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CHAPTER 1 INTRODUCTION - TM-5-6115-612-34_21
Section II. DESCRIPTION AND DATA
Figure 1-1 . Aviation Generator Set, Front 3/4 View
Figure 1-2. Aviation Generator Set, Rear View
TABULATED DATA. (cont)
DC ELECTRICAL AND CONTROL SYSTEM
Table 1-1. Repair and Replacement Standards
Table 1-1. Repair and Replacement Standards -Continued - TM-5-6115-612-34_28
Table 1-1. Repair and Replacement Standards -Continued - TM-5-6115-612-34_29
Table 1-1. Repair and Replacement Standards -Continued - TM-5-6115-612-34_30
S e c t I o n I . REPAIR PARTS, SPECIAL TOOLS, TEST, MEASUREMENT, DIAGNOSTIC EQUIPMENT (TMDE) , AND SUPPORT EQUIPMENT
Table 2-2. Inspection and Test Equipment
Table 2-2. Inspection and Test Equipment - Continued
Table 23. Fabricated Tools and Equipment
Table 2-3. Fabricated Toois and Equipment- Continued
Table 2-3. Fabricated Tools and Equipment - Continued
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_37
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_39
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_40
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_41
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_42
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_43
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_44
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_45
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_46
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_47
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_48
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_49
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_50
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_51
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_52
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_53
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_54
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_55
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_56
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_57
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_58
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_59
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_60
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_61
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_62
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_63
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_64
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_65
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_66
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_67
Table 2-3. Fabricated Tools and Equipment - Continued - TM-5-6115-612-34_68
Assembly fixture
Section II. TROUBLESHOOTING
Table 2-4. Troub leshooting - continued - TM-5-6115-612-34_71
Table 2-4. Troub leshooting - continued - TM-5-6115-612-34_72
Table 2-4. Troub leshooting - continued - TM-5-6115-612-34_73
Table 2-4. Troub leshooting - continued - TM-5-6115-612-34_74
Table 2-4. Troub leshooting - continued - TM-5-6115-612-34_75
Table 2-4. Troub leshooting - continued - TM-5-6115-612-34_76
Table 2-4. Troub leshooting - continued - TM-5-6115-612-34_77
Table 2-4. Troub leshooting - continued - TM-5-6115-612-34_78
Table 2-4. Troub leshooting - continued - TM-5-6115-612-34_79
GENERATOR OVERTEMP MALFUNCTION LIGHT COMES ON
OVERLOAD MALFUNCTION LIGHT COMES ON - CURRENT LOAD NORMAL
Repair or replace as necessary
NO OR POOR REGULATION - ALL INPUTS NORMAL
Section III. GENERAL MAINTENANCE
Turnlock Fasteners Replacement. (cont)
Section IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
Figure 2-2. Generator Replacement (Sheet 1 of 2)
Figure 2-2. Generator Replacement (Sheet 2 of 2)
Installation - TM-5-6115-612-34_90
ENGINE AND GEARBOX REMOVAL AND INSTALLATION
Figure 2-3. Engine and Gearbox Replacement (Sheet 1 of 3)
Figure 2-3. Engine and Gearbox Replacement (Sheet 2 of 3)
Figure 2-3. Engine and Gearbox Replacement (Sheet 3 of 3)
ENGINE AND GEARB0X REMOVAL AND INSTALLATION. (cont)
Installation - TM-5-6115-612-34_97
Removal - TM-5-6115-612-34_98
Figure 2-4. Control Panel Replacement (Sheet 1 of 2)
Figure 2-4. Control Panel Replacement (Sheet 2 of 2)
CHAPTER 3 MAINTENANCE OF FRAME AND HOUSING
Removal - TM-5-6115-612-34_102
Installation. - TM-5-6115-612-34_103
Repair - TM-5-6115-612-34_104
Installation - TM-5-6115-612-34_105
INLET AIR HOUSING
Installation. (cont)
Repair. (cont)
figure 3-1. air filter replacement
Installation - TM-5-6115-612-34_110
Removal. (cont)
Installation. (cont)
Figure 3-2. Engine Support Assembly Replacement
CHASSIS FRAME ASSEMBLY
figure 3-3. chassis frame replacement
Removal - TM-5-6115-612-34_116
Installation - TM-5-6115-612-34_117
CHAPTER 4 MAINTENANCE OF DC ELECTRICAL AND CONTROL SYSTEM
PURPOSE TM 5-6115-612-34 TM 6115-34/8 TO 35C2-3-471-2 AG-320BO-MME-OOO AND FUNCTION ELECTRICAL AND CONTROL SYSTEM
Figure 4-1. GECM Test Setup
GENERATOR ELECTRONIC CONTROL MODULE.
