The error at any point
on frequency meter shall not be
greater than 1 percent.
(d) Energize 120/208V AC 3 phase, 4 wire,
60 Hz power source.
(c)
If the above requirements are not
satisfied, replace both the frequency meter and
transducer as a matched set.
(f) With S1 closed, close switch S2, and
adjust T2 until 0.7 ampere is indicated on ammeter A2.
The percentage of RATING METER shall indicate 66
percent.
(e) Adjust T1 until 0.7 ampere is indicated on
ammeter A1. At this point, the percentage of RATING
METER shall indicate 33 percent.
(2) Transducers A107 and A108 (7, figure 15-3) are
tested as follows:
(g) With S1 and S2 closed, close S3. Adjust
T3 until 0.7 ampere is indicated on ammeter A3. The
percentage of RATING METER shall indicate 100
percent.
WARNING
HIGH VOLTAGES PRESENT DURING TEST.
(h) If requirements of steps (e), (f), and (g)
are not met, replace the transducers.
DEATH
OR SEVERE BURNS MAY RESULT IF PERSONNEL
FAIL TO OBSERVE SAFETY PRECAUTIONS.
b. Replacement. Transducers A103, (26, figure
15-3), and
FUNCTION
Alarm Silence
Alarm Silence
Alarm Arming
High Coolant Temperature
High Oil Temperature
Low Oil Pressure
Low Fuel Level
Overspeed
Overvoltage
Undervoltage
Reverse Power
Overload
Short Circuit
(a) Connect transducer
REF DES
K25A
K25B
K26
K27
K28
K29
K30
K31
K32
K33
K34
K35
K36
A107 and A108 (7), are removed from the plate
assembly (30) by disconnecting and tagging
wires. Remove transducer (26) by removing four
screws (24) and nuts (25).
Remove both
transducers (7) by removing screws (5) and nuts
(6).
(either A107 or A108) as shown in figure
15-7, using test equipment as shown.
(b) Adjust T1, T2, and T3 to their minimum
position, fully counterclockwise.
(c) Close S1 and open S2 and S3.
15-10. ANNUNCIATOR CONTROL ASSEMBLY A20 (13,
figure 15-3). The annunciator control relay assembly
contains four terminal boards, 20 diodes, and 13 relays:
15-7
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
indicated, it is defective and must be
replaced.
a. Test.
(1)
Check each relay using test circuits
shown in figure 15-8. Energize each
set of relay contacts individually by
applying 24V DC directly to leads.
Check for open or closed contacts (no
continuity or continuity) as indicated in
figure 15-8. Check that each set of
contacts revert (to either closed or open
position) when deenergized. If only
relay fails to either open or close as
(2) Check diodes for polarity. A good diode
will read high resistance one way and
low resistance the other way.
A
defective diode will read full scale both
ways, or will read infinity (no reading) in
either direction.
(3) Check terminal boards and printed circuit
wiring by repeating steps (1) and (2),
but apply 24V DC to A20 terminals.
Figure 15-6. Transducer A103, Test Setup
15-8
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 15-7. Transducer A107 and A108, Test Setup
b.
Repair. If any of the relays or diodes are
defective,
Annunciator
Control
Relay
Assembly A20 is repairable by replacing the
defective component. If the printed circuit
wiring or a terminal board proves defective, or
a non-replaceable component is defective, the
entire assembly must be replaced.
CAUTION
Do not apply excessive heat when
soldering or unsoldering components.
It may damage the printed circuit
wiring.
c. Replacement.
(d)
If Annunciator Control Relay
Assembly is to be replaced,
remove screws (8) and nuts (9)
to release annunciator (13) from
brackets (12).
(e)
Prepare annunciator (13) for
installation by attaching brackets
(12) using screws (8) and nuts
(9).
(1) Remove annunciator (13, figure 15-3) as
follows:
(a) Tag and then disconnect wires from
terminal boards.
(b) Remove screws (10) and nuts (11)
to remove annunciator (13) and
brackets (12).
(c)
(f) If components are being replaced,
carefully solder new component
into place.
Components are replaced by
carefully unsoldering them from
the printed circuit board.
15-9
TM5-6115-593-34-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND
1. Relay K36
2. Diode CR21
3. Diode CR22
4. Relay K35
5. Diode CR19
7. Diode CR20
8. Diode CR17
9. Relay K34
10. Diode CR16
11. Diode CR15
12. Relay K33
13. Relay K32
14. Diode CR14
15. Diode CR13
16. Diode CR12
17. Diode CR4
18. Relay K27
19. Diode CR3
20. Relay K26
21. Diode CR11
22. Diode CR6
23. Diode CR5
24. Relay K25B
25. Relay K28
26. Relay K31
27. Diode CR8
28. Diode CR7
29. Relay K25A
30. Relay K29
31. Diode CR9
32. Diode CR10
33. Relay K30
Figure 15-8. Annunciator Control Assembly A20 (Sheet 1 of 2)
15-10
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 15-8. Annunciator Control Assembly A20 (Sheet 2 of 2)
15-11
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(g) Install annunciator (13) by securing
brackets (12) using screws (10) and
nuts (11).
15-13. RESISTOR R30 (14, figure 15-3).
a. Remove R30 (14) from terminal block (19) by
removing screws (17).
(h) Connect wires to terminal boards,
then remove wire tags.
15-11. FLASHER FC1. The flasher (23, figure 15-3) is
plugged into terminal block (22) which is mounted on the
plate assembly (30) with two screws (20) and nuts (25).
Test the flasher by connecting it in series with a 24V DC
power source and test lamp. The test lamp should flash
on and off; otherwise the flasher is defective and should
be replaced.
b. Use an ohmmeter to test R30 for resistance of
39,000 ohms ±5 percent. Replace R30 if
specified resistance value is not met.
c. Install resistor R30 (14) onto terminal block (19)
using screws (17).
15-14. DIODE CR36 (15, figure 15-3).
15-12. TRANSFORMER T103 (29, figure 15-3).
a.
Remove phase shift transformer T103 as
follows:
a.
Disconnect one end of the diode (15) by
removing screw (17).
b.
Connect an ohmmeter (scale set at Rx100)
across the diode, and note reading.
(1) Tag and disconnect lead wires.
c. Reverse ohmmeter leads to the diode, and again
note reading. A good diode will read high
resistance one way and low resistance the other
way. A shorted diode will read full scale both
ways. An open diode will read infinity (no
reading, in either direction.
(2) Remove screws (27) and nuts (28) and
remove T103 (29).
b.
Test transformer T103 in accordance with
procedures in paragraph 5-3 b.
d. Remove shorted or open diode (15) by removing
remaining screw (17).
c. Install T103 as follows:
(1)
Secure transformer T103 to plate (30)
using screws (27) and nuts (28).
e.
Reconnect lead of good diode, or install new
diode with screws (17).
(2) Connect wires and remove tags.
Section III. MAINTENANCE OF AUTOMATIC CONTROL MODULE
15-15. GENERAL. the Automatic Control Module can
automatically control up to four generator sets by
monitoring the utility bus voltage and frequency. If
voltage should vary by ±10 percent or frequency should
vary by ±3 percent the module will start the generators,
open the utility breaker and sequentially load generators.
The troubleshooting procedure contained in Table 5-5 and
5-6 of the Operator and Organizational Maintenance
manual isolates most faults that may occur. Test and
adjustment procedures are contained in this section.
15-16. UNDER/OVERVOLTAGE DEVICE. There is one
under/over voltage device. The device is preset for a ±10
percent deviation in the 120V AC bus sensing power. The
device is adjustable within the range specified in the
tabulated data in Chapter 1 of the Operator and
Organizational Maintenance manual. Trip settings are
made by removing protective plastic caps on front of the
device and turning adjustment screws beneath caps. A
clockwise rotation of adjustment screw will increase trip
point. Figure 15-9 shows component layout of Automatic
Control Module.
15-12
TM5-6115-593-34-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 15-9. Automatic Control Module
15-13
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND FOR FIGURE 15-9
1. Rivet
2. Schematic plate
3. Data plate
4. Harness assy
5. Nut
6. Washer
7. Relay panel assy
8. Screw
9. Over frequency relay
10. Under frequency relay
11. Under/overvoltage relay
12. Time delay relay
13. Time delay relay
14. Relay
15. Relay
16. Diode
17. Time delay relay
18. Diode pack
19. Time delay relay
20. Run relay
21. Terminal block
22. Terminal block
23. Marker strip
24. Marker strip
25. Marker strip
26. Panel
27. Fuse panel assy
28. Panel light
29. Selector switch
30. Toggle switch
31. AC fuse
32. Fuse, BR1
33.
34.
35.
36.
37.
38.
39.
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.
a. Test. Test the under/over voltage module as
follows:
(d) With ohmmeter connected between
terminals 5 and 6 adjust AC voltage
to read 130 volts.
(1) Under/over voltage relay (11, figure 15-9)
(a)
Connect the under/over voltage
device as shown in figure 15-10.
(b)
Close S1, adjust variac for 110V
AC on AC voltmeter.
(c) With ohmmeter connected between
terminals 5 and 7, reduce AC
voltage. Relay should trip at 103V
AC at this point, ohmmeter will no
longer show continuity.
BR2 fuse
BR3 fuse
BR4 fuse
Unit 1 fuse
Unit 2 fuse
Unit 3 fuse
Unite 4 fuse
MR1 fuse
MR2 fuse
MR3 fuse
MR4 fuse
Nut
Screw
Fuse holder
Plate, "normal Power"
Plate, "return"
Plate, "freq. select"
Plate, "AC-15A"
Plate, "BR1-5A"
Plate, "BR2-5A"
Plate, "BR3-5A"
Plate, "BR4-5A"
Plate, "unit 1DC-5A"
Plate, "unit 2DC-5A"
Plate, "unit 3DC-5A"
Plate, "unit 4DC-5A"
Plate, "MR1-5A"
Plate, "MR2-5A"
Plate, "MR3-5A"
Plate, "MR4-5A"
Fuse panel
Box assy
(e) Increase voltage. Relay should trip
at 132V AC. Ohmmeter will no
longer show continuity.
b. Replacement.
WARNING
REMOVE 120V AC POWER PRIOR TO MOVING AND
REPLACING DEVICE.
15-14
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 15-10. Under/Over Voltage Relay, Test Setup
Under/overvoltage relay (11, figure 15-9) is
removed as follows:
(1)
(2)
(3)
adjusted with the adjustment screw on the device. Test
and replace as follows:
Disconnect and tag wires to
under/overvoltage
device
terminal
board.
Remove four screws and washers.
Remove device.
Replace under/overvoltage device by
attaching to panel with four screws and
washers. Connect wires and remove
tags.
15-17. UNDERFREQUENCY RELAY. (10, figure 15-9).
The device is adjustable within the range specified in the
tabulated data in Chapter 1 of the Operator and
Organizational Maintenance manual. Test numbers given
in the procedures below are nominal. Trip setting is
15-15
a.
Test.
(1) Connect underfrequency relay as shown
in figure 15-11. Switch S1 closed.
(2)
Adjust variable frequency generator for
50 Hz output.
(3)
With ohmmeter connected between
terminals 5 and 7, adjust frequency
generator to 48.5 Hz. Relay should trip
as frequency is decreased. Ohmmeter
will no longer show continuity.
(4)
Open switch S1.
Adjust frequency
generator for 60 Hz output.
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 15-11. Underfrequency and Overfrequency-Relay, Test Setup
(5) Decrease frequency generator frequency
to 58. 2 Hz. With ohmmeter connected
between terminals 5 and 6, relay should
trip at 58. 2 Hz (57. 7 to 58. 7 Hz), at
which time ohmmeter will no longer
show continuity.
b.
and washers.
remove tags.
Connect wires and
(6) Turn adjustment screw clockwise to raise
trip point.
15-18. OVERFREQUENCY RELAY. The overfrequency
relay (9,. figure 15-9) is adjustable within the range
specified in the tabulated data in Chapter 1 of the
Operator and Organizational Maintenance manual. Trip
setting is adjusted with the adjustment screw on the
device. Test the device as follows: a. Test.
Replacement. The underfrequency relay (10,
figure 15-9) is removed and replaced a follows:
(1) Connect overfrequency relay as shown in
figure 15-11.
(1)
Disconnect and tag wires connected to
the underfrequency terminal board.
(2)
Adjust variable frequency generator for
50. 0 Hz output. Close switch SI.
(2)
Remove four screws and washers.
Remove device (10) from panel (7).
(3)
(3)
Replace underfrequency relay (10) by
attaching to panel (7) with four screws
With ohmmeter connected between
terminals 5 and 7, adjust frequency
generator to 51. 5 Hz (51 to 52). At
this point, relay should trip. Ohmmeter
will no longer show continuity.
15-16
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(4) Open switch S1.
(5) Set frequency generator output to 60. 0
Hz and connect ohmmeter between
terminals 5 and 6; ohmmeter should
indicate continuity. Increase frequency
generator output to 61. 8 Hz; relay
should trip at 61. 8 Hz (61. 3 to 62. 3)
and ohmmeter indicate infinite ohms.
(6) Turn adjustment screw clockwise to raise
trip point.
(1)
Disconnect and tag wires connected to
the time delay relay.
(2)
Remove four screws and washers.
Remove relay from panel (7).
(3) Replace relay (19) by attaching to panel
(7) with four screws and washers.
Connect wires and remove tags.
15-20. RELAYS (BR1-BR4, MR1-MR4, RR). BR1-BR4,
MR1-MR4 (14, figure 15-9) and RR (20) relays are
mounted on panel (7).
b. Replacement. The overfrequency relay (9) is
removed and replaced as follows:
a. Test.
(1)
Disconnect and tag wires connected to
the overfrequency terminal board.
(1) Connect a 120V AC power source to relay
coil as shown in figure 15-13.
(2)
Remove four screws and washers.
Remove device from panel (7).
(2) Check that normally open contacts close
and normally closed contacts open relay
coil is energized, by verifying ohmmeter
indication of 'zero' with contacts closed
and 'infinity' with contacts open.
(3) Replace relay (9) by attaching to panel
(7) with four screws and washers.
Connect wires and remove tags.
b. Replacement. Relays (14 and 20, figure 15-9)
are removed and replaced as follows:
15-19. TIME DELAY RELAY. The time delay relay (19,
figure 15-9) is a "delay on drop-out" type relay, set for 1.
5-15 seconds delay. The relay is adjustable within the
range specified in the tabulated data in Chapter 1 of the
Operator and Organizational Maintenance manual.
Timing is adjusted with the calibrated dial on the relay.
Test and replace relay as follows:
(1)
(2) Remove two screws and two washers for
each relay, remove relay from panel (7).
(3) Replace relay (14 or 20) by attaching the
panel (7) with two screws and washers.
Connect wires and remove tags.
a. Test.
(1) Connect the time delay relay as shown in
figure 15-12.
(2) Momentarily close switch S1. Lamp DS1
will light and remain lit for 1. 5-15
seconds.
Disconnect and tag wires connected to
relays.
15-21. RELAYS (LR1-LR4, LRTD1-LRTD4). Relays LR1LR4 (15, figure 15-9) and LRTD1-LRTD4 (13) are
mounted on relay panel (7).
a. Test.
(3) Turn calibrated dial clockwise to increase
timing.
b. Replacement. Remove and replace time delay
relay (19) as follows:
15-17
(1) Connect a 24V DC power supply across
coil of relay as shown in figure 15-14.
(2) Check that normally open contacts close
and normally closed contacts open
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
instantly on LR relays, by verifying
ohmmeter indication.
b. Replacement. Remove and replace time delay
relay (12) as follows:
(3) Check that normally open contacts close
and normally closed contacts open after a
time delay of . 2-20 seconds on LRTD
relays. The LRTD relays are adjustable
from . 2-20 seconds.
NOTE
The LRTD relays are designed for
horizontal mounting. When testing, it
must be placed in this position to
operate properly.
Disconnect and tag wires connected to
relay.
(2)
Remove four screws and washers.
Remove relay from panel (7).
(3) Replace relay (12) by attaching to panel
(7) with four screws and washers.
Connect wires and remove tags.
b. Replacement. Relays (15, 13, figure 15-9) are
removed and replaced as follows:
(1)
Disconnect and tag wires to relays.
(2)
(1)
15-23. TIME DELAY RELAY. (UTR) (17, figure 15-9) is a
time delay on energize type relay set for 5 minutes delay.
The relay is adjustable within 3-30 minutes and prohibits
load to be transferred back to utility power until timed out.
Remove two screws and two washers.
Remove relay from panel (7).
(3) Replace relay (15) by attaching to panel
(7) using two screws and washers.
Connect wires and remove tags.
15-22. TIME DELAY RELAY. (SDT) (12, figure 15-9) is a
delay on a drop-out type relay set for 5 minute delay. The
relay is adjustable within 1-300 seconds and allows the
engines to cool down after load has been removed.
a. Test.
(1) Connect the relay as shown in figure 1512.
(2) Close switch S1. The lamp DS1 will not
light until the relay has timed out (5
minutes).
b. Replacement. Remove and replace relay (17)
as follows:
(1) Disconnect and tag wires to relay.
a. Test.
(1) Connect a 24V DC supply to L1(-) and
L2(+) as shown in figure 15-15.
(2)
(2) With ohmmeter across terminals 5 and 3
note that resistance reading does not
change until 5 minutes after power has
been applied.
(3) Replace relay (17) by attaching to panel
(7) with four screws and washers.
Connect wires and remove tags.
15-18
Remove four screws and washers.
Remove relay from panel (7).
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 15-12. Time Delay Relay, Test Setup
Figure 15-13. Relay Test Setup
15-19
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 15-14. LR, LRDT, Test Setup
Figure 15-15. SDT Timer Test Setup
15-20
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Section IV. HOUSING KIT
15-24. GENERAL. The housing kit encloses the top,
sides, and ends of the generator set and is removable to
provide access for overhaul or replacement of major
components of the generator set.
The housing is
attached to the base assembly and the support frame
assembly. With the housing kit installed the generator set
can be operated at ambient temperatures from 125 F
(51.7 C) down to -25 F (-31.7 C). The housing doors
allow access to the inside of the generator set. The
shutter assembly at the radiator end of the generator set
is automatically controlled and helps in maintaining
correct temperatures of the generator set. Major portions
of the housing kit include panels, doors, shutters,
electrical harness, and necessary hardware items to
assemble the housing kit.
The troubleshooting
procedures contained in table 5-8, of the Operator and
Organizational Maintenance manual completely isolate
any faults that may occur.
Test and adjustment
procedures are contained in this section.
15-25.
INSTALLATION.
