TM-9-6115-730-24 Generator Set Skid Mounted Tactical Quiet 200 kw 50/60 Hz MEP-809A Manual

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TM-9-6115-730-24

FIELD AND SUSTAINMENT MAINTENANCE FOR GENERATOR SET, SKID MOUNTED, TACTICAL QUIET AND GENERATOR SET, TRAILER MOUNTED, TACTICAL QUIET
WARNING SUMMARY
SAFETY AND HAZARDOUS MATERIAL
EXPLANATION OF SAFETY WARNING ICONS
GENERAL SAFETY WARNINGS DESCRIPTION
GENERAL SAFETY WARNINGS DESCRIPTION - Continued
GENERAL SAFETY WARNINGS DESCRIPTION - Continued
GENERAL SAFETY WARNINGS DESCRIPTION - Continued
GENERAL SAFETY WARNINGS DESCRIPTION - Continued
EXPLANATION OF HAZARDOUS MATERIALS ICONS
HAZARDOUS MATERIALS DESCRIPTION
HAZARDOUS MATERIALS DESCRIPTION - Continued
HAZARDOUS MATERIALS DESCRIPTION - Continued
LIST OF EFFECTIVE PAGES/WORK PACKAGES
LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued
TECHNICAL MANUAL
TABLE OF CONTENTS
TABLE OF CONTENTS - Continued
TABLE OF CONTENTS - Continued
TABLE OF CONTENTS - Continued
TABLE OF CONTENTS - Continued
TABLE OF CONTENTS - Continued
TABLE OF CONTENTS - Continued
TABLE OF CONTENTS - Continued
HOW TO USE THIS MANUAL
UNIT (FIELD) LEVEL MAINTENANCE WORK PACKAGES
DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE WORK PACKAGES
Chapter 1. GENERAL INFORMATION, EQUIPMENT DESCRIPTION AND THEORY OF OPERATION
WORK PACKAGE INDEX
GENERAL INFORMATION
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)
WARRANTY INFORMATION
Table 1. Manufacturer's Warranties for 200 kW Generator Set.
Table 1. Manufacturer's Warranties for 200 kW Generator Set - Continued.
NOMENCLATURE CROSS REFERENCE LIST
LIST OF ABBREVIATIONS AND ACRONYMS
LIST OF ABBREVIATIONS AND ACRONYMS - Continued
SAFETY, CARE, AND HANDLING INFORMATION
EQUIPMENT DESCRIPTION AND DATA
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
Figure 1. 200 kW Tactical Quiet Generator Location of Components (Sheet 2 of 6).
Figure 1. 200 kW Tactical Quiet Generator Location of Components (Sheet 3 of 6).
Figure 1. 200 kW Tactical Quiet Generator Location of Components (Sheet 4 of 6).
Figure 1. 200 kW Tactical Quiet Generator Location of Components (Sheet 5 of 6).
ALTERNATOR
LOAD BOARD
DEAD CRANK SWITCH
GENERATOR HOUSING
EQUIPMENT DATA
Table 1. 200 kW TQG Equipment Data
THEORY OF OPERATION
ENGINE SENSORS
Speed Input
FUEL SYSTEM
Figure 2. Fuel System.
AUXILIARY FUEL SYSTEM
ELECTRONIC UNIT INJECTOR FUEL SYSTEM
ENGINE COOLING SYSTEM
LUBRICATION SYSTEM
Figure 5. Engine Lubrication System.
Engine Lubrication
AIR INLET AND EXHAUST SYSTEM
AC POWER OUTPUT
DC POWER DISTRIBUTION
Batteries
Engine Control Switch (ECS)
BATTLE SHORT Switch (BSS) Input to ECM
SYNC MODE Switch (SMS)
AC POWER DISTRIBUTION
Digital Voltage Regulator (DVR) A3
ELECTRONIC MODULAR CONTROL PANEL (EMCP)
GENERATOR SET CONTROL (GSC)
GSC Outputs
Table 1. GSC Display Relay Identification.