Overload Test
Power Limit Test
figure 4-2. circuit card replacement
Regulator Test
Figure 4-3. GECM Component Replacement
Removal - TM-5-6115-612-34_128
Diode Replacement
Figure 4-4. GECM Resistor and Relay Replacement
Removal - TM-5-6115-612-34_131
Figure 4-5. Starter Test Setup
Testing and Troubleshooting.
Figure 4-6. Starter Disassembly (Sheet 1 of 2)
Figure 4-6. Starter Disassembly (Sheet 2 of 2)
STARTER ASSEMBLY
STARTER ASSEMBLY. (cont)
Test After Repair
CHAPTER 5 MAINTENANCE OF ELECTRICAL POWER GENERATION SYSTEM
GENERATOR ASSEMBLY MAINTENANCE - TM-5-6115-612-34_140
Table 5-1. GECM Connector Resistance Test
GENERATOR ASSEMBLY MAINTENANCE - TM-5-6115-612-34_142
figure 5-4. filter box assembly (sheet 1 of 4)
Figure 5-4. Filter Box Assembly (Sheet 2 of 4)
figure 5-4. filter box assembly (sheet 3-4)
Figure 5-4. Filter Box Assembly (Sheet 4 of 4)
Disassembly - TM-5-6115-612-34_147
Figure 5-5. 10kW Generator Assembly (Sheet 1 of 2)
Figure 5-5. 10kW Generator Assembly (Sheet 2 of 2)
Disassembly - TM-5-6115-612-34_150
Repair and Rebuild
Reassembly - TM-5-6115-612-34_152
figure 5-6. measuring for spring washer axial distance
Reassembly. (cont) - TM-5-6115-612-34_154
Figure 5-7. Stator to Diode Wire Routing
Reassembly. (cont) - TM-5-6115-612-34_156
CHAPTER 6 MAINTENANCE OF FUEL SYSTEM
Figure 6-1. Fuel System Block Diagram
figure 6-2. engine fuel tank
ELECTRICAL HIGH PRESSURE FUEL PUMP
figure 6-3. electrical fuel pump (high pressure) and solenoid valve
Figure 6-4. Electrical Fuel Pump (High Pressure) Test Setup
Figure 6-5. Electrical Fuel Pump (High Pressure) Electric Motor Disassembly
Electric Motor Repair
figure 6-6. replacing broken brush guide
Electric Motor Reassembly.
figure 6-7. solenoid valve test setup
SOLENOID VALVE. (cont)
figure 6-8. solenoid valve disassembly
Figure 6-9. Silicone Sealer Application
Reassembly. (cont)
Figure 6-10. Fuel Injection Nozzle Test Setup
figure 6-11. fuel injection nozzle spray patterns
CHAPTER 7 MAINTENANCE OF LUBRICATION SYSTEM
Figure 7-1. Lubrication System
figure 7-2. lubrication system components
Figure 7-3. Oil Pressure Relief Valve Installation
OIL COOLER
Figure 7-4. Oil Cooler Replacement
OIL PUMP
OIL PUMP. (cont)
Installation - TM-5-6115-612-34_183
CHAPTER 8 NAVY AG-320BO-MME-OOO MAINTENANCE OF ENGINE
Table 8-1. General Defect Definitions
Table 8-1. General Defect Definitions (cont)
Table 8-1. General Defect Definitions - (Continued)
GENERAL. (cont)
Table 8-2. Engine Disassembly Fixture
Table 8-2. Engine Disassembly Fixture - Continued
COMBUSTION CHAMBER CASE ASSEMBLY
figure 8-1. combustion chamber case assembly removal
Figure 8-2. Removing Combustion Chamber Fabricated Tool FT-21519
Cleaning and Inspection. (cont)
Table 8-3. Nondestructive Test Inspection Data
Table 8-3. Nondestructive Test Inspection Data - Continued
Figure 8-3. Combustor Housing Disassembly
figure 8-4. combustor housing diassembly - fuel injection nozzle removal
Overhaul (cont)
Overhaul. (cont)
Figure 8-5. LEGEND WASHER RETAINING PLATE 20. WASHER 21. SPEED SENSOR OIL SUPPLY FITTING 22. SHIM FUEL DRAIN FITTING 23. PREFORMED PACKING OIL DRAIN FITTING 24. BOLT BLEED AIR CONNECTOR 25. WASHER PREFORMED PACKING 25.1 FOREIGN OBJECT BOLT DEFLECTOR SPEED SENSOR CLIP 26. PADEYE Turbine Assembly Removal
Inspection - TM-5-6115-612-34_203
Figure 8-6. Turbine Assembly Disassembly
Disassembly (cont) - TM-5-6115-612-34_205