Install housing kit in the
following sequence: door and shutter assembly, right
side, front (radiator end), left side, rear, top, and electrical
harness.
(4)
Install spacer (14) and bracket (17) on
door with four screws (7), washers (9),
and nuts (8) attaching clamp (40) with
the same hardware. Install actuator (6)
on bracket (17) with two clamp
assemblies (1), washers (2), and nuts
supplied with clamp assembles (1).
Install rod (5) with pin (4) onto actuator
(6) shaft and through hole in bracket
(25), then secure with quick-release pin
(3).
(5)
Install switch support (21) with spacers
(23) and shim (22) and switch cover (16)
using two screws (18), washers (20), and
nuts (19). Install switch (15) onto switch
support (21) with its attaching hardware.
Line up toggle switch (15) with slot in
bracket (25), so that lateral movement of
shutters will actuate switch.
(6) Install chain (28) with screw (26) and nut
(27).
(7)
a.
Door and Shutter Assembly. There are four
door and shutter assemblies (figure 15-16).
Two are for the right side of the generator set,
and two are for the left side. Assemblies are
similar, except that the lower actuator
assemblies are mounted in different locations,
depending upon right-hand or left-hand door
location. Assemble two right-hand doors as
follows:
(1) Attach shutter assembly (32, figure 15-16)
to door (39) with screws (29), washers
(31), and nuts (30).
(2) Attach both brackets (13) to drive support
bracket (17) with four flat head screws
(10), washers (12), and nuts (11).
(3) Install bracket (25) to control bar (36) with
two screws (24).
15-21
This completes assembly of right-hand
doors. Left-hand doors are similarly
assembled, except actuator mechanism
is on the opposite side.
b. Right Side. Refer to figure 5-17 and install as
follows:
(1)
Attach upper side panel (42) to the
support frame with nine screws (39),
washers (41), and nuts (40).
(2) Attach lower side panel (35) to the base
assembly with nine screws (32),
washers (34), and nuts (33); and one
screw (59), washer (34), and nut (33).
(3)
Attach side panel (54) to the support
frame (at the top and bottom only) with
five screws (52), and nuts (53). Install
two screws (36), washers (38),
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
1. Clamp
2. Lockwasher
3. Quick-release pin
4. Dowel pin
5. Drill rod
6. Actuator
7. Screw
8. Nut
9. Lockwasher
10. Screw
11. Nut
21. Switch support
12. Lockwasher
22. Shim
13. Bracket
23. Spacer
14. Spacer
24. Screw
15. Switch
25. Bracket
16. Switch cover
26. Screw
17. Bracket
27. Nut
18. Screw
28. Chain assy
19. Nut
29. Screw
20
Lockwasher
Figure 15-16.
Housing Kit, Door and Shutter Assembly
15-22
31.
32.
33.
34.
35.
36.
37.
38.
39.
30.
Lockwasher
Shutter assy
Bolt
Bolt with lock
Arm
Control bar
Vanes
Hook
Access door
Nut40. Clamp
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
and nuts (37) joining side panel (54) and upper side panel (42).
(4) Install side panel (45) to support frame with eleven screws (43) and nuts (44). Install two screws (39),
washers (41), and nuts (40) joining side panel (45) and upper side panel (42).
(5) Similarly, install side panel (51) with eleven screws (49), and nuts (50) to support frame. Add two screws
(29), washers (31), and nuts (30) to attach side panel (51) to lower side panel (35), and attach two clamps
(58) with the same hardware.
NOTE
Clamps (17, 23 and 31A) are used to secure louver wiring harness (3, figure 15-23)
(6) Install side panel (48) to support frame (at the top and bottom only) with five screws (46), and nuts (47).
Install two screws (29), washers (31), and nuts (30) joining lower side panel (35) and side panel (48)
together.
(7) Install top side panel (28) to support frame with nine screws (25), washers (27), and nuts (26).
(8) Install bottom side panel (24) to support frame with nine screws (20), washers (22), and nuts (21). Use the
same hardware to attach three clamps (23).
NOTE
Door and shutter assemblies are left-hand and right-hand assemblies. (Two left-hand
assemblies on left side of housing and two right-hand assemblies on right side of housing).
Use correct door assembly.
(9) Install right-hand preassembled door and shutter assembly (19) by attaching hinge to side panel (54) with
twelve screws (14), washers (15), and nuts (16). Using the same hardware, attach two clamps (17). Attach
door holder rod (18); then close loop ends.
(10) Similarly, install other right-hand pre-assembled door and shutter assembly (19) to side panel (51) with
hinge attached with twelve screws (14), washers (15), and nuts (16). Using the same hardware attach one
clamp (17). Attach door holder rod (18); then close loop ends.
NOTE
All access doors (two on each side of housing) are different. Identify and locate by comparing
to illustrations.
(11) Install access door (8) by attaching hinge to side panel (45) with twelve screws (1), washers (2), and nuts
(3). Attach rod holder (18); then close loop ends.
(12) Similarly, install the other access door 98) by attaching hinge to side panel (48) with twelve screws (1),
washers (2), and nuts (3). Attach door holder rod (18); then close loop ends.
(13) Install relay assembly (4) in the external power box with four screws (5), washers (7), and nuts (6). Install
DC wiring diagram plates (10 and 11) and DC schematic plate (12) using eighteen rivets (9).
(14) Attach corner post (57) to support frame with eight screws (55) and washers (56) and install three screws
(52) and nuts (53) attaching corner post (57) to support frame at the bottom.
c. Front. See figure 15-18 and install as follows:
(1) Install identification plate (32) to enclosure panel (30) with two rivets (31).
15-23
Figure 15-17. Housing Kit, Right side
15-24
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND FOR FIGURE 15-17
1. Screw
2. Washer
3. Nut
4. Screw
5. Screw
6. Nut
7. Washer
8. Access door
9. Rivet
10. DC wiring diagram
11. DC wiring diagram
12. DC schematic plate
13. Stripping
14. Screw
15. Washer
16. Nut
17. Clamp
18. Door holder road
19. Soor and shutter assy
20. Screw
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
Nut
Washer
Clamp
Bottom panel
Screw
Nut
Washer
Top side panel
Screw
Nut
Washer
Screw
Nut
Washer
Lower side panel
Screw
Nut
Screw
Screw
Nut
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
Washer
Upper panel
Screw
Nut
Side panel
Screw
Nut
Side panel
Screw
Nut
Side panel
Screw
Nut
Side panel
Screw
Washer
Post
Clamp
Screw
(2) Line up panel (23) with right side post and attach with eight screws (18) and washers (20). Install two
screws (21) and washers (22) at bottom of panel (23) through base assembly.
(3) Line up panel (27) with left side post and attach with eight screws (24) and washers (26). Install two screws
(21) and washers (22) at bottom of panel (27) through base assembly
(4) Attach sides of upper panel (17) to panels (23 and 27) with two screws (14), washers (16) and nuts (15) per
side.
(5) Install enclosure panel (30) to base assembly with twelve existing screws (28) and washers (29).
(6) Install support frame (13) at sides on panels (23 and 27), with seven screws (9), washers (11 and 12), and
nuts (10), per side. (Use five (5) sets of hardware for code 'B').
(7) Install support frame (13) on panels (17 and 30) with seven screws (9), and washers (11 and 12), at the
top; and six screws (9), and washers (11 and 12), at the bottom.
(8) Install exhaust shutter (8) and grille (7) to support frame (13) with 28 screws (1), washers (3 and 33), and
nuts (2).
(9) Install two chain assemblies (6) with screws (4) and nuts (5).
d. Left Side. Refer to figure 15-19 and install as follows:
(1) Attach upper side panel (36) to support frame with nine screws (33), washers (35), and nuts (34).
(2) Attach lower side panel (29) to the base assembly with nine screws (25), washers (28), and nuts (27); and
one screw (26), washer (28), and nut (27).
(3) Attach side panel (42) to the support frame (at the top and bottom only) with five screws (40) and nuts (41).
Install two screws (30), washers (32), and nuts (31) joining side panel (42) and upper side panel (36).
(4) Install side panel (48) to support frame with eleven
15-25
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Screw
Nut
Lockwasher
Screw
Nut
Chain assy
Grille
Exhaust shutter
Screw
Deleted
Lockwasher
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Washer
Support frame
Screw
Nut
Washer
Upper panel
Screw
Deleted
Washer
Screw
Washer
Figure 15-18. Housing Kit Front
15-26
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Panel, LH
Screw
Deleted
Washer
Panel, RH
Screw
Washer
Enclosure
Rivet
Identification plate
Washer
Figure 15-19. Housing Kit, Left Side
15-27
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND FOR FIGURE 15-19
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Screw
Deleted
Washer
Nut
Clamp
Stripping
Door LH
Door holder rod
Door and shutter assy
Rivet
AC wiring diagram
AC wiring diagram
AC schematic plate
Screw
Nut
Washer
Bottom side panel
Screw
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
Nut
Washer
Top side panel
Screw
Nut
Washer
Screw
Screw
Nut
Washer
Lower side panel
Screw
Nut
Washer
Screw
Nut
Washer
Upper side panel
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
Screw
Nut
Side panel
Screw
Nut
Side panel
Screw
Nut
Side panel
Screw
Nut
Side panel
Screw
Washer
Post
Clamp
Clamp
screws (46) and nuts (47). Install two screws (30), washers (32), and nuts (31) joining side panel (48) and
upper side panel (36).
(5) Similarly, install side panel (39) with five screws (40) and nuts (38) to support frame. Add two screws (22),
washers (24), and nuts (23) to attach side panel (39) to lower side panel (29). Use same hardware to
attach two clamps (24A).
NOTE
Clamps (5, 52 and 53) are used to secure louver wiring harness (3, figure 15-23).
(6) Install side panel (45) to support frame (at the top and bottom only) with five screws (43) and nuts (44).
Install two screws (22), washers (24), and nuts (23) to join side panel (45) and lower side panel (29).
(7) Install top side panel (21) to support frame with nine screws (18), washers (20), and nuts (19).
(8) Install bottom side panel (17) to support frame with nine screws (14), washers (16), and nuts (15). Use
same hardware to attach three clamps (16A).
(9) Install pre-assembled door and shutter (9) by attaching hinge to side panel (42) with twelve screws (1),
washers (5), and nuts (4). Use same hardware to attach two clamps (5). Attach door holder rod (8); then
close loop ends.
(10) Similarly, install the other pre-assembled door and shutter assembly (9) to side panel (39) with twelve
screws (1), washers (3), and nuts (4). Use same hardware to attach one clamp (5). Attach door holder rod
(8); then close loop ends.
(11) Install access door (7) by attaching hinge to side panel (48) with twelve screws (1), washers (5) and nuts
(4). Attach door holder rod 98); then close loop ends.
(12) Similarly, install the other access door (7) by attaching hinge to side panel (45) with twelve screws (1),
washers (3), and nuts (4). Attach door holder rod (8); then close loop ends.
(13) Install AC wiring diagrams (11 and 12) and AC schematic (13)
15-28
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
to access door (7) with eighteen rivets (10).
(14) Attach corner post (51) to support frame with eight screws (49) and nuts (50); and install three screws (37)
and nuts (38) attaching corner post (51) to support frame at the bottom.
e. Rear. Refer to figure 15-20 and install as follows:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Attach corner post (36) to support frame with screws (34) and washers (35).
Similarly, attach corner post (39) to frame with screws (37) and washers (38).
Install upper panel (33) to both corner posts (36 and 39) with six screws (30), washers (32), and nuts (31).
Attach lower panel (24) to panel (20) with six screws (17) and washers (18). Attach bottom of panel (24) to
top of panel (29) with seven screws (21), washers (22) and nuts (23). These three panels will be installed
later on.
Install right-hand panel (12) to corner post (36) and upper panel (33) with ten screws (10).
Similarly, install left-hand panel (15) to corner post (39) and upper panel (33) with ten screws (13).
Install panels (20, (24), and (29) pre-assembled in step (4) by attaching to the base assembly with four
screws (25), nuts (48), washers (26); and four screws (27), and washers (28). Bolt right-hand panel (12) to
panel (20) with three screws (17), washers (18), and nuts (19). Bolt panel (24) to right-hand panel (15) with
three screws (10). Bolt left-hand panel (15) bottom to panel (24) with three screws (10). Bolt ends of panel
(24) to corner posts (36 and 39) with four screws (21), washers (22) and nuts (23). Install twelve screws
around fuel tank filler neck area. Bolt panel (20) to left-hand panel (15) with three screws (17), washers
(18), and nuts (19).
Install access door (9) to right-hand panel (12) with six screws (4) and nuts (5). Attach door holder rod (6);
then close loop ends.
Install operating instructions plate (8) to access door (9) with six rivets (7).
Install access door (3) to left-hand panel (15) with six screws 91) and nuts (2). Attach door holder rod (6);
then close loop ends .
Assemble cover and sleeve assembly by attaching sleeve (41) to cover slate panel (47) with bushing (40)
and retainer plate (44) fastened with four screws (42) and nuts (43). Attach assembled panel to panel (20)
with fourteen screws (45) and nuts (46).
f. Top. Refer to figure 15-21, partially disassemble muffler assembly, and install housing kit top, as follows:
(1) Refer to detail A of figure 15-21, remove eight screws and washers from the muffler support brackets as
indicated.
NOTE
Retain screws and washers; they will be replaced later on.
(2) Install panel (34) to support frame with fifteen screws (31) and washers (32).
15-29
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 15-20. Housing Kit, Rear
15-30
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND FOR FIGURE 15-20
Screw
25.
Screw
Nut
26.
Washer
Access door
27.
Screw
Screw
28.
Washer
Nut
29.
Washer
Door holder rod
30.
Screw
Rivets
31.
Nut
Operating instructions plate
32.
Washer
Access door
33.
Upper rear panel
Screw
34.
Screw
Deleted
35.
Washer
Rear panel
36.
Corner Post, LH
Screw
37.
Screw
Deleted
38.
Washer
Rear panel
39.
Corner post, RH
Stripping
40.
Bushing
Screw
41.
Sleeve
Washer
42.
Screw
Nut
43.
Nut
Rear panel
44.
Retainer plate
Screw
45.
Screw
Washer
46.
Nut
Nut
47.
Cover plate
Lower rear panel
48.
Nut
NOTE
Fasten front of panel with the top panel located over the control cubicle.
(3) Install panel (30) to support frame with ten screws (28) and nuts (29). Install five screws only on each
outside edge of panel (30).
(4) Radiator access door (10) must be attached to panel (7) by first assembling and attaching stud receptacle
(13). Insert stud (13A) into receptacle (13) and secure stud with cross pin (13B). Attach stud receptacle
(13) to panel (7) with two rivets (12). Next install access door (10) with its seal (11) to panel (7) with three
screws (8) and nuts (9).
(5) Install panel (7) (with radiator access door installed) to support frame with nineteen screws (5) and washers
(6). Install screws only in outer edges of panel (7).
NOTE
Be sure to line up front of panel (7) with top of panel located over shutter assembly.
(6) Install panel (16) onto support frame with twenty screws (14) and nuts (15). Install screws on edge nearest
muffler assemblies, and on both side edges.
(7) Panel (23) must be located under muffler assemblies. Carefully lift both muffler assemblies (just enough
to allow panel (23) to slip under) and locate panel (23) over support frame holes. Line up muffler assembly
brackets with holes. Attach panel (23) with sixteen screws (21) and nuts (22). Do not install screws on
front end of panel at this time.
(8) Replace the eight screws and washers, previously removed, on the muffler assembly brackets.
(9) Install strip (4), over panels (7) and (16), with twenty
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
15-31
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 15-21. Housing Kit, Top (Sheet 1 of 2)
15-32
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
LEGEND FOR FIGURE 15-21
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Screw
Nut
Washer
Strip
Screw
Washer
Front panel
Screw
Nut
Access door
Seal
Rivet
Receptacle
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Screw
Nut
Panel
Screw
Nut
Washer
Panel
Screw
Nut
Formed panel
Nut
Nut
Washer
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
Figure 15-21. Housing Kit, Top (Sheet 2 of 2)
15-33
Strip
Screw
Nut
Formed panel
Screw
Washer
Deleted
Panel
Stud
Crosspin
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 15-22. Housing Kit, Shutter Assembly
15-34
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
screws (1), washers (3), and nuts (2). In the one hole at each end of the strip (4), install one screw (14),
and nut (15).
(10) Similarly, install strip (27) over panels (34) and (30), with screws (24 and 28), washers (26), and nuts (25
and 29).
(11) Install panel (20) with eighteen screws (17), washers (19), and nuts (18).
(12) Walkway tread (detail A, figure 15-21) is a nonskid walkway compound MIL-W-5044B, Type II. Color is
FED-STD-595, No. X24087. Install in accordance with dimensions shown in detail A.
g. Shutter Assembly. Refer to figure 15-22 and install as follows:
(1) Attach control assembly (12) to shutter frame (17) with four screws (11).
(2) Attach rod (10) to control (12) with cotter pin (9).
(3) Mount studs (14) in control bar (13) and install control bar (13) in angle (15).
(4) Mount control block (8) to bar (13) with bolt (7).
(5) Attach lever (5) to angle (15) with bolt (2) and nut (3).
(6) Install pin (4) in lever (5) and control bar (13).
(7) Assemble vanes (16).
(8) Install cotter pins (9), assemble springs (1 and 6).
(9) Install connectors (20) in control (12) then connect hoses (19 and 20).
(10) Connect other end of hose (18) to elbow (22). Connect other end of hose (19) to connector (21). Install
two hose clamps (17A) using existing hardware.
(11) Fill radiator with coolant in accordance with paragraph 13 b, Operator and Organizational Maintenance
manual.
h. Electrical Harness. See figures 15-23 and fold outs FO-14 and FO-15. The electrical harness assembly for the
housing kit louver control consists of two harnesses and a relay assembly. The relay assembly is mounted in the
external power box with a harness connecting it to the other terminal boards in the external power box, and an
electrical connector to be installed in an existing opening in the external power box enclosure. The other harness
connects from the external power box to louver actuators and their switches and is secured with clamps using
existing hardware. Figure 15-23 is the wiring harness installation and FO14 and FO-15 are the wiring
information. Install as follows:
(1) Install the relay assembly (1) in the external power box as specified in paragraph 15-25 b, step (13).
(2) On external power box assembly enclosure wall, remove plate covering existing hole (next to electrical
connectors) and install connector J32 of harness (2) on wall.
(3) Refer to figure 15-23 and connect this harness as shown to terminal board TB303 on relay assembly and
terminal boards TB202 and TB203 on external power box assembly rear wall.
(4) Install harness (3) with sixteen clamps (4) using existing hardware.
