TM-5-6115-612-12 Generator Set Diesel Engine Driven Tactical Skid Mtd. 600 Kw 3 Phase 4 Wire 120/208 and 240/416 Volts Manual

CHAPTER 1 INTRODUCTION - TM-5-6115-612-12_28
SECTION II. DESCRIPTION AND DATA
Figure 1-1. Aviation Generator Set, Front 3/4 View
Figure 1-2. Aviation Generator Set, Rear Views
TABULATED DATA
DC ELECTRICAL AND CONTROL SYSTEM - TM-5-6115-612-12_33
FUEL SYSTEM
IGNITION SYSTEM
ENGINE
ENGINE/GENERATOR CONTROLS AND INSTRUMENTS
RUNNING GEAR - TM-5-6115-612-12_38
Torque Specifications
COARSE THREAD SERIES NUTS, BOLTS, SCREWS
Table 1-2. Identification and Instruction Plates
Figure 1-3. Fuel System Schematic.
Figure 1-4. Lubrication System Simplified Block Diagram
CHAPTER 2 OPERATING   INSTRUCTIONS
Table 2-1. Controls and Indicators - Continued
Figure 2-1. Control Panel Controls and Indicators
STARTING THE GENERATOR SET
Figure 2-2. Generator Set Operating Instructions Plate
Figure 2-3. Sequence of Operation, Generator Set Start (Steps 1 thru 3)
Figure 2-4. Sequence of Operation, Generator Set Start (Steps 4 and 5)
Starting Procedures
SLAVE START OPERATION
REMOVING    GENERATOR    SET    FROM OPERATION
Figure 2-6. Draining Primary Fuel Filter
Secure Fuel Housing.
Table 3-1. Consumable Operating and Maintenance Supplies
Table 3-1. Consumable Operating and Maintenance Supplies - Continued
Section II. LUBRICATION   INSTRUCTIONS
Figure 3-2. Lubrication Order (Sheet 1 of 2)
Figure 3-2. Lubrication Order (Sheet 2 of 2)
Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Table 3-2. Preventive Maintenance Checks and Services (PMCS) - Continued
Section IV. TROUBLESHOOTING
Section V. OPERATOR/CREW MAINTENANCE INSTRUCTIONS
Figure 3-3. Battery Holddown Inspection
Figure 3-4. Access Covers and Doors Inspection
DC ELECTRICAL AND CONTROL SYSTEM - TM-5-6115-612-12_67
Figure 3-5. Chassis Frame Inspection
Figure 3-6. Battery and Battery Cable Inspection
FUEL SYSTEM - TM-5-6115-612-12_70
Figure 3-7. Inspection of Internal Fuel System Components
ENGINE AND GENERATOR CONTROLS AND INSTRUMENTS
Figure 3-8. Inspection of Control Panel
Figure 3-9. Inspection of Power Cable Assembly
RUNNING GEAR - TM-5-6115-612-12_75
Figure 3-10. Inspection of Running Gear
CHAPTER 4 ORGANIZATIONAL MAINTENANCE
INSPECTING   AND   SERVICING THE EQUIPMENT
Figure 4-1. Battery Service
INSTALLATION - TM-5-6115-612-12_81
Figure 4-2. Installation   Clearances
Figure 4-3. Grounding the Generator Set
Flightline Hardstand Ground Stud
Driven Metal Rod.
Section II. MOVEMENT TO A NEW WORKSITE
REINSTALLATION AFTER MOVEMENT
Figure 4-5. Cable/Sling Hookup for Moving Generator Set
Figure 4-6. Movement by Forklift
Movement by Vehicle
Section IV. LUBRICATION   INSTRUCTIONS
Dralning Oil
Section V. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Table 4-1. Preventive Maintenance Checks and Services
Table 4-1. Preventive Maintenance Checks and Services - TM-5-6115-612-12_95
Table 4-1. Preventive Maintenance Checks and Services - TM-5-6115-612-12_96
Section VI. TROUBLESHOOTING
Table 4-2. Troubleshooting   Index
Table 4-2. Troubleshooting Index
PANEL LIGHTS DO NOT COME ON
DC CIRCUIT BREAKER TRIPS WHEN BATTERY IS CONNECTED
DC CIRCUIT BREAKER TRIPS WHEN MASTER SWITCH IS SET TO RUN
NO ELECTRICAL POWER TO CONTROL PANEL AND DC CIRCUIT BREAKER HAS BEEN RESET
Table 4-3. Organizational Troubleshooting - Continued - TM-5-6115-612-12_104
Table 4-3. Organizational Troubleshooting - Continued - TM-5-6115-612-12_105
ENGINE OVERTEMP INDICATOR COMES ON BEFORE ENGINE START
STARTER ENGAGES BUT UNIT SHUTS DOWN WITH ENGINE OVERTEMP LIGHT
Table 4-3. Organizational Troubleshooting - Continued - TM-5-6115-612-12_108
Table 4-3. Organizational Troubleshooting - Continued
Table 4-3. Organizational Troubleshooting - Continued - TM-5-6115-612-12_110
Table 4-3. Organizational Troubleshooting - Continued - TM-5-6115-612-12_111
Check oil level
Table 4-3. Organizational Troubleshooting - Continued - TM-5-6115-612-12_113
Table 4-3. Organizational Troubleshooting - Continued - TM-5-6115-612-12_114
Table 4-3. Organizational Troubleshooting - Continued - TM-5-6115-612-12_115
Table 4-3. Organizational Troubleshooting - Continued - TM-5-6115-612-12_116