Figure 8-8. Using Turbine Wheel Assembly Fixture, Fabricated Tool FT-21616
figure 8-9. removing/installing speed pickup nut usingfabricated tool ft-21368
Disassembly (cont) - TM-5-6115-612-34_208
figure 8-10. removing/installing bearing retainer nut using fabricated tools ft-21498 and ft-21583
Cleaning
Inspection. (cont)
Repair - TM-5-6115-612-34_212
Assembly and Balance of Rotating material. Group Assembly
OVERHAUL OF TURBINE ASSEMBLY. (cont) - TM-5-6115-612-34_214
Figure 8-11. Removing/Installing Retainer Nut Using Fabricated Tools FT-21538, FT-21570, and FT-21571
F i g u r e 8-12. O b t a i n i n g Reading f o r Turbine S h a f t S t r e t c h Using F a b r i c a t e d Tools FT-21540 and FT-21565
Figure 8-13. Obtaining Reading for Turbine Shaft Stretch Using Fabricated Tools FT-21540 and FT-21565
OVERHAUL OF TURBINE ASSEMBLY. (cont) - TM-5-6115-612-34_218
Reassembly (cont) - TM-5-6115-612-34_219
figure 8-14. measuring compressor impeller vane clearance using fabricated tool ft-21360
OVERHAUL OF TURBINE ASSEMBLY. (cont) - TM-5-6115-612-34_221
Reassembly. (cont) - TM-5-6115-612-34_222
Figure 8-15. Diffuser Shim Set Installation - Measurement Points
Reassembly. (cont) - TM-5-6115-612-34_224
Installation - TM-5-6115-612-34_225
OVERHAUL OF GEARBOX ASSEMBLY - TM-5-6115-612-34_226
Figure 8-17. Gearbox Removal (Sheet 1 of 2)
figure 8-17. gearbox removal (sheet 2 of 2)
Disassembly - TM-5-6115-612-34_229
figure 8-18. preparing gearbox using fabricated tool ft-21343
Figure 8-19. Preparing Gearbox Assembly for Disassembly Using Fabricated Tool FT-21343
OVERHAUL OF GEARBOX ASSEMBLY - TM-5-6115-612-34_232
Figure 8-20. Gearbox Disassembly (Sheet 1 of 2)
Figure 8-21. Gearbox Disassembly (Sheet 2 of 2)
Figure 8-21. Securing Generator Shouldered Shaft and Removing Nut Using Fabricated Tools FT-21322 and FT-21369
figure 8-22. removing bearing and output spur gear using fabricated tools ft- 21589 and ft-21325
OVERHAUL OF GEARBOX ASSEMBLY. (cont)
Repair and Replacement
Reassembly - TM-5-6115-612-34_239
OVERHAUL OF GEARBOX ASSEMBLY. (cont) - TM-5-6115-612-34_240
Figure 8-23. Angular Bearing Installation
Figure 8-24. Installing Generator Shouldered Shaft Using Fabricated Tools FT-21590 and FT-21324
OVERHAUL OF GEARBOX ASSEMBLY. (cont) - TM-5-6115-612-34_243
Figure 8-24.1 Preparing Gearbox Assembly for Disassembly Using Fabricated Tool FT-21343
Figure 8-25. Using Oil Impingement Test Stand, Fabricated Tools FT-21600
Reassembly (cont) - TM-5-6115-612-34_246
CHAPTER 9 MAINTENANCE OF ENGINE EXHAUST
Figure 9-1. Engine Exhaust System
EXHAUST DUCT ASSEMBLY. (cont)
Figure 9-2. Exhaust System Components Replacement (Sheet 1 of 2)
Figure 9-2. Exhaust System Components Replacement (Sheet 2 of 2)
Inspection - TM-5-6115-612-34_253
Repair - TM-5-6115-612-34_254
CHAPTER 10 MAINTENANCE OF ENGINE AND GENERATOR CONTROLS AND INSTRUMENTS
Functional Theory of 0peration. (cont)
Functional Theory of Operation. (cont) - TM-5-6115-612-34_258
Status monitoring/automatic shutdown
Functional Theory of Operation. (cont) - TM-5-6115-612-34_260
Status monitoring and con- trol
PURPOSE AND FUNCTION OF ENGINE AND GENERATOR CONTROLS AND INSTRU- MENTS. (cont)
Functional Theory of Operation. (cont) - TM-5-6115-612-34_263
ENGINE ELECTRONIC CONTROL MODULE (EECM). (cont)
ENGINE ELECTRONIC CONTROL MODULE (EECM). (cont) - TM-5-6115-612-34_265
ENGINE ELECTRONIC CONTROL MODULE (EECM). (cont) - TM-5-6115-612-34_266
Test.