(5) Connect Jacks and connectors to the respective actuators and switches located on the four door and
shutter assemblies. Connect P32 to connector installed in step (2).
15-35
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NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 15-23. Housing Kit Wiring
15-26. REMOVAL. Remove housing kit in the following sequence: Electrical harness, top, rear, left side, front (radiator
end), and right side.
a. Electrical Harness. See figures 15-23 and fold outs FO-14 and FO-15.
WARNING
TURN OFF ALL POWER
(1) Disconnect jacks and connectors from louver actuators and switches.
(2) Remove all clamps (4) securing harness (3) to housing kit structure.
(3) Disconnect J32 from external power box assembly. Remove harness.
(4) Disconnect harness (2) (in external power box assembly) from TB303 on relay assembly (1) and TB202
and TB203 in the rear wall of external power box assembly.
(5) Remove relay assembly (1) from rear wall of external power box assembly. Restore existing hardware.
(6) Remove connector J32 on harness (2) from wall of external power box assembly enclosure.
(7) Cover hole (created by removing connector J32) with plate.
(8) Remove harness (2).
15-36
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b. Shutter Assembly. See figure 15-22 and remove shutter assembly as follows:
(1) Remove grille (7), (figure 15-18) by removing hardware, (1, 2, 3, 33). Open draincock (33, figure 7-1), and
drain coolant into suitable container.
(2) Disconnect hoses (18, 19, 25, Figure 15-22) from actuators (12).
(3) Remove two hose clamps (24) and replace the hardware that secured them. Remove hoses (23 and 19)
and connectors (21). Place plug after removing connectors (21) in radiator (86), (figure 7-1).
(4) Remove shutter assembly (8) figure 15-18, by removing screws (1), nuts (2), washers (33) and support (13)
with screws (9), washers (11, 12) and nut (10).
c. Top. Refer to figure 15-21 and remove housing kit top as follows:
(1) Remove strip (4) by removing screws (1), washers (3), and nuts (2); and screws (14) and nuts (15).
(2) Similarly, remove strip (27) by removing screws (24), washers (26), and nuts (25); and screws (28) and
nuts (29).
(3) Remove panel (20) by removing screws (17), washers (19), and nuts (18).
(4) Referring to detail A in figure 15-21, remove the eight screws and washers from the muffler support
brackets as shown.
NOTE
Retain screws and washers. The will be replaced later on.
(5) Remove screws (21) figure 5-21 and nuts (22) attaching panel (23) to support frame. Now carefully lift
both muffler assemblies (just enough to allow panel to slip out) and remove panel (23)
(6) Replace the eight screws and washers, previously removed, on the muffler assembly brackets.
(7) Remove panel (16) by removing screws (14) and nuts (15).
(8) Remove panel (7) by removing screws (5) and washers (6).
(9) If so desired, remove radiator access door (10) by removing screws (8), nuts (9), and seal (11). Remove
stud receptacle (13) and its stud and pin by removing rivets (12).
(10) Remove panel (30) by removing screws (28) and nuts (29).
(11) Remove panel (34) by removing screws (31) and washers (32).
d. Rear. Refer to figure 15-20 and remove as follows:
(1) Disassemble cover and sleeve assembly by removing plate (47) from housing by removing screws (45)
and nuts (46). Disassemble sleeve (41), bushing (40), and retainer plate (44) by removing screws (42) and
nuts (43).
(2) Remove access door (3) by first opening loop ends on door holder rod (6) and then removing rod and
screws (1) and nuts (2).
(3) Remove access door (9) by first opening loop ends on door holder (6) and then removing rod, screws (4)
and nuts (5).
(4). Remove all three panels (20, 24, and 29) as a unit. Remove screws (17), washers (18), and nuts (19)
which secure panel (12) to panel (24). Remove screws (21), washers (22) and nuts (23) which secure
panel (24) at each end to corner
15-37
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NAVFAC P-8-631-34
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posts (36 and 39). Remove screws (17), washers (18), and nuts (19) which secure panel (12) to panel (20).
Remove screws (13) which secure left-hand panel (15) to bottom panel (24). Remove screws around fuel
tank filler neck area. Remove screws (13) left-hand panel (15) which secure panel (20). Remove screws
(25), washers (26), and nuts (48); and screws (27) and washers (28) securing panel (29) to base assembly.
(5) Remove right-hand panel (12) from corner post (36) and upper panel (33) by removing screws (10).
(6) Similarly, remove left-hand panel (15) from corner post (39) and upper panel (33) by removing screws
(13).
(7) Disassemble panels (20, 24 and 29). Remove screws (17), and washers (18) which secure panel (20) to
panel (24). Remove screws (21), washers (22), and nuts (23) which secure panel (24) to panel (29).
(8) Remove upper panel (33) from corner posts (36 and 39), by removing screws (30), washers (32), and nuts
(31).
(9) Remove corner post (36) from support frame by removing screws (34) and washers (35).
(10) Similarly, remove other corner post (39) by, removing screws (37) and washers (38).
e. Left Side. Refer to figure 15-19 and remove as follows:
(1) Remove corner post (51) by removing screws (37), and nuts (38); and screws (49) and washers (50) which
secure the post to the support frame.
(2) Remove access door (7) by first opening loop ends on door holder rod (8) and then removing rod, screws
(1), and washers (3), and nuts (4).
(3) Similarly, remove the other access door (7) by first opening loop ends on door holder rod (8) and then
removing rod, screws (1), washers (3), and nuts (4).
(4) Remove door and shutter assembly (9) by first opening loop ends on door holder (8) and then removing
rod, screws (1), washers (3), nuts (4), and clamps (5).
(5) Similarly, remove the other door and shutter assembly by first opening loop ends on door holder rod (8),
then removing rod, screws (1), washers (3), nuts (4), and clamps (5).
(6) Remove bottom side panel (17) by removing screws (14), washers (16), nuts (15), and clamps (16A).
(7) Remove top side panel (21) by removing screws (18), washers (20), and nuts (19).
(8) Remove side panel (45) by removing screws (43) and nuts (44) from support frame, and remove screws
(22), washers (24), and nuts (23) from panel (29).
(9) Remove side panel (48) from support frame by removing screws (46) and nuts (47). Remove screws (30),
washers (32), and nuts (31) from panel (36).
(10) Similarly, remove side panel (39) from support frame by removing screws (40) and nuts (38). Also remove
screws (22), clamps (53), washers (24), and nuts (23) from end of panel (29).
(11) Remove side panel (42) from support frame by removing screws (40) and nuts (41).
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Also remove screws (30), washers (32), and nuts (31) from end of panel (36).
(12) Remove lower side panel (29) from base assembly by removing screws (25), washers (28), and nuts (27);
and one screw (26), washer (28), and nut (27).
(13) Remove upper side panel (36) from support frame by removing screws (33), washers (35) and nuts (34).
f. Front. Refer to figure 15-18 and remove as follows:
(1) Remove screws (4), nuts (5), and chain assemblies (6). Remove shutter (8) and grille (7) from support
frame (13) by removing screws (1), nuts (2), and washers (3 and 33).
(2) Remove support frame (13) by removing seven screws (9) and washers (11 and 12) from top flange and
six screws (9), and washers (11 and 12) from bottom flange; and remove seven screws (9), washers (11
and 12), and nuts (10) from each side flange.
(3) Remove enclosure panel (30) from base assembly by removing screws (28) and washers (29), and replace
hardware in base assembly.
(4) Remove upper panel (17) by removing screws (14), nuts (15), and washers (16).
(5) Remove right-hand panel (23) from right side post by removing screws (18), and washers (20); and from
base assembly by removing screws (21) and washers (22).
(6) Remove left-hand panel (27) from left side post by removing screws (24), and washers (26); and from base
assembly by removing screws (21) and (22).
g. Right Side. Refer to figure 1'5-17 and remove as follows.
(1) Remove corner post (57) by removing screws (52) and nuts (53); and screws (55) and washers (56) which
secure the post to the support frame.
(2) Remove access doors (8) by first opening loop ends on door holder rod (18), then removing rod, screws
(1), washers (2), and nuts (3).
(3) Remove door and shutter assemblies (19) by first opening loop ends on door holder rods (18), then
removing rod. Remove screws (14), washers (15), nuts (16), and clamps (17).
(4) Remove bottom side panel (24) from support frame by removing screws (20), washers (22), nuts (21) and
clamps (23).
(5) Remove top side panel (28) from support frame by removing screws (25), washers (27), and nuts (26).
(6) Remove side panel (48) from support frame by removing screws (46) and nuts (47). Also remove screws
(29), washers (31), and nuts (30) from lower side panel (35).
(7) Remove side panel (45) from support frame by removing screws (43) and nuts (44). Also remove screws
(36), washers (38), and nuts (37) from panel (42).
(8) Similarly, remove side panel (51) by removing screws (29), washers (31), nuts (30), and clamps (31A) from
panel (35).
(9) Remove side panel (54) from support frame by removing screws (52) and nuts (53). Also remove screws
(36), washers (38), and nuts (37) from upper side panel (42).
(10) Remove lower side panel (35) from base assembly by removing screws (32), washers (34), and
15-39
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NAVFAC P-8-631-34
TO-35C2-3-463-2
nuts (33); and one screw (59), washer (34) and nut (33).
(11) Remove upper side panel (42) from support frame by removing screws (39), washers (41), and nuts (40).
h. Door and Shutter Assembly. Refer to figure 15-16 and disassemble the door and shutter assembly as follows:
NOTE
The following procedure is for right-hand doors. The disassembly of left-hand doors is similar,
except that the actuator mechanism is on the opposite side.
(1) Remove chain (28) by removing screw (26) and nut (27).
(2) Remove switch cover (16), switch support (21), spacer (23), and shim (22) by removing screws (18),
washers (20), and nuts (19). Unsolder wires from switch (15) and remove switch.
(3) Remove electrical connector on actuator (6). Remove actuator (6) from bracket (17) by removing clamps
(1), washers (2), and nuts. Remove quick-release pin (3) and pin (4) from rod (5) and remove from
actuator shaft.
(4) Remove bracket (17) spacer (14) and clamp (10A) from door by removing screws (7), nuts (8) and washers
(9).
(5) Remove brackets (13) from bracket (17) by removing screws (10), washers (12), and nuts (11).
(6) Remove shutter assembly (32) from door by removing screws (29), washers (31), and nuts (30).
5-27. REPAIR AND ADJUSTMENT
a. Sheet metal tears in doors, covers, and panels can be repaired by welding.
b. 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.
(2) Clean area with Federal Specification P-D-680 solvent and wipe dry with clean cloth.
(3) Treat area and paint in accordance with service requirements.
c. Replace any cover, door, panel, or hardware that is damaged beyond repair.
d. Adjust louver actuators in accordance with paragraph 15-28a.
e. Adjust radiator shutter actuators in accordance with paragraph 15-28b.
15-28. LOUVER ACTUATORS. The following paragraphs provide test, adjustment and replacement instructions for the
four identical louver actuators (6, figure 15-16) which are installed with the housing kit.
a. Test.
(1) Connect the positive lead of 24V DC power source to the black lead of the actuator, and the negative lead
of the power source to the orange lead of the actuator. The actuator piston should extend.
(2) Reverse the leads of the power source. The actuator piston should retract.
b. Adjustment. Refer to figure 15-16 and adjust the louver actuators by adjusting the switch support (21) of toggle
switch (15) so that the switch closes
15-40
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NAVFAC P-8-631-34
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when the shutters are fully open.
c. Replacement. Remove the actuators in accordance with paragraph 15-26h and replace them in accordance with
paragraph 15-25a.
15-29. LIMIT SWITCHES. There are four limit switches (15, figure 15-16) used in conjunction with the four louver
actuators.
a. Test.
(1) Connect ohmmeter (Rx1 scale) to terminals of switch.
(2) Toggle switch several times to closed position; ohmmeter should read zero to 1 ohm in the closed position
and read infinite ohms in the open position.
b. Replacement. Remove the limit switches in accordance with paragraph 15-26h and replace them in accordance
with paragraph 15-25a.
15-30. RELAY ASSEMBLY. The actuator control relay assembly used in conjunction with the housing kit is located in
the external power box and consists of four relays K60, K61, K62, and K63; terminal board TB303; four fuses F60, F61,
F62, F63; and a mounting bracket.
a. Test. Refer to figure 15-24 and proceed as follows:
(1) Apply 24V DC across relay coil K60, monitor contacts of relay with ohmmeter. Check that normally open
contacts (3, 6, and 1, 4) are now closed and check that normally closed contact (3, 5, and 2, 4) are now
open.
(2) Remove 24V DC and check that normally open contacts (3, 6, and 1, 4) are now open, and check that
normally closed contacts (3, 5, and 2, 4) are now closed.
(3) Repeat steps (1) and (2) for relay coils K61, K62, and K63.
15-31. RADIATOR SHUTTERS AND ACTUATORS. Two shutter actuators (see figure 15-22) are used in conjunction
with the housing kit. Radiator coolant is circulated to the actuators which expands parafin contained inside the actuator
housing. The parafin expands as coolant temperature increases and, in turn, drives the actuator piston which is
connected to the shutter assembly.
a. Inspect. Inspect the radiator shutters for bent or broken vanes. Inspect the radiator coolant lines to the actuators
for leaks and loose connections.
b. Adjustment. Refer to figure 15-22 and proceed as follows:
NOTE
The following adjustment must be made when the radiator coolant is cold.
(1) Remove cotter pins (9) and adjust rod (10) so that radiator shutters are fully closed. Ensure that actuator
piston is fully retracted.
(2) Reinstall cotter pins (9).
c. Replacement. Remove the radiator shutter actuators in accordance with paragraph 15-26b. and replace them in
accordance with paragraph 15-25f.
15-41
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NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 15-24. Actuator Control Relay Assembly
15-42
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NAVFAC P-8-631-34
TO-35C2-3-463-2
CHAPTER 16
GENERATOR SET TEST AND INSPECTION AFTER REPAIR OR OVERHAUL
Section I. GENERAL REQUIREMENTS
16-1. The activity performing the repair or overhaul is responsible for the performance of all applicable tests and
inspections specified herein. Activities performing maintenance on any portion of the generator set must perform those
tests and inspections required by the applicable component or system repair instruction.
Section II. INSPECTION
16-2. GENERAL. A thorough inspection of the generator set shall be conducted to ensure that workmanship and
materials are satisfactory. The inspection shall be conducted each time the generator set is overhauled or rebuilt.
16-3. HOUSING AND FRAME INSPECTION.
a. Check that drain holes are open to prevent moisture accumulation.
b. Ensure that exposed parts are properly treated to resist corrosion.
c. Open and close panel doors, engine area doors, and generator area doors to ensure proper installation and
freedom of motion.
d. Inspect movable door gasketing to ensure that it is weatherproof.
e. Check that all caps and covers are equipped with ties, chains, or other ties to prevent loss.
16-4. ENGINE INSPECTION.
a. Check mounting bolts of all components and accessories to ensure that they are firmly secured.
b. Check designation and data plates for legibility.
c. Ensure that fuel and hydraulic oil lines are protected from damage due to vibration.
16-5. GENERATOR INSPECTION.
a. Ensure that generator leads are properly identified and protected from damage due to vibration.
b. Ensure that inspection openings are protected by screening or protective plates.
c. Check that the engine generator screws are firmly secured. See table 1-1 for proper torque values.
16-6. ELECTRICAL ACCESSORIES INSPECTION.
a. Check all cable and harness assemblies for secure fastenings and protection against chafing and vibration.
b. Ensure that all cable and harness connectors are firmly secured in their proper place.
16-1
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NAVFAC P-8-631-34
TO-35C2-3-463-2
1.
2.
3.
4.
TEST
Start and Stop
Regulator and governor
stability and transient
response (short term)
Overspeed protection device
Phase balance
Table 16-1. OPERATIONAL TESTS
MIL-STD-705B
PROCEDURE
TEST PARAMETER
503.1
Unit will start and stop
608.1a
See tables 1-2 and 1-3
505.2a
508.1c
5.
Circuit interrupter
(short circuit)
512.1c
6.
Circuit interrupter
(overload trip)
512.2c
7.
Circuit interrupter
(undervoltage)
512.3c
8.
Circuit interrupter
(overvoltage)
512.3c
9.
High oil temperature
(4.7.2 of
MIL-G-52880)
515.la
10.
Low oil pressure protective device
11.
Reverse power protective
device
High coolant temperature
protective
-
13.
14.
Low fuel protective device
Regulator range
515.5
511.lc
15.
16.
17.
Phase sequence (rotation)
Frequency adjustment range
Parallel operation
507.1c
511.2b
12.
515.2a
2225 ±25 rpm
All L-L and L-N
voltages only.
Instantaneously at 425
±25 percent of rated
current
8 ±2 minutes at 130
percent of rated
current
Instantaneously below
48 volts. 6 ±2 seconds
at 99 ±4 volts or less
Not more than 1 second
after voltage has risen
to and remained at any
value greater than 163
±3 volts for not less
than 200 milliseconds
255 ±3 Warning
265 ±3 Shutdown
Trip pressure 13 ±2 psi
Warning pressure 21 ±2
psi
Refer to paragraph 16-8
Warning temperature +213
±3°F. (+100.5 ±1.70C)
Trip temperature +222
±3°F. (+105.5 ±1.70C)
Refer to paragraph 16-9.
Test at both 50 Hz and
60 Hz. See tables 1-2
and 1-3
L1 , L2 , L3
See tables 1-2 and 1-3
Refer to paragraph 16-10
provisions
16-2
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TEST
18.
19.
Malfunction indicator
system
Maximum power
20.
Test parameters at
Table 16-1. OPERATIONAL TESTS - Continued
MIL-STD-705B
PROCEDURE
TEST PARAMETER
-
Refer to paragraph 16-12
640.1b
In excess of 110 percent
of rated load
At 60 Hz
500 KW at 1500 ft (457 m)
at 90°F (32.2°C) 400 KW
at 5000 ft (1524 m) at
107°F (41.7°C)
375 KW at 8000 ft (2435
m) at 95°F (25°C)
At 50 Hz
417 KW at 1500 ft (457 m)
at 90°F (32.2°C)
332 KW at 5000 ft 1524 m)
at 107°F (41.7°C)
375 KW at 8000 ft (2435
m) at 95°F (35°C)
CAUTION
Prior to performing any of the operating tests listed in table 16-1, ensure that the generator set
is serviced with the correct fuel, oil, and coolant as listed on the data plate.