Table 4-3. Organizational Troubleshooting - Continued - TM-5-6115-612-12_117
Table 4-3. Organizational Troubleshooting - Continued - TM-5-6115-612-12_118
Table 4-3. Organizational Troubleshooting - Continued - TM-5-6115-612-12_119
Table 4-3. Organizational Troubleshooting - Continued - TM-5-6115-612-12_120
Table 4-3. Organizational Troubleshooting - Continued - TM-5-6115-612-12_121
Table 4-3. Organizational Troubleshooting - Continued - TM-5-6115-612-12_122
Table 4-3. Organizational Troubleshooting - Continued - TM-5-6115-612-12_123
Table 4-3. Organizational Troubleshooting - Continued - TM-5-6115-612-12_124
OIL SMOKE COMING FROM EXHAUST DURING OPERATION
Section VIII. MAINTENANCE OF FRAME AND HOUSING
Figure 4-8. Tiedown Ring and Battery Holddown Replacement
Removal - TM-5-6115-612-12_128
Figure 4-9. Access Door Replacement (Sheet 1 of 3)
Figure 4-9. Access Door Replacement (Sheet 2 of 3)
Figure 4-9. Access Door Replacement (Sheet 3 of 3)
ACCESS DOORS
Figure 4-10. Access Cover Replacement
Engine Electronic    Control Module (EECM) Access Cover
Figure 4-11.   Bleed Air Connector and Bleed Air Line Replacement
BLEED AIR CONNECTOR
Removal - TM-5-6115-612-12_137
figure 4-12. air filter, air filter muffler housing, and air baffle maintenance
Repair - TM-5-6115-612-12_139
Installation - TM-5-6115-612-12_140
Figure 4-13. Engine Support Inspection
Section IX. MAINTENANCE OF DC ELECTRICAL AND CONTROL SYSTEM
Figure 4-14. Battery Cable Replacement (Sheet 1 of 2)
Figure 4-14. Battery Cable Replacement (Sheet 2 of 2)
Repair - TM-5-6115-612-12_145
Service - TM-5-6115-612-12_146
Installation - TM-5-6115-612-12_147
Figure 4-15. Generator to GECM Wiring Harness
Installation - TM-5-6115-612-12_149
Figure 4-16. Slave Receptacle Maintenance
Insta llation - TM-5-6115-612-12_151
Figure 4-17. GECM Replacement
Figure 4-18. Circuit Breaker Test and Replacement
Test - TM-5-6115-612-12_154
Figure 4-19. Starter Test Point Locations
Test - TM-5-6115-612-12_156
Figure 4-20. Starter Replacement
Insta llation - TM-5-6115-612-12_158
Figure 4-21. Current Shunt (20 Amp) Replacement
Removal - TM-5-6115-612-12_160
Section X. MAINTENANCE OF FUEL SYSTEM
Figure 4-22. Fuel System Components
Figure 4-23. Fuel System Block Diagram
Inspection - TM-5-6115-612-12_164
Figure 4-24. Fuel Manifold Removal
Figure 4-25. Fuel Line Layout (Internal)
ELECTRICAL FUEL TRANSFER PUMP
Figure 4-26. Electrical Fuel Pump (Transfer) and Fuel (Fluid) Filter (Primary)
PRIMARY   FUEL   (FLUID)   FILTER
ENGINE FUEL TANK ASSEMBLY
Figure 4-27. Engine Fuel Tank Replacement
SECONDARY FUEL (FLUID) FILTER
Figure 4-28. Fuel Filter (Secondary)
Figure 4-29. Electrical Fuel Pump (High Pressure) and Solenoid Valve Removal
Insta llation - TM-5-6115-612-12_175
Figure 4-30. Fuel Injection Nozzles
Installation - TM-5-6115-612-12_177
Section XI. MAINTENANCE OF IGNITION SYSTEM
Figure 4-31. Ignition System Components
HIGH TENSION LEAD
SPARK IGNITER
Figure 4-32. Typical Electrode Erosion
IGNITION    COIL
Section XII. MAINTENANCE OF LUBRICATION SYSTEM
Figure 4-33. Oil Filler/Breather Assembly
OIL FILTER ASSEMBLY
OIL COOLER
Figure 4-34. Oil Cooler Service
service - TM-5-6115-612-12_189
Section XIII. MAINTENANCE OF ENGINE
Figure 4-35. Foreign Object Deflection Shield Removal
FOREIGN OBJECT DEFLECTION SHIELD
Figure 4-36. Turbine Maintenance Points
GEARBOX ASSEMBLY
Section XIV. 4-63.     GENERAL. tains     information MAINTENANCE OF ENGINE AND GENERATOR CONTROLS AND INSTRUMENTS
Figure 4-37. Control Panel and Control Panel Wiring Harness
Figure 4-38. Engine and Generator Controls and Instruments Block Diagram
Enqine Startup
ENGINE ELECTRONIC CONTROL MODULE
Figure 4-39. EECM Replacement
MONOPOLE    SPEED    SENSOR
Figure 4-40. Monopole Speed Sensor Replacement
MONOPOLE SPEED SENSOR
Figure 4-41. EGT Thermocouple Replacement
Installation - TM-5-6115-612-12_205
Figure 4-42. Low Oil Pressure Switch Replacement
Inspection - TM-5-6115-612-12_207
Inspection - TM-5-6115-612-12_208
Figure 4-43. Control Panel Component Replacement
Adjustment - TM-5-6115-612-12_210
MASTER SWITCH
MASTER SWITCH
PANEL LIGHTS
Figure 4-45. Indicator Lamp Test3
INCANDESCENT LAMPS
POTENTIOMETER.