Engine overtemperature test.
One hundred percent switch test.
Overspeed test.
test - TM-5-6115-612-34_272
Fuel pump control test.
Circuit Card Replacement.
Figure 10-2. EECM Circuit Card Replacement
Installation - TM-5-6115-612-34_276
Figure 10-3. EECM Transistor Replacement
Installation. - TM-5-6115-612-34_278
Figure 10-4. EECM Connector Replacement
Figure 10-5. EECM Connectors (Back) Wire Connections
Figure 10-6. Terminal Board/Multiple Ground Terminal Replacement
Diode Replacement
Figure 10-7. Contactor/Diode Replacement
CONTROL PANEL ASSEMBLY
CHAPTER 11 MAINTENANCE OF LOAD CONNECTION
CHAPTER 12 MAINTENANCE OF RUNNING GEAR
Figure 12-1. Torsion Axle Replacement
Installation (cont)
Figure 12-2. Swivel Caster Repair
SWIVEL CASTER ASSEMBLY
CHAPTER 13 GENERATOR SET TEST AND INSPECTION AFTER REPAIR AND OVERHAUL
GENERATOR INSPECTION
ENGINE OPERATIONAL TEST
Figure 13-1. Test Equipment Installation
table 13-1. engine-generator operational tests (uninstalled)
table 13-1. engine-generator operational tests (uninstalled) (cont) - TM-5-6115-612-34_299
table 13-1. engine-generator operational tests (uninstalled) (cont) - TM-5-6115-612-34_300
Figure 13-2. Envelope of Voltage Transient for 28 Volts (Nominal) DC System
fgure 13-3. exhuast gas temperature limits
figure 13-4. oil sump temperature lmits
figure 13-5. fuel flow limits
Table 13-2. Normal Operating Conditions
ENGINE OPERATIONAL TEST. (cont)
table 13-4. engine-generator operational tests (installed)
table 13-4. engine-generator operational tests (installed) (cont) - TM-5-6115-612-34_308
table 13-4. engine-generator operational tests (installed) (cont) - TM-5-6115-612-34_309
Figure 13-6. Control Panel
Section II. COATING INSTRUCTIONS
Spray coating - TM-5-6115-612-34_313
Flame Spray Coating-Nickel Aluminum Composite
Engineering Process Specifications
Plasma Spray Coating - Molybdenum
Flame Spray Coating - Aluminum Alloy (4043)
Requirements
Flame Spray Coating - Aluminum Bronze, Silicone Resin Impregnated
Spray coating - TM-5-6115-612-34_320
APPENDIX A REFERENCES - TM-5-6115-612-34_321
GENERAL INFORMATION. (cont)
SHIPMENT AND STORAGE
APPENDIX B EXPENDABLE SUPPLIES AND MATERIALS LIST
SECTION II. EXPENDABLE SUPPLIES AND MATERIALS LIST
fo-1. engine electronic control module (eecm)schematic
FO-2 . Engine Electronic Control Module (EECM) Wire List
fo-3. eecm switch circuit card schematic
f0-4. eecm mpu board schematic
fo-5. eecm power supply board schematic
FO-6. Generator to Generator Electronic Control Module (GECM) Wiring Harness
FO-7 . Branched Engine Electronic Control Module (EECM) to Engine Wiring Harness
fo-8. branched generator electronic control module (gecm) to control panel engine electronic control module (eecm)wiring harness
FO-9. Engine and Generator Controls and Instruments Detailed Block Diagram (Sheet 1 of 2 )
FO-9. Engine and Generator Controls and Instruments Detailed Block Diagram (Sheet 2 of 2)
FO-10. Generator Electronics Control Module Printed Wiring Assembly Schematic (Sheet 1 of 4)
fo-10. generator electronics control module printed wiring assembly schematic (sheet 2 of 4)
FO-10. Generator Electronics Control Module Printed Wiring Assembly Schematic (Sheet 3 of 4)
F0-10. Generator Electronics Control Module Printed Wiring Assembly Schematic (Sheet 4 of 4)
FO-11. Generator Electronic Control Module Assembly Wiring Diagram
FO-12. Generator Electronic Control Module Assembly Schematic
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