16-3
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Section III. OPERATIONAL TESTS
16-7. 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.
b. Unless otherwise specified, all test instrumentation will be in accordance with Military Standardization Handbook
MIL-HDBK-705 and Military Standard MIL-STD-705B.
c. Temperatures will be measured by means of approximately located thermocouples and properly calibrated readout 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. Aneroid barometers will not be used.
d. Operation procedures required in support of the individual tests specified herein shall be performed as in the
Operator/Crew and Organization Maintenance manual.
e. All test results, for generator set overhaul, shall be logged on the appropriate forms as required.
f. Perform the operating tests as indicated in table 16-1.
16-8. REVERSE POWER PROTECTIVE DEVICE TEST.
a. Start generator and apply 15 percent load.
b. Depress the red button, marked PRESS TO ADJUST AND TEST, on the control cubicle. Reverse power relay
should activate and open load connector.
16-9. LOW FUEL PROTECTIVE DEVICE.
a. To conduct the low fuel protective device test, load instrumentation (as described and illustrated in MIL-HDBK705) and a stopwatch are required.
b. Test the low fuel protective device as follows:
(1) Connect the load instrumentation in accordance with the applicable figure of MIL-HDBK-705, Method
205.1.
(2) Level the generator set.
(3) Fill the fuel tank using the fuel transfer pump.
(4) Disconnect the auxiliary fuel lines from the fuel tank.
(5) Start and operate the generator set at rated load, till the low fuel fault lights and alarm is energized. This
indicates that there is enough fuel in the day tank to operate at rated load and frequency for one hour.
Simultaneously start the stop watch.
(6) Continue operating the set for approximately 50 to 60 minutes or until the low fuel protective device switch
FL4 shuts down the generator set. This indicates that there is enough fuel left to operate the set at rated
load for 15 minutes. Record the time
16-4
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16-10.
a.
b.
16-11.
a.
b.
c.
d.
16-12.
a.
b.
16-13.
a.
b.
c.
when the low fuel protective device actuates and shuts down the set.
(7) If the low protective device does not actuate within an hour after the LOW FUEL ENGINE FAULT indicator
lights up, the device is faulty. Shut down the generator set immediately and replace the low fuel protective
device.
PARALLEL OPERATION PROVISIONS (Real Power).
For 0% Droop Sets:
(1) Place the FREQUENCY DROOP-ISOCHRONOUS switch in the ISOCHRONOUS position.
(2) With rated (500 kw) load on the generator set, measure the DC voltage across pins A and B of one of the
paralleling receptacles. Adjust the LOAD GAIN potentiometer, located on the electronic governor
controller, until 5 volts DC is indicated. Ensure that pin A is positive. For decrease in load, voltage will
decrease proportionately.
For 3% Droop Sets:
(1) Place FREQUENCY DROOP-ISOCHRONOUS switch, located on the AC-DC control panel, in the DROOP
position.
(2) Adjust the DROOP potentiometer, located on the electronic governor controller for 3 percent droop.
PARALLEL OPERATION PROVISION (Reactive Power).
Remove the shorting plug.
With rated load 500 kw at 0.8 PF on the generator set, and the PARALLEL OPERATION-SINGLE UNIT
OPERATION switch, located on the generator panel, in the PARALLEL OPERATION position, adjust the
REACTIVE LOAD COMPENSATION TM5-6115-593-34 NAVFAC P-8-631-34 TO-35C2-3-463-2 CONTROL,
located on AC-DC control panel, until 7.2 volts AC is indicated across pins A and B of one of the paralleling
receptacles. For decrease in load, voltage will decrease proportionately.
Install the shorting plug.
With 500 KW 0.8 PF load applied, the voltage change from no load should be approximately 3 percent.
MALFUNCTION INDICATOR TEST.
The malfunction indicator system is electrically insolated 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 3, 5, 6, 7, 8,
9, 10, 11, 12, and 13 of table 16-1.
In the event that one of the indicator circuits does not work, verify that the lamp is functional by operating the
ANNUNCIATOR TEST switch located on the generator panel.
PHASE BALANCE TEST VOLTAGE.
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.
Apparatus. An rms indicating AC voltmeter, having an accuracy of ±0.1 percent of reading, is required.
Test.
(1) Start and operate the generator at rated frequency and at no load.
(2) Adjust the excitation so that any one of the output voltages is at rated power.
(3) Read and record the
16-5
d.
16-14.
a.
b.
c.
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
generator frequency (speed) and the voltage of each L-L and L-N condition. With the generator operating
at rated voltage, frequency, and no load, the maximum difference in the three line-to-neutral voltages shall
be not more than 1 percent of rated line-to-neutral voltage. The maximum difference between the voltages
of the 120-volt windings of any one phase shall be not more than one volt.
Generator with separate excitation.
(1) Determine from the data obtained in 16-13d(2) the maximum and minimum L-L and L-N voltages.
(2) The voltage unbalance is the difference between the maximum and minimum L-L voltages. To express
this in percent, divide this difference by rated L-L and multiply by 100.
Voltage Unbalance (Coil) in percent = V max - V min X 100
V Rated
(3) Compare the results of step (2) above with the requirements.
REGULATOR RANGE TEST.
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 and operating voltage other than
rated voltage for special types of equipment and to compensate the external line drop.
Apparatus. Instrumentation for measuring load conditions, ambient temperature, and the generator field (or
exciter field) voltage and current shall be as described in MIL-HDBK-705.
Preparation for Test.
(1) Preparation for test.
(a) Connect the load and field instrumentation in accordance with the applicable figure of MIL-HDBK705, Method 205.1, paragraph 205.1.10 for one voltage and frequency.
(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 instrumention at
minimum intervals of 10 minutes. If necessary, adjustments of 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 advices. 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
16-6
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TO-35C2-3-463-2
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.
(e) Record all instrument readings (after transients have subsided).
(f) Adjust the terminal voltage to the maximum specified value.
(g) Record all instrument readings.
NOTE
All 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).
(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 transients have subsided).
(l) Apply rated load.
(m) Record all instrument readings (after transients 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 connection(s).
d. Sample Calculations. Regulation (droop) is defined for the purpose of this method as the no-load value minus
the rated load value divided by the rated load value the quantity expressed in percent.
16-7
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
% Regulation = NLV - RLV x 100
RLV
Where:
NLV = No-Load Voltage
RLV = 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.
Frequency stability describes the tendency of the frequency to rea3in 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.
(1) Preparation for test.
(a) Connect the load and field instrumentation in accordance with the applicable figure of MIL-HDBK705, 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 charge speed(s) to a minimum of 6 inches per hours. The following items
shall be recorded on both the data sheets and recording chart(s):
16-8
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NAVFAC P-8-631-34
TO-35C2-3-463-2
1.
2.
3.
4.
5.
The date
The serial number(s) of the recording meter(s)
Generator set identification
The recording chart speed(s)
The data reading number.
(c) Place all instrumention referred to in paragraph 16-15b in operation.
(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, 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 both the data sheet and the recording chart(s) at the time of an
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 of the load, voltage or frequency has been made.
(b) After stabilization has occurred, drop the load to no load and reapply rated load in 50 percent load
increments a number of times (three should be sufficient) to ensure that the no load and rated load
voltage and frequency 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) 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 terms stability period plus the allowable recovery time as specified in the procurement
document). During each load condition read and record all instrument readings except termal
instrumentation (for three-phase sets it is
16-9
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
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:
No load
1/2 rated load
No load
1/2 rated load
No load
1/2 rated load
No load
1/2 rated load
Rated load
1/2 rated load
Rated load
1/2 rated load
Rated load
1/2 rated load
Rated load
1/4 rated load
3/4 rated load
1/4 rated load
3/4 rated load
1/2 rated load
3/4 rated load
1/4 rated load
3/4 rated load
Repeat (a) through (c) for all voltage connection(s) and frequency(ies).
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
(d)
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
steadystate 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.
16-10
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 16-1. Overshoot and Undershoot Chart Recording
(b) Divide each of the values obtained
in (a) by the rated voltage of the
generator and multiply by 100 to
convert to percentage.
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
(4) To determine the maximum overshoot
and undershoot at each load step, and
express this as a percentage of its rated
voltage,
16-11
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NAVFAC P-8-631-34
TO-35C2-3-463-2
for illustration of overshoot and
undershoot.
no load, 1/2 rated load to no load to 1/4
load, etc.) as follows:
(b) Divide the result obtained in (a) by
rated voltage (as given on the
generator nameplate), then multiply
by 100 to convert to percentage.
(a) Using the indicating voltmeter
readings subtract the load value of
voltage from the no load value for
each load change (for example 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 multiphase sensing the
average value of the sensed
voltage shall be used.)
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):
(b) Convert each of the values obtained
(1) 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.
(a) The prescribed steady-state voltage
bandwidth, extended to the point at
which the voltage trace leaves the
prescribed steadystate 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.
(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.
(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.
16-16. FREQUENCY ADJUSTMENT RANGE TEST.
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.
(c) Divide this distance by the chart
speed (in inches per second). This
will give the voltage recovery time,
in seconds.
b. Apparatus. Instrumentation for measuring load
conditions, field voltage and current, and
ambient temperature shall be as described and
illustrated in MIL-HDBK-705.
(6) Determine the voltage regulation for all
load changes (for example, rated load to
16-12
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
2 minutes between each adjustment
and the subsequent instrument
readings.
c. Procedure
(1) Preparation for test. Connect the load
and field instrumentation in accordance
with the applicable figure of MIL-HDBK705, Method 205.1., paragraph 205.1.10.
(d) Adjust the generator set frequency
for
the
specified
minimum
frequency at rated load. Read and
record all instrument readings.
(2) Test.
(e) Reduce the load to zero.
(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.
(f) Adjust the generator set frequency
for
the
maximum
attainable
frequency. Read and record all
instrument readings. If the overfrequency or overspeed 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.
NOTE
This step is not applicable to
generator sets having governors
that utilize a threaded shaft and
locknut(s) or other mechanical
means as a method of operator
speed adjustment.
(g) Adjust the generator set frequency
for
the
minimum
attainable
frequency. Read and record all
instrument readings.
(h) Repeat 16-16c(1) and 16-16c(2)(a)
through (e) 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.
(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
16-13
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
16-17. OVERSPEED PROTECTIVE DEVICE TEST.
short-circuiting switch as illustrated
in figure 512.1.1.
a. General. Overspeeds will not be possible to
obtain due to limiting factors incorporated in the
fuel injection pump.
(2) Test.
(a) Start and operate the generator set
at rated voltage, rated frequency
and rated load.
b. Overspeed Switch. Perform a bench test on the
overspeed switch to check the proper trip points.
c. Functional Check. Perform a function check of
the circuit manually.
Refer to AC-DC
schematics.
(b) Set the oscillograph time marker to
a minimum of 0.01 seconds or use
a 60 Hz 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).
16-18. CIRCUIT INTERRUPTER TEST (Short Circuit).
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.
(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.
b. Apparatus. Instrumentation for measuring load
conditions shall be as described and illustrated
in MIL-HDBK-705. In addition, a noninductive
shunt; a short-circuiting switch; a galvanometer
matching networks; as 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 Hz will be
required.
(d) With oscillograph still recording the
steady state current, close the shortcircuiting 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.
c. Procedure.
(1) Preparation for the test.
(e) The generator set contains a shortcircuit malfunction indicator, check
and, record its indication.
(a) Connect
the
load
and
instrumentation in accordance with
the applicable figure of MIL-HDBK705,Method
205.1,
paragraph
205.1.10 for one for one voltage
and frequency.
(f) Repeat steps (a) through (e) above
for each possible short circuit
condition (L1-L0,L2-L3, L1-L2-L3 etc.)
(g) Repeat steps (a) through (f) above
for both
(b) Connect the shunt, galvanometer
matching network, oscillograph, and
16-14
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
705, Method 205.1, paragraph 205.1.10
for one voltage and frequency.
voltage connections if applicable.
d. Results.
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
impedance 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.
(1) From the oscillograms taken in 1618c(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-II.
(2) Calculate the short-circuit current using
the peak-to-peak amplitudes of the
current trace and the steadystate
ammeter reading prior to application of
the short circuit. See figure 512.1-II.
(3) Tabulate the above results and the
malfunction indicator indication for each
line
connection
at
each
voltage
connection and compare the results with
the requirements in table 16-1.
(2) Test.
(a) Start and operate the generator set
at rated voltage, rated frequency,
and rated load.
16-19. CIRCUITS INTERRUPTER TEST (OVERLOAD
CURRENT).
a. General. A circuit interrupter is connected
between the generator voltage reconnection
system and the generator output terminals to
disconnect the generator output from the load
and to protect the generator from sustained
overload current.
The circuit interrupter is
operated from a current sensor external to the
interrupter.
(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.
Adjustments to the load, voltage, or
frequency shall be noted on the
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. Apparatus. Instrumentation for measuring load
conditions and 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
noninductive 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
percent) from DC to 3,000 Hz.
c. Procedure.
(1) Preparation for Test. Connect the load
and field instrumentation in accordance
with the applicable figure of MIL-HDBK16-15
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
and B remain at the rated load
value of current.
(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; for example, reactively or
using reduced voltage levels).
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 conditions and the
stabilization data.
Compare the time(s)
requirements of table 16-1.
NOTE
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.
16-20. CIRCUIT INTERRUPTER TEST (OVERVOLTAGE AND UNDERVOLTAGE).
a. General. To protect the load from generator
malfunction (for example, 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 an undervoltage
condition occurs and thus protects the load from
a generator malfunction.
(d) Record all load instrumentations
and the time, in seconds, required
for the circuit interrupter to operate.
(e) The generator set contains an
overload malfunction indicator,
check and record its indication.
b. Apparatus.
Instrumentation for measuring
voltage and frequency shall be as described and
illustrated in MIL-HDBK-705.
Resistor(s),
galvanometer
matching
networks,
an
oscillogram (as described and illustrated in MILHDBK-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 Hz and the voltage
divider transformer network will be required.
(f) Allow the generator set to cool at
rated load for a minimum of 15
minutes.
(g) Repeat steps (c) through (f) except
that the load current is increased to
the overload current value in Phase
A only. Phase B and C remain at
the rated load current value.
c. Procedure I (Overvoltage).
(h) Repeat step (g) except that the load
is increased to the overload current
value in phase B only. Phases A
and C remain at the rated load
value of current.
(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.
(i) Repeat step (g) except that the load
is increased to the overload current
value in phase C only. Phases A
16-16
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(h) Reactivate the shutdown provision if
used.
(b) Connect the frequency meter to the
output terminals of the generator set.
(i) The generator set contains an
overvoltage malfunction indicator,
check and record its indication.
(2) Test.
(a) Start and operate the set at rated
frequency and no load.
(j) Record whether or not the set shuts
down.
(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 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.
(k) Open the switch, reset the
overvoltage circuit if necessary,
restart the set if required, and close
the circuit interrupter.
(l) Repeat steps (d) through (k) above
two additional times.
d. Procedure II (Undervoltage).
(1) Preparation for test.
(c) Open the switch, reset the
overvoltage circuit and adjust the
resistance, R2, until voltmeter
number 2 reads rated voltage.
(a) Locate the input terminals of the
undervoltage sensing circuit and
connect the apparatus as illustrated
in figure 512.3-I.
(d) Repeat (b) and (c) to ensure that
the specified overvoltage and rated
voltage settings are correct.
(b) Repeat step (b) of paragraph
16-20c(1)(b).
(2) Test.
(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 Hz
time trace. Adjust the trace peakto-peak amplitude to a minimum of
one inch (or 25 millimeters).
(a) Start and operate the set at rated
frequency and no load.
(b) Close the switch (see figure 512.3-I)
and use the resistance, R1 to adjust
the voltage to the rated value.
(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
under
(f) Read and record both voltmeter
readings.
(g) With the oscillograph recording and
the circuit interrupter closed, close
the switch. (See figure 512.3-I.)
16-17
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
undervoltage value.
16-20c determine and tabulate the time
between
the
application
of
the
overvoltage and operation of the circuit
interrupter for each application of
overvoltage.
(d) Repeat steps (b) and (c) above to
ensure
that
the
specified
undervoltage and rated voltage
settings are correct.
(2) From the oscillograms made in paragraph
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.
(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 Hz
timing trace. With the switch open,
adjust the trace peak to-peak
amplitude to a minimum of one inch
(or 25 millimeters).
(3) Compare
these
results
requirements of table 16-1.
switch
and
the
16-21. LOW OIL PRESSURE PROTECTIVE DEVICE
TEST.
(f) With the set operating and the
circuit interrupter and the switch
open, read and record both
voltmeter readings.
(g) Close the
interrupter.
with
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.
circuit
(h) With the oscillograph recording,
open the switch.
b. Apparatus. The following equipment shall be
required to perform this test:
(i) After allowing sufficient time for the
circuit interrupter to operate, check,
and record the indication of the
undervoltage malfunction indicator.
(1) Oil pressure gauge (±1 percent)
(2) Flexible oil line (or copper tubing).
(3) Regulating valves
(j) Close the switch, and close the
circuit interrupter.
(4) Brass fittings.
(k) Repeat steps (e) through (j) above
two additional times.
c. Procedure.
(1) Preparation for test.
With 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 gauge
in approximately the same horizontal
plane as the protective device tap located
on the engine.
(l) Repeat (a) through (k) for the other
undervoltage value specified in
paragraph 16-1.
e. Results.
(1) From the oscillograms made in paragraph
16-18
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
(2) Test.
c. Procedure.
(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.
(1) Preparation for test.
(a) Connect the load instrumentation in
accordance with the applicable
figure of MIL-HDBK-705, Method
205.1, paragraph 205.1.10.
(b) Open the bleeder valve slightly to
purge air from the system.
(b) Install a thermocouple to measure
the same temperature as seen by
the protective device sensor.
(c) Close the bleeder valve and record
the oil pressure as indicated on the
external gauge.
(2) Test.
(d) Almost completely close the shut-off
valve.
(a) Start and operate the generator set
at rated voltage, rated frequency
(speed), and rated load.
(e) Slowly open the bleeder valve until
the low oil pressure protective
device shuts down the engine.
Record the reading of the oil
pressure gauge at the point of set
shutdown (see figure 515.1-II).
(b) Block the cooling air to the
generator set or manually trip
overload sensors on fan motor
contactor, located in the 2c central
box.
(f) Record operation of the malfunction
indicator light.
(c) Continuously monitor the temperature seen by the thermocouple
installed in paragraph 16-22c(1)(b)
above. Record the temperature at
which
the
overtemperature
protective device actuates. Record
the temperature at which the
coolant
temperature
indicator
illuminates.
(g) Repeat (a) through (f) for the
warning switch.
d. Results.
Compare the value of shutdown
pressure with the requirement of table 16-1.