SWITCHES - TM-5-6115-612-12_217
SWITCHES - TM-5-6115-612-12_218
WIRING HARNESSES - TM-5-6115-612-12_219
HIRING HARNESSES
Figure 4-47. Wiring Harness Loop Clamp and Grommet Plate Details
WIRING HARNESSES - TM-5-6115-612-12_222
WIRING HARNESSES - TM-5-6115-612-12_223
Section XV. MAINTENANCE OF LOAD CONNECTION
Figure 4-48. Power Cable Replacement
POWER CABLE ASSEMBLY
Figure 4-49. Component Mounting Panel Replacement
Installation - TM-5-6115-612-12_228
MAGNETIC CONTACTOR - TM-5-6115-612-12_229
Figure 4-51. Magnetic Contactor/Capacitor (C4) Replacement
MAGNETIC CONTACTOR - TM-5-6115-612-12_231
Figure 4-52. Current Shunt (1000 Amp)/Resistor (R5) Replacement
CURRENT SHUNT
TERMINAL BOARDS
TERMINAL   BOARDS
CAPACITOR (C4)
S e c t i o n   X V I . MAINTENANCE   OF   RUNNING   GEAR
Figure 4-54. Brake Control Adjustment
Adjustment - TM-5-6115-612-12_239
Figure 4-55. Brake Control Replacement
BRAKE CONTROL.
Figure 4-56. Torsion Axle Assembly and Wheel Assembly
TORSION   AXLE   ASSEMBLY
Installation - TM-5-6115-612-12_244
Figure 4-58. Brake Assembly Inspection
Figure 4-59. Brake Assembly Replacement
BRAKE ASSEMBLY
LUNETTE   EYE
Installation - TM-5-6115-612-12_249
Figure 4-61. Swivel Caster Wheel and Tire
Installation. - TM-5-6115-612-12_251
APPENDIX A REFERENCES - TM-5-6115-612-12_252
GENERAL INFORMATION
SHIPMENT AND STORAGE
APPENDIX B BASIC ISSUE ITEMS LIST AND TROOP INSTALLED OR AUTHORIZED ITEMS LIST
EXPLANATION OF COLUMNS - TM-5-6115-612-12_257
National Stock Number (column b)
Section II. BASIC ISSUE ITEMS LIST
APPENDIX C MAINTENANCE ALLOCATION CHART
EXPLANATION OF COLUMNS IN SECTION II
EXPLANATION OF COLUMNS IN SECTION III - TM-5-6115-612-12_262
section ii - maintenance chart - TM-5-6115-612-12_263
section ii - maintenance chart - TM-5-6115-612-12_264
section ii - maintenance chart - TM-5-6115-612-12_265
section ii - maintenance chart - TM-5-6115-612-12_266
section ii - maintenance chart - TM-5-6115-612-12_267
section ii - maintenance chart - TM-5-6115-612-12_268
section ii - maintenance chart - TM-5-6115-612-12_269
section ii - maintenance chart - TM-5-6115-612-12_270
section ii - maintenance chart - TM-5-6115-612-12_271
section ii - maintenance chart - TM-5-6115-612-12_272
section ii - maintenance chart - TM-5-6115-612-12_273
section ii - maintenance chart - TM-5-6115-612-12_274
section ii - maintenance chart - TM-5-6115-612-12_275
section ii - maintenance chart - TM-5-6115-612-12_276
section ii - maintenance chart - TM-5-6115-612-12_277
section ii - maintenance chart - TM-5-6115-612-12_278
Section IV. REMARKS - TM-5-6115-612-12_279
FO-1. Generator Set Wiring Installation
fo-2. generator set system schematic
FO-3. Generator   Set   Wiring   Diagram
FO-4. Control   Panel   Wiring   Diagram

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