16-22. OVERTEMPERATURE PROTECTIVE DEVICE
TEST.
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.
a. General. The overtemperature device must be
capable of 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 MILHDBK-705, Method 205.1, paragraph 205.1.10.
d. Results. Compare the results with the requirements of table 16-1.
16-23. PHASE SEQUENCE TEST (ROTATION)
a. General. Unless the phase sequence (rotation)
of the load
16-19
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
GEN switch to the BUSS position. The 13-2 lamp should illuminate.
terminals of a 3 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.
d. Results. The phase sequence (rotation) as
indicated by the test shall be checked against
the requirements of table 16-1.
b. Apparatus.
A phase sequence (rotation)
indicator as described and illustrated in MILHDBK-705, Method 116.1 or a 3 phase motor
whose direction of operation in relation to phase
sequence is known shall be required.
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.
See table 16-1 for test parameters for various
altitudes.
c. Procedure.
(1) Connect the generator set load terminals
to the applicable test apparatus for one of
the set 3 phase voltage connection.
Recheck the connections to ensure that
L1, L2, and L3 of the generator set age
connected to L2, and L3 of the test
apparatus respectively.
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.
(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.
CAUTION
This procedure subjects the
generator set to a severe overload
which may be damaging if
maintained for too long a period
of time.
(3) Close the circuit interrupter and determine
the direction of phase sequence (rotation)
by observing the indicator, or by noting he
direction of rotation if a 3 phase motor is
used. Record results.
(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.
(4) Repeat steps (a) through (d) above for all
other 3 phase voltage output connections
of the generator set.
(5) Phase sequence can also be checked by
placing PHASE SEQUENCE-BUSS-OFFGEN switch, located on the generator
panel, to the GEN position and the 1-3-2
lamp should illuminate.
(b) Install appropriate thermocouples to
measure
the
following
temperatures:
1. Engine coolant (engine outlet
and inlet).
(6) Place the AC PWR CKT BKR, located on
the generator panel, to the close position
and the PHASE SEQUENCE-BUSS-OFF-
2. Exhaust gas(es)(the exhaust
manifold(s) shall be drilled
16-20
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
and tapped as close as possible
to the combustion chamber(s).
rated voltage and rated frequency.
However, adjustments to the
voltage and frequency shall be
limited
to
those
adjustments
available
to
the
operator.
Specifically adjustments so the
voltage or frequency adjust devices.
No other adjustments to the voltage
and frequency control systems
should 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 conditions with no
evident continued increase or
decrease in value after the last
adjustment to the load, voltage, or
frequency has been made.
3. Lubricating oil sump.
4. Engine combustion air in
(located at the inlet of the intake
manifold).
(c) Install
appropriate
instrumention to measure the following items:
pressure
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.
(c) Perform this test using resistive
load only. Remove reactive load
after stabilization.
(f) Connect the set to a source of fuel
containing a specified fuel required
by the procurement document.
(d) Alternately increase the load,
voltage and frequency in small
increments until the fuel system
controls are in the maximum fuel
position as permitted by the
governor control linkage and the
voltage and frequency are within 1
percent of their rated values.
(2) Test.
(a) Set governor to zero-droop.
(b) Start and operate the generator set
and allow it to stabilize at rated
load, rated voltage and rated
frequency (speed).
During this
period, reading 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 may be
made to maintain rated load at
NOTE
Small increments should be taken
to avoid passing the maximum
power at the rated voltage and
frequency point and to avoid
racing and bogging the engine.
16-21
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
CAUTION
Do not exceed 125 percent of
rated load.
heating or damage to the
generator set if the above
conditions cannot be readily
attained.
(Monitor instrumentation.)
(e) Hold the conditions in step (c)
above for two minutes. However, if
the voltage and frequency cannot
be maintained within 1 percent of
their rated values, the load must be
adjusted to the point at which the
voltage and frequency can be
maintained within 1 percent of their
rated values for two minutes.
(f) During the two minute period record
all instrument readings including
thermal and pressure instrumentation. (On 3-phase sets it is not
necessary to record line-to-line
voltages).
CAUTION
(g) Reduce the load to rated kilowatt
load and allow the generator set to
cool for 10 minutes.
It may be necessary to reduce the
load to a value below the rated
kilowatt load for a short period of
time to prevent serious over-
(h) Repeat steps (d) through (g) above
until three valid sets of maximum
power data are obtained.
16-22
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
CHAPTER 17
GENERATOR SET INSTALLATION PRACTICES
Section I. SAFETY PRECAUTIONS
17-7. When filling the fuel tank, do not smoke or use
open flame in the vicinity. Be extremely careful when
using a carbon tetrachloride fire extinguisher in an
enclosed area. A poisonous gas is generated by the
contact of carbon tetrachloride with heated surfaces.
Provide adequate ventilation before entering an
enclosed area where carbon tetrachloride has been
used.
17-1 GENERAL.
This chapter provides safety
precautions, site selections guidelines, air, cooling, fuel,
exhaust, electrical, and service requirements relevant to
the proper installation of the generator set. All other
input requirements not covered in this chapter and
required by the user are the responsibility of the
cognizant installation manager.
17-2. Do not use a lifting device with a marginal
capacity when lifting and moving the generator set.
Observe the center of gravity of the equipment to be
lifted and do not allow the generator set to swing while it
is suspended. Make certain the structure to support the
generator set is strong enough to support the weight of
the set. Failure to observe this warning may result in
serious injury or death to personnel.
17-8. When operating in an enclosed area, pipe the
engine exhaust outside. Be sure to increase the pipe
diameter and use a minimum amount of bends and
elbows to prevent back pressure in the engine exhaust
system. Be sure the enclosure has proper ventilation to
accommodate the engine cooling system.
17-9. When servicing batteries, do not smoke or use an
open flame in the vicinity. Batteries generate explosive
gas during charging.
17-3. The voltage produced by generators is dangerous
to personnel coming in contact with any part of the
electrical system during operation. Severe, possible
fatal shock may result. See that adequate grounding
provisions have been made and the generator sets are
grounded using the ground studs provided before
operation.
Be extremely careful when unit or
surrounding area is damp or wet.
7-10. DANGER signs must be placed in the vicinity of
the engine. There is to be no smoking in the vicinity.
No work is to be performed on the engine involving
open flames, such as cutting, welding, grinding,
chiseling, or any similar operation which may produce
sparks.
17-4. In case of an accident from electrical shock, shut
down the set at once. If the set cannot be shut down,
free the victim from contact with a nonconductor, and
avoid direct contact with victim. Use a dry rope, dry
board, or any nonconducting implement to free the
victim. If the victim is unconscious, apply artificial
respiration and get medical help.
17-11. A fire extinguisher (dry powder or carbon
dioxide, CO2) must be placed next to the mechanic's
working area, handy for immediate use.
17-12. Pay particular attention that all generator output
phase leads are properly insulated before starting set.
Neglect to do this may result in extensive damage to
equipment and personnel injury. This condition is most
prevalent when set is started before electrical
installation is completed.
17-5. When servicing any part of the electrical system
or making any connections, be sure the maintenance
switch is in the MAINTENANCE position and padlocked.
Clean or service the generator set only when the engine
is shut down.
CAUTION
17-6. If the unit stops by operation of the safety
devices, do not attempt to operate it until the cause has
been eliminate.
For proper unit operation, battery
minus (-) terminal must be
connected to ground.
17-1
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Section II. LOCATION
k. Hand-hole covers
17-13. A complete housing kit is available for the 500
KW generator set and should be used when the unit is
installed outdoors on a pad. Without the housing kit, the
generator set may be installed indoors on a pad. Both
the indoor and outdoor pads should be fitted with twelve
spring-loaded shock mounts for mounting the generator
set.
l. Removal of oil -pan
m. Removal of rocker covers
n. Battery servicing and removal
o. Starter
17-14. The location of the unit is governed primarily by
its related systems and proximity to the incoming
electrical service. Weather conditions will also affect
both location and the accessory equipment required to
provide proper system operation. Locations where
extreme ambient temperatures occur should be
avoided. Where the generator set must be exposed to
low temperature ambients, the integral engine heater
may be used to assist starting.
p. Battery charger
q. Diode removal from generator endbell.
17-16. Before final plans are made for locating a
generator set, the following points should be considered
for both housed and unhoused units:
a. Mounting provisions must be strong enough to
support the set and related equipment.
17-15. Whether located indoors or outdoors, preventive
maintenance is an important consideration when
selecting or designating a generator set location. In
addition to the control cubicle, the following service
points should be accessible to the operator:
b. Vibration should be effectively isolated and
dampened to reduce noise and prevent
damage.
a. Air cleaner
c. Area should be clean and dry and not subject to
flooding.
b. Primary fuel filter
d. Area should be large enough to provide easy
access for servicing and repair, and free
movement of cooling air (see figure 17-1).
c. Secondary fuel filter
d. Lube oil dip stick
e. The set should be in close proximity to the
auxiliary fuel tank.
e. Lube oil filter
f. Lube oil drain
f. For generator sets installed indoors:
g. Fan belt adjustment
(1) Ventilation should be available in the area
with a minimum amount of duct work and
which will maintain set temperature in a
range for efficient engine operation.
(2) Exhaust gases should be expelled safely
out of and away from the structure.
h. Radiator filler opening
i. Cooling system drains
j. Fuel tank drain
Section III. MOUNTING THE GENERATOR SET
17-17. The 500 KW generator set should be mounted
on a substantial level base, preferably class B concrete
with a design strength of 2500 psi.
17-18. For generator sets enclosed
17-2
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 17-1. Generator Set Operational Requirements (Sheet 1 of 2)
17-3
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 17-1. Generator Set Operational Requirements (Sheet 2 of 2)
17-4
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
within a building where maximum vibration isolation is
required, the following methods provide vibration
isolation between the generator mounting foundation
and the structure.
17-21. If the floor slab has sufficient strength to support
the weight of the unit, and a separate foundation is not
used, a satisfactory mounting can be accomplished by
the use of vibration isolators between the floor slab and
the unit. To limit vibration effects to an absolute
minimum, the unit should be isolated from its foundation
by flexible mounts and the foundation isolated, as
described, from the floor.
17-19. The foundation should be separated from the
floor slab and the subsoil so vibrations will not be
transmitted to the structure (see figure 17-2). Water
resistant, processed natural cork has been found to be
one of the most effective organic materials for isolating
the foundation from the subsoil. By lining the foundation
pit and its perimeter with cork plates before pouring the
concrete foundation, it is usually possible to reduce the
units vibration to a satisfactory degree.
17-22. To facilitate maintenance on the unit once it is
installed, the foundation should be constructed so as to
protrude above floor level by 6 to 8 inches (15 to 20 cm)
as illustrated in figure 17-2 and extend 8 inches (20 cm)
wider beyond the front and sides of skid and 18 inches
(20 cm) beyond the rear skid as shown in figure 17-3.
17-20. Another method of isolating a foundation is to
use 8 or 10 inches (20 or 25 cm) of wet gravel or sand
as a bed in the foundation pit. Tests have shown sand
and gravel are capable of reducing the amount of unit
vibration transmitted by as much as one-third to onehalf. The isolating value of gravel is somewhat greater
than that of sand and does not vary appreciably with its
depth.
To minimize settlement of the concrete
foundation from the floor slab, expansion joints should
be incorporated between the slab and the foundation.
GEN
SET
500
17-23. A minimum clearance of 5 feet (15 m) between
an installed set and adjacent walls should be maintained
on three sides of the unit. A minimum clearance of 8
feet (24 m) should be maintained at the rear of the unit
to facilitate the removal of the generator should it
become necessary. See table 17-1 for generator set
weight and dimensions.
Table 17-1. Weight and Dimensions
HEIGHT
WEIGHT
(WITHOUT
(FILLED)
WIDTH
MUFFLER)
34,050
pounds
(15,445 kg)
HEIGHT
(WITH
MUFFLER
88
101
120
LENGTH
219
(226 cm)
(265.5)
(304.5)
(556)
17-5
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 17-2. Mounting Bolt Layout in Concrete Pad
17-6
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 17-3. Cross Section View of Pad and
Mounting Bolt Installation
Section IV. VIBRATION
17-24. A certain amount of vibration is inherent in the
operation of any generator set.
If vibration is
transmitted to surrounding areas, the noise level
increases. The engine generator is mounted directly to
the skid; therefore, twelve vibration isolators are
recommended to be installed between the skid and
foundation. Figure 17-4 illustrates the recommended
type of isolator.
17-25. When the generator set is installed within a
building, all fuel, coolant, exhaust, and electrical
connections must have flexible sections so that vibration
is not transmitted along these lines. See Figure 17-5.
Section V. AIR REQUIREMENTS FOR UNHOUSED 500 KW GENERATOR SETS INSTALLED WITHIN A BUILDING
17-26. A ventilation system must be installed to provide
adequate air at the generator set to remove heat
radiated by the engine generator and supply combustion
air for the engine.
c. Ambient temperature.
d. Routing of exhaust air duct.
e. Placement of discharge louver.
17-27. When installing the ventilation system the
following factors should be considered:
f. Whether radiator and fan assembly will be
separated from the generator set.
a. Location of inlet and outlet air ports.
17-28. The air inlet and outlet must be in the same
room position to allow convection air flow from the inlet,
across the unit, and exhausted through
b. Method of actuation of inlet and outlet louvers.
17-7
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 17-4. Vibration Isolator (12 required)
the outlet positioned slightly higher than the inlet. The
inlet and outlet openings must be large enough to
provide the volume/time flow air necessitated by the
heat rejection rating of the generator set.
radiator core. When radiator and
fan assembly remains mounted
with the generator set.
NOTE
Output cooling air ducting should
never be smaller than engine
17-29. To determine the air needed to remove unit heat
rejection in the installation enclosure or room, use the
heat rejection factors from table 17-2 and the following
formula:
Q=
H
1.08 T
Where:
Q = Air in cubic feet/minute
H = heat in BTU/HR to be removed
T = Permissible room temperature rise in
degrees F.
17-8
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Table 17-2. Air Requirements Cubic Foot
Per minute (Cubic Liters Per Sec)
RPM
1800
COMBUSTION
AIR
COOLING
AIR
TOTAL
AIR
1640
(774)
33,500
(15,812)
35,140
(16,586)
Figure 17-5. 500 KW Generator Set Installation
17-9
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
17-30. In most installations, intake and exhaust louvers
are used. Figures 17-6 through 17-9 illustrate a variety
of louver installations which may be used. The use of
louvers requires the opening area to be increased by a
factor of 1/4 to 1/2 times that of an unobstructed
opening. Where possible, the inlet duct should be on
the shaded side of the building. Care should be taken to
provide adequate unobstructed space outside the outlet
to prevent development of back pressure and
consequent limiting of outlet air flow. Where possible,
the outlet duct should not be exposed to strong
prevailing winds, since wind may cancel fan effect and
impair cooling. A duct should be installed between the
radiator and the outlet vent to prevent recirculation of air
passed through the radiator, as its effectiveness as a
heat exchanger would be diminished. The duct should
be installed between the radiator and outlet vent with as
few bends as possible.
should be mounted as close as possible to the outlet
vent.
Figure 17-7. Thermostatically Controlled Louvers
17-32. Intake and exhaust ventilation shutters are used
to prevent entry of cold air, which would reduce the
ambient temperature of the area in which the unit is
located causing difficulty in engine starting. Shutters
also exclude entry of rain, snow, and insects into the
building.
Figure 17-6. Fixed Louvers for Air Inlet
17-31. All units can be fitted with radiator duct flanges.
If bends are required, they should be in the form of
gradual sweeps to allow an air flow against minimum
restriction. Increase duct size 1/4 to 1/2 to compensate
for bends. Exhaust duct static pressure should be
essentially zero. If a duct is not used, the outlet vent
should be twice the area of the radiator and the unit
Figure 17-8. Exhaust Fan Operated Louvers
17-10
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
spring tension and are driven to the open position by a
stall type motor operating through a mechanical linkage.
Care should be taken in wiring the system to ensure that
the intake shutter motor is supplied during all possible
modes of unit operation; i.e., true power failure,
simulated power failure due to incorporation of a system
test switch, or automatic plant exercising due to the
incorporation of a plant exercising timer.
17-35. Supplying the intake shutter motor from the
generator output (before any incorporated line circuit
breaker) will ensure its operation whenever the unit
operates.
The shutter motor is usually of the
reconnectible type to accommodate either 110/220V AC
supplies. Special application transformers are available
to supply these values if the generator output does not
permit its use directly.
Figure 17-9. Exhaust Fan
17-33. For electric generating sets that do not utilize
automatic starting provisions, manual shutters may be
used. A gravity drop shutter may be used for the
exhaust duct if the shutters are of light metal. When the
set operates, outlet air flow will open the shutter, which
closes automatically due to gravity when the unit is shut
down. Manual intake shutters operated by a pull chain
or pulley device must be opened to provide intake air.
The open-closing operation is a manual function.
17-36. Thermal fusible links are available connected in
the motor circuitry to de-energize the motor and cause
the shutter to close in case of fire.
17-37. In some cold weather applications, the opening
of inlet shutters immediately on the starting may cause
carburetor icing, and vaporizing problems.
Diesel
engines may not operate efficiently if extreme cold air is
admitted through fully open louvers. Thermostatically
controlled shutters can be used to counter the difficulties
inherent in cold weather applications.
17-34. For electric generating sets utilizing automatic
start functions, the use of motor-operated intake shutters
is recommended. The exhaust shutter may be of the
gravity drop type if the shutters are of lightweight
material. Motor-operated shutters are held closed by
Section VI. COOLING SYSTEM
17-38.
A properly functioning cooling system is
extremely important to any internal combustion engine
since only a fractional part of the heat energy (fuel)
supplied to the engine is converted into useful work.
The excess heat of combustion is rejected in three
ways, by radiation to ambient air and engine oil, etc., via
the engine's exhaust system, and via the engine's
cooling system. See table 17-3.
Table 17-3. Generator Set Heat Rejection, Radiator
Connections
Heat rejection to...................................564,900 BTU/HR
room by engine
generator
Heat rejection to................................1,368,000 BTU/HR
radiator by engine generator
Radiator inlet..................................................... 3 inches
(2) size
(7.62 cm)
Radiator outlet............................................. 3-1/2 inches
(8.89 cm)
Radiator water............................................ 210 gal./min.
flow
(13.25 liters/
sec.)
17-39. LIQUID COOLING SYSTEM. The engine
utilizes a liquid coolant with jackets or chambers
surrounding each cylinder. Coolant water and engine
17-11
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
oil heat exchangers are also utilized. A liquid coolant
under pressure enters the water jackets absorbing heat
from the cylinders and other components described
above, and by the time it reaches the outlet has risen in
temperature. Water cooling systems are configured
such that the temperature differential between inlet and
outlet does not exceed 10 to 12°F (-12 to -11°C). It is
not good practice, and may be destructive to the engine
to have a low intake temperature.
a. Provide an entrance for fresh air at least as
large in area as the radiator itself. Do not
depend solely on apertures such as windows,
etc. Where possible, inlet shutters are utilized
to increase the inlet opening area by a factor of
one quarter to one half that of the radiator area.
In
areas
of
extremely
cold
ambient
temperatures, thermostatically controlled inlet
shutters should be considered.
17-40. The coolant leaving the engine outlet enters a
radiator heat exchanger to exchange its heat to the
environment.
b. Cool inlet air should not be required to find its
way to the engine room through stairwells,
corridors, etc., nor should it be required to travel
upward through a duct.
17-41. RADIATOR COOLING. See table 17-4.
Table 17-4. Radiator and Crankcase Capacities
Radiator and ................................................ 54 gallons
block capacities
(204 liters)
Crankcase oil ............................................... 18 gallons
capacity
(168 liters)
away. The exit opening should be larger than
the inlet opening to compensate for the
expansion of air due to heat. Bends in the
exhaust duct should be avoided where possible,
but if they are required, they should be
proportionally enlarged.
17-42. A radiator is a closed system heat exchanger
consisting of finned tubes through which the engine
coolant passes. The heat exchanging air stream over
the fins is produced by a beltdriven, pusher-type fan (air
flow from rear of set towards the radiator). Cooling air is
drawn over the engine and pushed through the radiator
into a duct leading to the outlet vent, or unducted toward
the outlet vent. A radiator cannot itself absorb heat
(except for the very small amount to warm its own
metal) and is not to be regarded as a bottomless pit
capable of absorbing unlimited heat. The radiator
exposes the finned surface of its tubes to the passing air
stream to carry off engine heat.
d. Cooling fan pressure generally should not be
required to force air through semiclosed
openings, louvers, swinging traps, etc.
However, if gravity drop louvers are utilized, the
louvers should be lightweight metal.
e. Where possible, position so that the direction of
fan output is directly toward the outlet.
17-43. A free supply of fresh air must be available and
recirculation of the air must be avoided. If the cooling
air is allowed to recirculate it would soon acquire enough
heat to raise the ambient temperature to approximately
the same temperature as the radiator, resulting in
engine overheating. A few basic rules should be
observed in locating a radiator cooled generating unit.
f. Avoid ducting so the outlet constructed to the air
must make one or more right angle bends after
leaving.
g. Where possible, position the engine so that
minimum distance
c. Provide an exit for heated air, preferably
ducted, allowing it to be carried completely
17-12
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 17-10. 500 KW Deaerating Top Tank Design
17-13
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 17-11. 500 KW DOD Deaerating Top Tank Piping
17-14
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 17-12. Recommended Auxiliary Tank Piping
17-15
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 17-13. Remote Radiator Application "A"
exists between the outlet and the face
of the radiator, and arrange so that hot
air cannot re-enter.
remote radiator system requirements. Figures 17-10
through 17-12 illustrate deaerating and auxiliary tank
piping. Figure 17-13 illustrates a simple remote radiator
installation, with an electric motor driven fan used as a
heat exchanger for engine coolant. The radiator is
mounted so that the radiator top tank is the highest point
in the water system, preventing air pockets which could
cause stoppage of coolant flow and consequent engine
overheating. The top tanks of the radiators used on the
500 KW generator set are of oversized design and in the
application shown act as a surge tank. A filler neck and
pressure cap are supplied to allow for coolant filling and
pressurized system operation. Air can be-vented from
the system by means of a float-type trap which allows
the escape of air, but not allow water to escape. The air
escape trap should have a pipe extending down into the
NOTE
Engine exhaust outlets should not
be placed adjacent to either intake
air or outlet air louver openings.
17-44. The 500 KW radiator assembly may be mounted
separately from the generator set. The horizontal and
vertical displacement of the radiator from the engine's
centerline will determine the additional system
components necessary for the installation.
Since
particular installation requirements will vary, it is
advisable to contact the Cognizant Authority regarding
17-16
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
top part of the top tank, from 1 to 3 inches (2.54 to 7.62
cm), so that a cushion of air is trapped here to take care
of normal surge.
17-47. Flexible hoses used to isolate vibration should
be used at the inlet and outlets of both the engine and
radiator.
17-45. A strainer is used in the water line returning from
the radiator to catch dirt, scale, and core sand. The
electric auxiliary water pump shown in figure 17-13 is
used to assist the engine driven pump in maintaining the
desired coolant flow rate which would have been
reduced in remoting the radiator by the line and fitting
drop incurred by the additional piping. A drain valve
should be incorporated to facilitate servicing the
radiator.
17-48. The fan motor and electric auxiliary pump must
be electrically connected to ensure their operation
whenever the unit is running.
17-49.
For applications in which the radiator is
positioned at some horizontal distance from the unit and
is not the highest point in the water system the
configuration shown in figure 17-14 is recommended.
The surge tank, located in a position elevated above the
radiator provides the space to accommodate the natural
expansion of heated water and the air and gases
trapped and dissolved in the water. The surge tank is
vented permitting escape of vapor and air.
17-46. The pipe size utilized should be the same size
as the radiator inlet an outlet fittings. Use the same pipe
size throughout the entire system. Use straight lengths
of pipe wherever possible in conjunction with radius
elbows wherever turns are required.
Figure 17-14. Remote Radiator Application "B"
17-17
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
component failure which by itself could prevent
operation should be overlooked.
17-50. The surge tank should also be equipped with a
sight gauge, overflow pipe, and vent to atomosphere. It
should also have connections for makeup feed water.
17-53. A drain valve should be incorporated to facilitate
servicing the radiator. As shown in figure 17-14, the use
of a drain valve and water pump bypass valve permits
the draining of the radiator, surge tank, and the engine.
A strainer is used in the line returning from the radiator
to catch dirt, scale, and core sand.
17-51. Another important function of the surge tank is
the maintenance of a positive head of pressure on the
engine water pump inlet. The line connecting the
bottom of the surge tank to the engine water pump inlet
services this function.
17-54. The fan motor and electric auxiliary pump must
be connected to ensure their operation whenever the
unit is running.
17-52. The electric auxiliary water pump shown in
figure 17-14 is used to assist the engine driven pump in
maintaining the desired coolant flow rate which would
have been reduced in remoting the radiator by the line
and fitting drop incurred by the additional piping. In the
event of a failure of the auxiliary pump, a bypass valve
connected across the pump can be opened preventing
the complete loss of an emergency standby unit. No
17-55.
For applications in which the radiator is
positioned at some distance above the engine
centerline, a hot-well tank and an auxiliary water pump
are
Figure 17-15. Remote Radiator Application "C"
17-18
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
radiator and its piping to the tank, an additional 130
percent of the radiator piping capacity must be allowed
for expansion and surge damping. See table 17-5 for
radiator data.
required (see figure 17-15). The hot-well tank protects
the cooling system component seals against the
pressure produced by the column of water whose
vertical distance is the height of the radiator above the
engine.
17-58. When the unit is shut down, the radiator coolant
drains into the hot-well tank, whose hot and cold sides
are interconnected by a small opening, thereby reducing
the head of pressure on the engine later pump seals. A
10 psi (7031 kg/m²) maximum external static pressure at
the water pump is held to be the upper limit to provide
for satisfactory water pump seal operation. Static
pressures exceeding this limit may cause fact-type,
spring-loaded seals to lift causing engine coolant
leakage.
17-56. The tank is divided into two sections by a partial
baffle separating the hot side (engine outlet) from the
cold side (engine inlet). Engine connections to the hotwell tank must be below the radiator connections to
prevent aeration of the engine. The bottom of the hotwell tank must be a minimum of 12 inches (30.5 cm)
above the engine coolant outlet. The engine driven
water pump supplies heated coolant from the engine to
the hot side of the tank. The tank provides a quiet area
of low flow velocity with a large surface area to permit
entrained air to dissipate and escape through the vent.
The auxiliary water pump draws water from the hot side
of the tank and pumps it through the radiator and back
to the cold side of the tank where it is tempered to
prevent too low an inlet of the engine driven water
pump.
17-59. The hot-well tank should be vented and mounted
within 10 feet (3 m) of the engine. To prevent aeration
of the cooling system, the auxiliary pump connected to
the tank must be below normal water level in the tank.
17-57. The hot-well tank must be capable of containing
60 percent of the coolant system capacity when the unit
is not in operation. The 60 percent figure includes the
Table 17-5. 500 KW DOD Generator Set Radiator data
Section VII. FUEL SYSTEM
17-60. Since diesel fuel is less volatile than gas or
gasoline, it may be considered a safer fuel from the
standpoint of storage and handling. This is often
reflected in less stringent regulations for placement of
tanks. In some locations, fuel tanks of considerable size
are permitted inside the building or enclosure; however,
planning the installation.
17-61. The very fact that diesel fuel is a safe fuel can
lead to careless installation practices which can result in
poor performance of the engine and generator set.
Diesel fuel may not leak out of an improperly tightened
fitting; however, air can be drawn in through this loose
fitting when the engine is operating.
17-19
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
injectors. Flexible lines must be of the type approved
for diesel fuels.
Air trapped in the fuel causes erratic performance and
hard starting.
For this reason, piping must be
completely sealed against entrance of air and fine dust
or dirt.
17-64. The auxiliary fuel tank should be vented so that
air and other gases can escape to atmosphere (see
figure 17-16 through 17-18). The vent must, however,
prevent dust, dirt, and moisture from entering the tank.
Where return lines are required, keep the return spaced
at least 12 inches (30.5 cm) away from the pickup or
fuel dip tube if this is not done, air bubbles could be
entrained in the fuel and cause erratic operation. At
least 5 percent of capability should be allowed in a
diesel main tank for expansion of the fuel. Auxiliary fuel
tank capacity can be computed by using table 17-6.
17-62. Auxiliary tank fuel filters and sediment drains are
located in the set and are easily accessible to promote
regular and frequent service. Cleanliness of the fuel is
especially important on diesel engines which have easily
clogged, precision fuel injectors, and pumps.
17-63. Black iron pipe or copper tubing must be used
for diesel fuel systems galvanized tanks and piping must
not be used since the diesel fuel and the galvanized
coating react chemically to produce flaking which
quickly clogs filters or causes failure of the fuel pump or
Table 17-6. Fuel Consumption for 500 KW DOD Generator Set
c. A fuel supply line connected from the tank to
the electric fuel transfer pump.
17-65. SET FUEL TANK. The capacity of the fuel tank
is determined by the fuel consumption of the unit and
the continuous operating time necessary. Fuel supply
capacity for generator service is 2 hours under full load
without refueling. All auxiliary tanks must have:
d. The tank should be fitted with a foot valve
(permits flow in one direction only) to prevent
loss of transfer pump prime when the
transfer
pump is not in operation.
a. A vent line terminating above grade level in a
screened or hooded type vent cap with
unrestricted opening to atmosphere.
17-66. The auxiliary fuel oil transfer pump is an internal
part of the generator set and has the capacity to fill the
fuel tank in one hour when pumping fuel at a
temperature of 25°F (-31.7°C). Additionally, the pump is
capable of lifting fuel 10 feet (3 m) and provides
sufficient pressure to supply fuel through the filtration
system under all possible viscosities of the fuel.
b. A fuel fill line terminating above grade level
and fitted with an appropriate cap or
terminating in a fuel filler box with an
appropriate cap and plainly marked for the
fuel utilized.
17-20
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 17-16. Auxiliary Diesel Fuel System
17-21
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 17-17. 500 KW Generator Set Installation
17-22
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 17-18. 500 KW Generator Set Anti-Siphon Installation
17-23
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
17-69. A typical levelometer system is shown in figure
17-19. Levelometers should be used only with vented
tanks.
17-67. A motor starter will cause the fuel oil transfer
pump to operate when its pilot circuit is closed by the
action of the float switch. Fuel is then drawn from the
auxiliary tank via a foot valve and is pumped into the set
tank. Operation continued until the fuel level in the set
tank causes the float to rise, opening the float switch
and disconnecting the fuel transfer pump motor from the
power supply.
17-70. FUEL AND LUBRICANTS . The set is capable
of satisfactorily starting and operating on fuels
conforming to VV-F-800 Grades DF-A and DF-2, MILF16884, and turbine fuel conforming to MIL-T-5624
Grade JP-5. All components of the engine and fuel
system are capable of operating on Grade JP-5 turbine
fuel, except that rated load may be reduced to a
maximum of 20 percent of rated kw. When operated
continuously on Grade JP-5 fuel, the set meets all
requirements except that the injectors and fuel pumps
may be changed and timing adjusted from the diesel
setting at the time of changing fuel. The set is capable
of continuous operation using lubricating oil conforming
to MIL-L-9000, MIL-L-46167, and MIL-L-2104.
17-68. FUEL LEVEL INDICATING SYSTEMS . When
remote indication of the quantity of fuel in an
underground tank is required, a levelometer system can
be provided. Two types are available. The automatic
type operated by compressed air can be located up to
1000 feet (300 m) from gauged. The manually operated
type makes use of a hand pump located in the indicator
case and can be located up to 150 feet (45 m) from the
tank. Dials for the levelometer gauges can be supplied
calibrated in pounds, gallons, liters, feet, inches or any
other unit of measurement.
Section VIII. EXHAUST SYSTEM
radiated within the building; insulating the exhaust piping
with asbestos will further reduce radiated heat.
17-71. The engine exhaust system must dispose of the
exhaust gases remaining after combustion with a
minimum of back pressure applied to the engine. The
exhaust gas flow for any engine will be approximately
three times the engine's intake and consumption. The
adverse effects of materially exceeding back pressure
recommendations of the engine manufacturers loss of
power, poor fuel economy, high combustion
temperatures resulting in shorter service life, jacket
water overheating, and crankcase sludging and
corrosion or bearing damage. When the generator set is
installed indoors, the exhaust system back pressure can
be kept within the acceptable limits by the selection of
properly sized and installed exhaust pipe and the use of
the two mufflers supplied with the set.
17-73. To ensure an exhaust system which will not
produce a back pressure in excess of the engine
manufacturer's specifications (shown in table 17-7).
a. Use an exhaust flex connector not less than 5
inch (12.7 cm) ID.
b. Use the silencers supplied with the generator
set.
c. Do not exceed the maximum equivalent
exhaust pipe length in feet in table 17-8.
17-72. When the generator set is installed indoors, it is
desirable but not mandatory, to have the mufflers
outdoors.
This will greatly reduce the heat
17-24
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 17-19. 500 KW Levelometer System Installation
Table 17-7. Data On Engine
Used in 500 KW DOD Generator Set
17-25
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
17-75. Adequate support must be given to the exhaust
piping, no more than 4 feet (12 m) should be allowed to
extend from the engine exhaust manifold without
adequate support.
17-74.
The engine exhaust manifold should be
connected to the exhaust piping with a flexible exhaust
connector (see figure 17-20). The flexible exhaust
connector provides a means of taking up thermal growth
of the exhaust system due to the hot exhaust gas and
absorbing vibration.
Table 17-8. Exhaust Line Recommendations
NOTE
17-77.
Engine exhaust piping can accumulate a
considerable amount of condensed moisture after unit
shut down, particularly if the exhaust system is run
through lengthy piping. To prevent condensed moisture
from running back into the engine, a condensate trap
and drain should be incorporated at some low point
ahead of the engine manifolds (see figures 17-21
through 17-23).
When installing mufflers, make certain air flow
direction is correct.
17-76. Exhaust piping passing through combustible
walls or partitions shall be guarded at the point of
passage by a metal ventilated thimble not less than 12
inches (30.5 cm) larger in diameter than the exhaust
pipe or metal or burned fire clay thimbles built in
brickwork providing not less than 8 inches (20.3 cm) of
insulation between the thimble and combustible material
(see figure 17-20). Exhaust pipes must not terminate
near inlet vents of any type or near combustible
materials.
17-78. Where vertical exhaust stack is necessary, a
rain cap should be fitted to exclude rain and snow from
the exhaust pipe. Fully automatic counter-balanced rain
caps are provided with each generator set.
Section IX. ELECTRICAL REQUIREMENTS
overcome the self-discharge characteristics of idle
batteries.
17-79. BATTERIES. The sets lead acid batteries are
shipped dry. They can be stored indefinitely and when
ready to use filled with electrolyte (acid) with a specific
gravity of 1.265 to 1.280. It is recommended that
batteries be placed on charge after electrolyte is added.
17-82. SYSTEM DESCRIPTION. The 500 KW DOD
generator set is designed to be used as a single unit or
in conjunction with as many as three additional units.
Two to four units may be paralleled with the use of one
automatic control module (ACM).
Another added
feature of the generator set is the ability to either add a
remote set control box or to remove the set's control box
for remote operation.
The ACM is designed to
automatically control up to four MEP-029A, 500KW
generator sets.
17-80. Coat battery terminal connections with grease to
prevent corrosion.
Check the electrolyte level
periodically. Make certain all battery vent caps are in
place and unobstructed.
17-81. The integral charger will maintain batteries in a
fully charged condition. It will float at a very low rate to
17-26
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 17-20. Double Thimble-Wall Outlet Details
Table 17-9.
Typical Full Load AC Generator Amps
THREE PHASE 0.8 POWER FACTOR
17-27
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 17-21. 500 KW Exhaust System
The utility monitor circuit which includes 120 VAC
over/under voltage relay (27/59N), under frequency
relay (81N-U), over frequency relay 81N-0), 1.5 - 15
second (adjustable) time delay relay (TD), 50/60Hz
frequency select switch and a run rely (RR), continually
monitors the 120 VAC utility voltage from the line side
of the utility breaker.
allow all generators to begin a start-up cycle providing
the generators are in the automatic mode. Relays
27/59N, 81N-U, TD and RR de-energize allowing 24
volts D. C. to energize the K5 engine start circuit via
normally closed contacts TD and RR through TB4-5, 6,
7, 8 through J3-B through the automatic position of the
auto-trip manual switch (s53) on each set. The utility
breaker (located within user switchgear will open via
additional sets RR contacts at TB3-17, 18, and 19.
When the utility power is normal, relays 27/59N, 81N-U
and TD are energized (81N-0 will only energize during
an over-frequency condition) and the normal power
available lamp will be on.
As the generators run up to speed, each generator's
quality circuit (81G-0, 81G-U, 27/59G and CR) monitors
the condition of their respective set. This circuit has
identical voltage and frequency specifications as the
utility monitor circuit in the ACM and is only completely
functional if the generator set is in the automatic mode.
If the utility power completely fails or voltage varies by
more than ±10% and/or frequency varies more than
±3%, TD relay after a 1.5 - 15 second time delay will
17-28
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
prevents RR relay from being re-energized if utility
power returns via LR1 normally closed contacts in series
with RR relay coil. This allows all sets, which are in the
automatic mode, to complete their start-up and parallel
cycles regardless of utility power returning. As each
remaining set is automatically synchronized and
paralleled to the bus, the remaining LR and LRTD relays
will energize in numerical order.
As each generator satisfies its own quality circuit,
control relay (CR) will energize and provide 120 VAC
through J3-N to TB2-5, 6, 7, or 8 to its applicable MR
relay (MR1, 2, 3, or 4) in the ACM. However, the first
MR to be energized will lock out all other MR relays and
also provide a closure to its generator circuit breaker
control circuit via its applicable normally open contact
(TB3-1 through TB3-8) through J3-D and J3-E. The first
set to close its circuit breaker via MR will also energize
its own breaker control relay (BCR)which now
disconnects its synchronizer to electric governor (2301)
connection which is no longer needed since this
generator is already on line. Once all other units have
satisfied their quality circuit and energized CR, their
respective synchronizers will be energized via CR
contacts at terminal one of the synchronizer. The fact
that all other MR relays have locked out and
synchronizers are now energized, enables the remaining
units circuit breakers to be closed only when proper
synchronization has taken place. It should be noted that
K106 sync check relay (N. O. contacts 5 and 6) is
always in the circuit breaker closure circuit in series with
MR closure contacts and/or the synchronizer closure
contacts. This will preclude any set circuit breaker
closure, in automatic or manual unsynchronized.
The ACM has a 3 position rotary switch labeled
“Instant”, "Time Delay" (TD) and "No Return". This
switch allows the user three options as to what will
happen when the utility power returns after a failure. If
the switch is in the "Instant" return position, immediately,
when the utility power returns, the utility 120 VAC will be
supplied through energized T. D. relay normally open
contacts through S1 to TB2-1, 2, 3, and 4 to J3-C on all
units, energizing the breaker trip relay (BTR) which will
shunt trip each unit's circuit breaker (CB2). At this time,
all BR, LR and LRTD relays de-energize causing the
LR1 normally closed contact, in series with RR coil, to
re-close allowing RR relay to re-energize, thereby
allowing the utility breaker to close back to the load. In
the "TD" position, a 3-30 minute (adjustable) time delay
via UTR (Utility Trip Relay) allows a pre-determined
time delay after the utility power returns before the unit
circuit breakers (CB2) are tripped. This insures utility
power has returned to stay, avoiding unnecessary
transfer and re-transfers of the utility breaker control. In
the "no return" position, the generators will carry the
load until switched off by the operator.
As each set circuit breaker (CB2) closes, its auxiliary
contacts (CB2-5) will close allowing 120 V.A.C. via J3-P
to TB2-9, 10, 11 or 12 to energize each sets respective
BR1-BR4 relay. These BR relays along with the 24
VDC available to LR1 (LRTD1) - LR 4 (LRTD4) make up
the prioritized feeder breaker control circuits. The first
set to close to the bus will energize a BR relay which will
always close LR1 (Load Relay) and its .2 - 20 second
(adjustable) time delay (LRTD1) secondly. Each LR and
LRTD should control loads not to exceed 250KW each.
LRTD's allow a time delay between load applications as
to allow engine turbochargers to build up speed. LR1
relay will always be the first relay to energize on start-up
and the last relay to de-energize when the sets are shut
down. Therefore, it is classified as the #1 priority feeder
breaker control. When LR1 relay energizes, it also
At the same instant when all units CB2's are tripped
open via BTR, SDT (Shut Down timer) begins a 1-300
second (adjustable) time out before de-energizing. This
SDT relay allows the engines to continue to run and cool
down after the load has been removed.
At the end of this time delay period, SDT N. O. contacts
re-open, removing the 24 VDC to TB4-5, 6, 7, 8 and
J3-B which in turn allows K5 relays to de-energize and
stop all units.
17-29
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 17-22. Installation of Mufflers on Generator Set.
17-30
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 17-23. Muffler Provided with Generator Set
17-31
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 17-24. Generator Voltages and Schematic
requiring regular service.
An item requiring daily
attention must, of course, be made more accessible
than one requiring service every 5000 hours.
17-83. Generator sets should be located in easy-toclean, dry areas. When installed outdoors, the set
should be a housed unit, or an enclosure should be built
to protect it from inclement weather. Don't overlook the
possibility of spring flooding or high water level during
storms if the set is to be located in a low area such as a
water front or basement installation.
NOTE
For standby units it is important that servicing is
performed on a calendar basis since it may take
years to accumulate any significant number of
hours to the set. Failure to do this may result in
the set not starting or operating properly when
the unit is most needed.
17-84. Screens or other protection should be provided
to safeguard against potential fire hazards and/or
operational problems which can be caused by rodents,
insects, birds, etc. They have been known to live or
build nests inside enclosures and even inside
generators.
17-87. Before initial startup, refer to the installation
check list, table 17-10 to ensure that the generator set is
installed properly.
17-85. Whenever possible, install the set in an area
which can be quickly reached for repair in case of
malfunction. Service entrances should be large enough
to permit removal of large components such as engine,
radiator, or generator in the even major overhaul or
replacement becomes a necessity.
Connect battery just prior to starting set. Be sure
connections are tight and polarity is correct. (Check
wiring diagram. ) All 500 KW DOD generator sets are
designed for negative ground. Make certain muffler is
installed with proper air flow.
Inlet and outlet
connections must be made as labeled on the muffler.
17-86. Service items that are hard to reach will not be
properly maintained. Make sure ample room is provided
around the set especially at points requiring regular
attention. Figure 17-25 illustrates the location of items
17-32
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Figure 17-25. Service Points on 500 KW Generator Set
17-33
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
Table 17-10. Installation Check List
17-34
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
APPENDIX A
REFERENCES
A-1.
Fire Protection
TB 5-4200-200-10
Hand Portable Fire Extinguishers
Approved by Army Users.
A-2.
Lubrication
C9100-IL
L05-6115-593-12
LI-6115-12/1
Identification list for Fuels,
Lubricants, Oils and Waxes.
Lubrication Order
A-3.
Painting
T.O. 35-1-3
TM 43-0139
Painting and Marking of USAF Aerospace
Ground Equipment.
Painting Instructions for Field Use.
A-4.
Radio Suppression
MIL-STD-461
TM 11-483
Radio Interference Suppression.
Radio Interference Suppression.
A-5.
Maintenance
T.O. 00-25-225
Repair of External Power Cables, Aerospace
Ground Equipment.
General Shop Practice Requirements for
the Repair, Maintenance and Test of
Electrical Equipment.
Cleaning of Aerospace Equipment.
Corrosion Control and Treatment for
Aerospace Equipment.
Installation Practices for Aircraft
Electric and Electronic Wiring.
General Maintenance Practices
Organization, Intermediate and Depot
Level Maintenance for FSC 6115
Non-Airborne Equipment.
Components and Procedures for Cleaning
Aerospace Ground Equipment.
Repair/Replacement Criteria for FSC 6115
Aerospace Ground Equipment.
USAF Equipment Registration Number System
Applicable to FSC 6115 Equipment.
Use of Antifreeze Solutions and Cleaning
Compounds in Engine Cooling Systems.
The Army Maintenance Management System
Welding
T.O. 00-25-234
T.O. 1-1-1
T.O. 1-1-2
T.O. 1-1A-14
T.O. 35-1-75
T.O. 35-1-11
T.O. 35-1-12
T.O. 35-1-26
T.O. 35-1-524
T. B. 750-651
DA PAM 738-750
TM 9-237
A-1
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
APPENDIX A
REFERENCES
A-6.
A-7.
A-8.
TM 5-6115-593-12
T.O. 35C2-3-463-1
P-8-631-12
TM-6115-12/6
Operator/Crew and Organizational Maintenance Manual.
TM 5-6115-593-34
T.O. 35C2-3-463-2
P-8-631-34
TM-6115-34/7
Intermediate (Field) (Direct and General)
Support) and Depot Level Maintenance
Manual.
TM 5-6115-593-24P
P-8-631-24P
SL-4-6115-24/2
T.O. 35C2-3-463-4
Organizational, Intermediate (Field)
(Direct and General Support) and Depot
Maintenance Repair Parts and Special
Tools List.
Shipment and Storage
T.O. 35-1-4
Processing and Inspection of Aerospace
Ground Equipment for Storage and
Shipment.
T.O. 38-1-5
Processing and Inspection of Non-mounted,
Non-Aircraft Gasoline and Diesel Engines
for Storage and Shipment.
TB 740-97-2
Preservation of USAMEC Mechanical
Equipment for Shipment and Storage.
Destruction of Material
TM 750-244-3
Procedures for Destruction of Equipment
to Prevent Enemy Use.
Radioactive Material
TB 750-248
Instructions for Safe Handling,
Maintenance, Storage, and Disposal of
Radioactive Commodities Managed by U.S.
Army Mobility Equipment Command.
A-2
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
INDEX
Paragraph,
Figure, Table,
Number
Subject
A
AC-DC CONTROL BOX
Battery Charger
Inspect ..................................................................................................................................................4-7
Test.......................................................................................................................................................4-9
Replace.................................................................................................................................................4-8b
Repair ...................................................................................................................................................4-10
Capacitors
Test.......................................................................................................................................................4-25a
Replace.................................................................................................................................................4-25e
Circuit Card
Test.......................................................................................................................................................4-29a
Replace.................................................................................................................................................4-29b
Repair ...................................................................................................................................................4-29b
Diodes
Test.......................................................................................................................................................4-9b
Replace.................................................................................................................................................4-3b
Governor (A106)
Inspect ..................................................................................................................................................4-12
Test.......................................................................................................................................................4-15b
Adjust....................................................................................................................................................3-13
Replace.................................................................................................................................................4-14b
Repair ...................................................................................................................................................4-16b
Harness Assembly
Replace.................................................................................................................................................10-2c
Potentiometer, Motor Driven
Test.......................................................................................................................................................4-26b
Replace.................................................................................................................................................4-26a
Repair ...................................................................................................................................................4-26c
Relays
Test.......................................................................................................................................................4-23a
Replace.................................................................................................................................................4-23b
Resistor
Test.......................................................................................................................................................4-4a
Replace.................................................................................................................................................4-3b
Shunt
Replace.................................................................................................................................................4-22b
Voltage Regulator
Inspect ..................................................................................................................................................4-18
Test.......................................................................................................................................................4-19
Replace.................................................................................................................................................4-20b
Repair ...................................................................................................................................................4-20a
AUTOMATIC CONTROL MODULE
Under/Overvoltage Device
Test.......................................................................................................................................................15-16a
Adjust....................................................................................................................................................15-16
Replace.................................................................................................................................................15-16b
Underfrequency Device
Test.......................................................................................................................................................15-17a
Adjust....................................................................................................................................................15-17
Replace.................................................................................................................................................15-17b
Index-1
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
INDEX
Paragraph,
Figure, Table,
Number
Subject
A-Continued
Overfrequency Device
Test.......................................................................................................................................................15-18a
Adjust....................................................................................................................................................15-18
Replace.................................................................................................................................................15-18b
Time Delay Relays
Test............................................................................................................................................15-19, 22, 23a
Adjust.......................................................................................................................................... 15-19, 22, 23
Replace......................................................................................................................................15-19, 22, 23b
Relays
Test................................................................................................................................................ 15-20, 21a
Replace.......................................................................................................................................... 15-20, 21b
C
CONTROL CUBICLE
Annunciator Control Assembly
Test.......................................................................................................................................................5-6a
Replace.................................................................................................................................................5-6c
Repair ...................................................................................................................................................5-6b
Diodes
Test.......................................................................................................................................................5-9b
Replace.................................................................................................................................................5-9b
Digital Clock
Test.......................................................................................................................................................5-10a
Replace.................................................................................................................................................5-10b
Flashing Circuit (FC1)
Test.......................................................................................................................................................5-7
Replace.................................................................................................................................................5-7
Harness Assembly
Replace.................................................................................................................................................10-2c
Horn, Alarm
Test.......................................................................................................................................................5-11b
Replace.................................................................................................................................................5-11b
Relays
Test.......................................................................................................................................................5-4
Replace.................................................................................................................................................5-4
Resistors
Test.......................................................................................................................................................5-9a
Replace.................................................................................................................................................5-9a
Synchroscope
Inspect ..................................................................................................................................................5-8a
Test.......................................................................................................................................................5-8b
Replace.................................................................................................................................................5-8c
Time Delay Module (TD2)
Test.......................................................................................................................................................5-4i
Replace.................................................................................................................................................5-4i
Repair ...................................................................................................................................................5-4i
Transducer, Electrical Signal
Test.......................................................................................................................................................5-2a
Replace.................................................................................................................................................5-2b
Index-2
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
INDEX
Paragraph,
Figure, Table,
Number
Subject
C-Continued
Transformers
Test.......................................................................................................................................................5-3a
Replace.................................................................................................................................................5-3c
Relays Mounted on Rear of Control Panel
Test.......................................................................................................................................................5-12
Replace.................................................................................................................................................5-12
E
ELECTRIC HYDRAULIC ACTUATOR
Test .........................................................................................................................................................12-2
Adjust ......................................................................................................................................................12-3
Replace ...................................................................................................................................................12-4
Repair......................................................................................................................................................12-5
Overhaul..................................................................................................................................................12-6
ENGINE ASSEMBLY
Crankshaft and Block
Camshaft Bushings
Inspect. ..............................................................................................................................................13-29b
Replace..............................................................................................................................................13-29
Crankshaft
Inspect ...............................................................................................................................................13-29b
Replace..............................................................................................................................................13-29
Cylinder Block
Inspect ...............................................................................................................................................13-29b
Replace..............................................................................................................................................13-29
Repair ................................................................................................................................................13-29c
Overhaul ............................................................................................................................................13-29d
Rebuild...............................................................................................................................................13-29d
Cylinder Liners
Inspect ...............................................................................................................................................13-29b
Replace..............................................................................................................................................13-29
Main Bearings
Inspect ...............................................................................................................................................13-29b
Replace..............................................................................................................................................13-29b
Cylinder Head and Valve Operating Mechanism
Camshaft
Inspect ...............................................................................................................................................13-27b
Replace..............................................................................................................................................13-27b
Cylinder Head Assembly
Inspect ...............................................................................................................................................13-22c
Replace..............................................................................................................................................13-22a
Repair ................................................................................................................................................13-22d
Overhaul ............................................................................................................................................13-22e
Rebuild...............................................................................................................................................13-22f
Head Cylinder
Inspect ...............................................................................................................................................13-22c
Replace..............................................................................................................................................13-22d
Overhaul ............................................................................................................................................13-33e
Rebuild...............................................................................................................................................13-22f
Index-3
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
INDEX
Paragraph,
Figure, Table,
Number
Subject
E-Continued
Lifters, Valves
Inspect ...............................................................................................................................................13-22c
Replace..............................................................................................................................................13-22a
Pushrod and Tappet
Inspect ...............................................................................................................................................13-21
Replace..............................................................................................................................................13-21b
Rocker Arm Shaft Assembly
Inspect ...............................................................................................................................................13-20b
Replace..............................................................................................................................................13-20b
Seats Intake and Exhaust Valves
Inspect ...............................................................................................................................................13-22c
Replace..............................................................................................................................................13-22d
Spring Valve
Inspect ...............................................................................................................................................13-23
Test....................................................................................................................................................13-23c
Replace..............................................................................................................................................13-23d
Valve Intake and Exhaust
Inspect ...............................................................................................................................................13-23b
Test....................................................................................................................................................13-23c
Replace..............................................................................................................................................13-23d
Repair ................................................................................................................................................13-23d
Valve Spring
Inspect ...............................................................................................................................................13-22c
Replace..............................................................................................................................................13-22d
Flywheel and Housing
Flywheel
Inspect ...............................................................................................................................................13-17a
Replace..............................................................................................................................................13-17a
Housing
Inspect ...............................................................................................................................................13-17a
Replace..............................................................................................................................................13-17a
Ring Gear
Inspect ...............................................................................................................................................13-17a
Replace..............................................................................................................................................13-17a
Timing Gear and Cover
Inspect ...............................................................................................................................................13-18b
Replace..............................................................................................................................................13-18b
Oil Filters and Sensors
Bypass Filters
Replace..............................................................................................................................................13-11c
Bypass Valve
Inspect ...............................................................................................................................................13-12b
Test....................................................................................................................................................13-12b
Replace..............................................................................................................................................13-12d
Repair ................................................................................................................................................
Fuel Injection Pump
Test....................................................................................................................................................13-14
Adjust.................................................................................................................................................13-14
Index-4
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
INDEX
Paragraph,
Figure, Table,
Number
Subject
E-Continued
Replace..............................................................................................................................................13-14
Repair ................................................................................................................................................13-14
Overhaul ............................................................................................................................................13-14
Rebuild...............................................................................................................................................13-14
Injectors
Test....................................................................................................................................................13a-13c
Adjust.................................................................................................................................................13f
Repair ................................................................................................................................................13e
Lube Oil Cooler
Test....................................................................................................................................................13-7a
Repair ................................................................................................................................................13-7b
Turbocharger
Repair ................................................................................................................................................13-11
Piston and Rings
Connecting Rod
Inspect ...............................................................................................................................................13-28b
Replace..............................................................................................................................................13-28c
Piston
Inspect ...............................................................................................................................................13-28b
Replace..............................................................................................................................................13-28c
Piston Pin
Inspect ...............................................................................................................................................13-28b
Replace..............................................................................................................................................13-28c
Piston Rings
Inspect ...............................................................................................................................................13-28b
Replace..............................................................................................................................................13-28c
Bearing
Inspect ...............................................................................................................................................13-28b
Replace..............................................................................................................................................13-28c
Speed Switch and Drive
Adapter
Replace..............................................................................................................................................13-4c
Speed Switch
Adjust.................................................................................................................................................13-3c
Repair ................................................................................................................................................13-3c
Tachometer Drive
Inspect ...............................................................................................................................................13-5b
Replace..............................................................................................................................................13-5
Repair ................................................................................................................................................13-5c
Starter Assembly
Inspect ...............................................................................................................................................13-6b
Test....................................................................................................................................................13-6c
Replace..............................................................................................................................................13-6
Repair ................................................................................................................................................13-6j
Overhaul ............................................................................................................................................13-6k
Armature Starter
Test....................................................................................................................................................13-6g
Index-5
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
INDEX
Paragraph,
Figure, Table,
Number
Subject
E-Continued
Brushes
Inspect ...............................................................................................................................................13-6b
Replace..............................................................................................................................................13-6f
Drive Starter
Inspect ...............................................................................................................................................13-6f
Field Coil
Test....................................................................................................................................................13-6h
Solenoid Starter
Test....................................................................................................................................................13-6i
Thermostat and Housing
Engine Front Support
Inspect ...............................................................................................................................................13-14a
Replace..............................................................................................................................................13-14a
Oil Pan Assembly
Replace..............................................................................................................................................13-15
Repair ................................................................................................................................................13-15b
Oil Pump
Inspect ...............................................................................................................................................13-16a
Test....................................................................................................................................................13-16b
Replace..............................................................................................................................................13-16d
Repair ................................................................................................................................................13-16c
Vibration Damper and Crankshaft Pulley
Replace..............................................................................................................................................13-13
Water Pump
Repair ................................................................................................................................................13-12
ENGINE PREHEAT ASSEMBLY
Heating Element
Replace.................................................................................................................................................8-2a
Test.......................................................................................................................................................8-2b
Thermostat
Replace.................................................................................................................................................8-3a
Test.......................................................................................................................................................8-3b
INE POWER BOX ASSEMBLY
Contactor (K120)
Test.......................................................................................................................................................3-3a
Replace.................................................................................................................................................3-3c
Repair ...................................................................................................................................................3-3c
Contactors (K107) (K109)
Repair ...................................................................................................................................................3-1b
Harness Assembly
Replace.................................................................................................................................................10-2
Transfer Contactor (K108)
Repair ...................................................................................................................................................3-2
Index-6
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
INDEX
Paragraph,
Figure, Table,
Number
Subject
F
FUEL TRANSFER PUMP ASSEMBLY
Pump
Replace.................................................................................................................................................9-2
Repair ...................................................................................................................................................9-3
Solenoid Valve
Test.......................................................................................................................................................9-3g
Replace.................................................................................................................................................9-3g
G
GENERAL MAINTENANCE
Cleaning ..................................................................................................................................................2-8
Soldering .................................................................................................................................................2-10
Welding ...................................................................................................................................................2-11
Wiring......................................................................................................................................................2-9
GENERATOR AND RECONNECTION ASSEMBLY
Bearing
Replace.................................................................................................................................................11-9
Buss Bar
Replace.................................................................................................................................................11-3b
Current Transformer
Inspect ..................................................................................................................................................11-4a
Test.......................................................................................................................................................11-4a
Replace.................................................................................................................................................11-4c
Drive Plate Assembly
Replace.................................................................................................................................................11-10a
Exciter Armature
Inspect ..................................................................................................................................................11-14a
Test.......................................................................................................................................................11-14b
Replace.................................................................................................................................................11-14c
Repair ...................................................................................................................................................11-14d
Rebuild .................................................................................................................................................11-14d
Exciter Stator
Inspect ..................................................................................................................................................11-13a
Test.......................................................................................................................................................11-13b
Replace.................................................................................................................................................11-13c
Repair ...................................................................................................................................................11-13d
Rebuild .................................................................................................................................................11-13d
Fan
Inspect ..................................................................................................................................................11-11a
Replace.................................................................................................................................................11-11a
Frame and Stator Combination
Inspect ..................................................................................................................................................11-15a
Test.......................................................................................................................................................11-15b
Replace.................................................................................................................................................11-15c
Repair ...................................................................................................................................................11-15d
Rebuild .................................................................................................................................................11-15e
Generator
Inspect ..................................................................................................................................................11-5
Test.......................................................................................................................................................11-5b
Replace.................................................................................................................................................11-5c
Index-7
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
INDEX
Paragraph,
Figure, Table,
Number
Subject
G-Continued
Overhaul ...............................................................................................................................................11-5d
Rebuild .................................................................................................................................................11-5e
Harness and Cable
Inspect ..................................................................................................................................................10-2
Replace.................................................................................................................................................10-2
Repair ...................................................................................................................................................10-2
Permanent Magnet Rotor Assembly
Inspect ..................................................................................................................................................11-7a
Test.......................................................................................................................................................11-7b
Replace.................................................................................................................................................11-7c
Repair ...................................................................................................................................................11-7d
Rebuild .................................................................................................................................................11-7e
Permanent Magnet Stator and Frame Assembly
Inspect ..................................................................................................................................................11-6b
Test.......................................................................................................................................................11-6c
Replace.................................................................................................................................................11-6d
Reconnection Board
Replace.................................................................................................................................................11-2b
Rotating Rectifier
Inspect ..................................................................................................................................................11-8a
Test.......................................................................................................................................................11-8b
Replace.................................................................................................................................................11-8c
Repair ...................................................................................................................................................11-8d
Rotor Assembly
Inspect ..................................................................................................................................................11-12a
Test.......................................................................................................................................................11-12b
Replace.................................................................................................................................................11-12c
Repair ...................................................................................................................................................11-12c
Rebuild .................................................................................................................................................11-12c
Switch, Limit
Test.......................................................................................................................................................11-2c
Replace.................................................................................................................................................11-2c
GENERATOR SET INSTALLATION PRACTICES
Air Requirements .....................................................................................................................................17-26
Cooling System........................................................................................................................................17-38
Electrical Requirements ...........................................................................................................................17-79
Exhaust System.......................................................................................................................................17-71
Fuel System.............................................................................................................................................17-60
Location...................................................................................................................................................17-13
Mounting..................................................................................................................................................17-17
Safety Precautions...................................................................................................................................17-1
Service Requirements..............................................................................................................................17-83
Vibration ..................................................................................................................................................17-18
GENERATOR SET.TEST AND INSPECTION AFTER REPAIR OR OVERHAUL
Inspections
Electrical Accessories ...........................................................................................................................16-6
Engine ..................................................................................................................................................16-4
General.................................................................................................................................................16-2
Generator..............................................................................................................................................16-5
Index-8
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
INDEX
Paragraph,
Figure, Table,
Number
Subject
G-Continued
Housing and Frame...............................................................................................................................16-3
Operational Tests
Circuit Interrupter (Overhaul Current) ....................................................................................................16-19
Circuit Interrupter (Overvoltage and Undervoltage Current)...................................................................16-20
Circuit Interrupter (Short Circuit)............................................................................................................16-18
Frequency Adjustment Range ...............................................................................................................16-16
Frequency and Voltage Regulation........................................................................................................16-15
General.................................................................................................................................................16-7
Low Fuel Protective Device...................................................................................................................16-8
Low Oil Pressure Protective Device ......................................................................................................16-21
Malfunction Indicator.............................................................................................................................16-12
Maximum Power ...................................................................................................................................16-24
Overspeed Protective Device................................................................................................................16-17
Overtemperature Protective Device ......................................................................................................16-22
Parallel Operation Provisions ................................................................................................................16-10
Phase Balance ......................................................................................................................................16-13
Phase Sequence ...................................................................................................................................16-23
Regulator Range ...................................................................................................................................16-14
Reverse Power Protective Device .........................................................................................................16-8
H
HOUSING KIT
Adjust ......................................................................................................................................................15-32
Install.......................................................................................................................................................15-30
Replace ...................................................................................................................................................15-32
Repair......................................................................................................................................................15-32
Actuators, Louver
Test.......................................................................................................................................................15-28a
Adjust....................................................................................................................................................15-28b
Replace.................................................................................................................................................15-28c
Harness Assembly
Replace ...........................................................................................................................................15-26a
Relays
Test .................................................................................................................................................15-30
Shutter Assembly
Inspect ..................................................................................................................................................15-26b
Adjust....................................................................................................................................................thru
Replace.................................................................................................................................................15-26h
Switches, Limit
Test.......................................................................................................................................................15-29a
Replace.................................................................................................................................................15-29b
I
INTERCONNECTING ELECTRICAL HARNESS
Replace ...................................................................................................................................................10-2
Index-9
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
INDEX
Paragraph,
Figure, Table,
Number
Subject
P
PARALLEL CABLE ASSEMBLIES
Inspect.....................................................................................................................................................10-4
Replace ...................................................................................................................................................10-6
Repair......................................................................................................................................................10-5
R
RADIATOR ASSEMBLY
Fan and Bearing
Inspect ..................................................................................................................................................7-6a
Replace.................................................................................................................................................7-6c
Indicator, Sight Valve
Replace ...........................................................................................................................................7-9
Motor
Test.......................................................................................................................................................7-6
Replace.................................................................................................................................................7-9f
Repair ...................................................................................................................................................7-9f
Radiator
Test.......................................................................................................................................................7-2
Replace.................................................................................................................................................7-7b
Repair ...................................................................................................................................................7-4
REMOTE CONTROL CABLE
Inspect.....................................................................................................................................................15-3
Replace ...................................................................................................................................................15-4
Repair......................................................................................................................................................15-15
REMOTE CONTROL MODULE
Annunciator Control Assembly
Test.......................................................................................................................................................15-1-a
Replace.................................................................................................................................................15-10c
Repair ...................................................................................................................................................15-10b
Diodes
Test.......................................................................................................................................................15-14
Replace.................................................................................................................................................15-14
Flasher
Test.......................................................................................................................................................15-11
Replace.................................................................................................................................................15-11
Relays
Test.......................................................................................................................................................15-8a
Replace.................................................................................................................................................15-8b
Resistors
Test.......................................................................................................................................................15-13b
Replace.................................................................................................................................................15-13
Synchroscope
Inspect ..................................................................................................................................................15-7a
Test.......................................................................................................................................................15-7b
Replace.................................................................................................................................................15-7c
Transducers
Test.......................................................................................................................................................15-9a
Replace.................................................................................................................................................15-9b
Index-10
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
INDEX
Paragraph,
Figure, Table,
Number
Subject
R-Continued
Transformers
Test.......................................................................................................................................................15-12b
Replace.................................................................................................................................................15-12a
REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
AC-DC Control Box..................................................................................................................................2-14
Control Cubicle ........................................................................................................................................2-13
Engine .....................................................................................................................................................2-18
External Power Box .................................................................................................................................2-15
Generator ................................................................................................................................................2-17
Radiator...................................................................................................................................................2-16
SUPPORT FRAME ASSEMBLY
Support Frame, Center
Replace ...........................................................................................................................................6-2
Support Frame, Front
Replace ...........................................................................................................................................6-2
Support Frame, Rear
Replace ...........................................................................................................................................6-2
Tie Bars
Replace ...........................................................................................................................................6-2
T
TABULATED DATA .........................................................................................................................................1-7
TORQUE DATA ...............................................................................................................................................T1-1
TROUBLESHOOTING .....................................................................................................................................T2-2
Index-11
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
By Order of the Secretaries of the Army, Air Force, and Navy:
CARL E. VUONO
General, United States Army
Chief of Staff
Official:
PATRICIA P. HICKERSON
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. BOTTORFF
Rear Admiral, CEC, US Navy
Commander
Navy Facilities Engineering Command
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25E, (qty rqr block no. 0867).
U.S. GOVERNMENT PRINTING OFFICE: 1991 - 554-030/40062
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-1. Generator Set, Electrical Layout
FP-1/FP-2 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-2. Main Control Harness (Sheet 1 of 2)
FP-3/(FP-4 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-3. Main Control Harness (Sheet 2 of 2)
FP-5/(FP-6 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-4. AC Power Wiring Harness
FP-7/(FP-8 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-5. External Power Box Harness Assembly (Sheet 1 of 2)
FP-9/(FP-10 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-6. External Power Box Harness Assembly (Sheet 2 of 2)
FP-11/(FP-12 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO 7. AC-DC Control Box Harness Assembly (Sheet 1 of 5)
FP-13/(FP-14 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO 8. AC-DC Control Box Harness Assembly (Sheet 2 of 5)
FP-15/(FP-16 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO 9. AC-DC Control Box Harness Assembly (Sheet 3 of 5)
FP-17/(FP-18 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO 10. AC-DC Control Box Harness Assembly (Sheet 4 of 5)
FP-19/(FP-20 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-11. AC-DC Control Box Harness Assembly (Sheet 5 of 5)
FP-21/ (FP-22 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-12. Control Box Harness Assembly (Sheet 1 of 8)
FP-23/ (FP-24 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-13. Control Box Harness Assembly (Sheet 2 of 8)
FP-25/ (FP-26 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-14. Control Box Harness Assembly (Sheet 3 of 8)
FP-27/ (FP-28 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-15. Control Box Harness Assembly (Sheet 4 of 8)
FP-29/ (FP-30 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-16. Control Box Harness Assembly (Sheet 5 of 8)
FP-31/ (FP-32 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463
FO-17. Control Box Harness Assembly (Sheet 6 of 8)
FP-33/ (FP-34 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463
FO-18. Control Box Harness Assembly (Sheet 7 of 8)
FP-35/ (FP-36 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463
FO-19. Control Box Harness Assembly (Sheet 8 of 8)
FP-37/ (FP-38 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463
FO-20. Reconnection Box Harness Assembly
FP-39/ (FP-40 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-21. Reconnection Harness
FP-41 / (FP-42 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-22. Engine Accessory Harness (Sheet 1 of 3)
FP-43/(FP-44 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-23. Engine Accessory Harness (Sheet 2 of 3)
FP-45/(FP-46 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-24. Engine Accessory Harness (Sheet 3 of 3)
FP-47/(FP-48 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-25. Remote Control Cable Assembly (Sheet 1 of 2)
FP-49/(FP-50 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-26. Remote Control Cable Assembly (Sheet 2 of 2)
FP-51/(FP-52 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-27. Remote Control Box Harness Assembly (Sheet 1 of 4)
FP-53/(FP-54 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-28. Remote Control Box Harness Assembly (Sheet 2 of 4)
FP-55/(FP-56 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-29. Remote Control Box Harness Assembly (Sheet 3 of 4)
FP-57/(FP-58 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-30. Remote Control Box Harness Assembly (Sheet 4 of 4)
FP-59/(FP-60 blank)
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-31. Paralleling Cables, Governor Control
FP-61/(FP-62 blank)
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-32. Paralleling Cables, Voltage Regulator
FP-63/(FP-64 blank)
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-33. Louver Harness Assembly (Sheet 1 of 2 )
FP-65/(FP-66 blank)
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-34. Louver Harness Assembly (sheet 2 of 2 )
FP-67/(FP-68 blank)
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-35. Louver Control Harness (External Power Box )
FP-69/(FP-70 blank)
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-36. Auxiliary Power Harness
FP-71/(FP-72 blank)
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-37. Electrical Cable Assembly
FP-73/(FP-74 blank)
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-38. AC Neutral Power Cable
FP-75/(FP-76 blank)
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-39. AC-DC Control Cable Assembly
FP-77/ ( FP-78 blank)
TM 5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-40. Battery Cables
FP-79/(FP-80 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-41. Cables 25- and 37 -Conductor
FP-81/(FP-82 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-42. ACM Wiring Harness (Sheet 1 of 3)
FP-83/(FP-84 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-43. ACM Wiring Harness (Sheet 2 of 3)
FP-85/(FP-85 blank)
TM5-6115-593-34
NAVFAC P-8-631-34
TO-35C2-3-463-2
FO-44. ACM Wiring Harness (Sheet 3 of 3)
FP-87/(FP-88 blank)
The Metric System and Equivalents
Linear Measure
Liquid Measure
1 centiliter = 10 milliters = .34 fl. ounce
1 deciliter = 10 centiliters = 3.38 fl. ounces
1 liter = 10 deciliters = 33.81 fl. ounces
1 dekaliter = 10 liters = 2.64 gallons
1 hectoliter = 10 dekaliters = 26.42 gallons
1 kiloliter = 10 hectoliters = 264.18 gallons
1 centimeter = 10 millimeters = .39 inch
1 decimeter = 10 centimeters = 3.94 inches
1 meter = 10 decimeters = 39.37 inches
1 dekameter = 10 meters = 32.8 feet
1 hectometer = 10 dekameters = 328.08 feet
1 kilometer = 10 hectometers = 3,280.8 feet
Square Measure
Weights
1 sq. centimeter = 100 sq. millimeters = .155 sq. inch
1 sq. decimeter = 100 sq. centimeters = 15.5 sq. inches
1 sq. meter (centare) = 100 sq. decimeters = 10.76 sq. feet
1 sq. dekameter (are) = 100 sq. meters = 1,076.4 sq. feet
1 sq. hectometer (hectare) = 100 sq. dekameters = 2.47 acres
1 sq. kilometer = 100 sq. hectometers = .386 sq. mile
1 centigram = 10 milligrams = .15 grain
1 decigram = 10 centigrams = 1.54 grains
1 gram = 10 decigram = .035 ounce
1 decagram = 10 grams = .35 ounce
1 hectogram = 10 decagrams = 3.52 ounces
1 kilogram = 10 hectograms = 2.2 pounds
1 quintal = 100 kilograms = 220.46 pounds
1 metric ton = 10 quintals = 1.1 short tons
Cubic Measure
1 cu. centimeter = 1000 cu. millimeters = .06 cu. inch
1 cu. decimeter = 1000 cu. centimeters = 61.02 cu. inches
1 cu. meter = 1000 cu. decimeters = 35.31 cu. feet
Approximate Conversion Factors
To change
To
inches
feet
yards
miles
square inches
square feet
square yards
square miles
acres
cubic feet
cubic yards
fluid ounces
pints
quarts
gallons
ounces
pounds
short tons
pound-feet
pound-inches
Multiply by
centimeters
meters
meters
kilometers
square centimeters
square meters
square meters
square kilometers
square hectometers
cubic meters
cubic meters
milliliters
liters
liters
liters
grams
kilograms
metric tons
Newton-meters
Newton-meters
2.540
.305
.914
1.609
6.451
.093
.836
2.590
.405
.028
.765
29,573
.473
.946
3.785
28.349
.454
.907
1.356
.11296
To change
ounce-inches
centimeters
meters
meters
kilometers
square centimeters
square meters
square meters
square kilometers
square hectometers
cubic meters
cubic meters
milliliters
liters
liters
liters
grams
kilograms
metric tons
To
Newton-meters
inches
feet
yards
miles
square inches
square feet
square yards
square miles
acres
cubic feet
cubic yards
fluid ounces
pints
quarts
gallons
ounces
pounds
short tons
Temperature (Exact)
°F
Fahrenheit
temperature
5/9 (after
subtracting 32)
Celsius
temperature
°C
Multiply by
.007062
.394
3.280
1.094
.621
.155
10.764
1.196
.386
2.471
35.315
1.308
.034
2.113
1.057
.264
.035
2.205
1.102
PIN: 040843-000
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