DIGITAL VOLTAGE REGULATOR (DVR A3) MODULE
Startup Profile
Loading and Stopping Profile
LOAD SHARING MODULE (LSM A4) INTERNAL OPERATION
Speed Trim Summer
GENERATOR
WINTERIZATION KIT
COMMON TOOLS AND TEST EQUIPMENT
Chapter 2. FIELD LEVEL TROUBLESHOOTING PROCEDURES
WORK PACKAGE INDEX
INTRODUCTION
TQG TROUBLESHOOTING
GSC ALARM INDICATORS AND FAULT CODE TROUBLESHOOTING
DIAGNOSTIC EVENTS AND EVENT CODES
GSC FAULT CODES
VIEWING FAULT LOG OP1
FAULT LOG CLEARING OP4
TRANSIENT CODES DURING TROUBLESHOOTING
DVR FAULT CODE TROUBLESHOOTING
TROUBLESHOOTING USING MAINTENANCE SUPPORT DEVICE (MSD) AND ELECTRONIC TECHNICIAN (ET) TOOL
TROUBLESHOOTING INDEX
GSC FAULT CODE
GSC FAULT CODE - Continued
GSC FAULT CODE - Continued
DVR FAULT CODE
FAILURES WITHOUT A FAULT CODE
GSC ALARM INDICATORS AND FAULT CODE TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING USING DEDICATED SHUTDOWN INDICATORS
OVERCRANK light
FAULT ALARM light flashing yellow.
Undiagnosed shutdown.
SP FAULT CODE TROUBLESHOOTING PROCEDURES
Low Fuel Level.
Bus Frequency Fault (Paralleling Only)
CORRECTIVE ACTION
AL FAULT CODE TROUBLESHOOTING PROCEDURES
High Coolant Temperature
Low Coolant Temperature
Fault Detected by Engine ECM
Generator Over Voltage
Generator Over Frequency
Generator Reverse Power
Phase Over Current
Phase A No Voltage Input at GSC input (P7-10)
Incorrect Phase Sequence - Paralleling fault code
Improper Generator or Bus Voltage - Paralleling fault code
Synchronizer Time-out - Paralleling fault code
GSC FAULT CODE TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING USING GSC FAULT CODES
TROUBLESHOOTING USING GSC FAULT CODES - Continued
TROUBLESHOOTING USING GSC FAULT CODES - Continued
8 Volt Power Supply not Normal.
Throttle Position Signal.
Fuel Pressure Sensor.
Fuel Pressure Sensor.
High Fuel Pressure Warning.
Derate Overridden.
Oil Pressure Sensor.
Coolant Temperature Sensor.
Low Coolant Sensor.
CORRECTIVE ACTION - Continued
Electrical System Voltage.
Engine Oil Maintenance Required.
Intake manifold air temperature sensor.
CORRECTIVE ACTION Continued
Fuel Temperature Sensor.
Loss of Engine Speed Signal.
Crankshaft (bottom) engine timing sensor.
CAT Data Link.
ECM Self Test.
5 V Sensor Power Supply.
CORRECTIVE ACTION - Continued
E-Stop Shutdown.
GSC Electronic Control.
GSC 8V Sensor Power Supply.
Turbo Outlet Pressure Sensor.
Atmospheric Pressure Sensor.
Cool Down circuit (P7-36).
ENGINE CONTROL switch.
Camshaft (Top) Engine Timing Sensor.
Low Engine Oil Pressure Warning (Active & Logged).
High engine coolant temperature warning (Active & Logged).
Overspeed Warning (Active and Logged).
Fuel Filter Restriction Warning (Active and Logged).
GSC Engine Governor Relay (EGR) Output.
GSC Generator Fault Relay (GFR) Output.
GSC Crank Termination Relay (CTR) Output.
CORRECTIVE ACTION - Continued
GSC Run Relay (RR) Output.
GSC Fuel Control Relay (FCR) Output.
CORRECTIVE ACTION - Continued
FMI 12 - Failed Component.
Ether Control Relay.
Engine Electronic Control Module.
Customer Communication Module (CCM) Data Link.
Close Breaker Output.
Speed Adjust 1 Output (P7-27 (+) and P7-28 (-).
CORRECTIVE ACTION - Continued
K1 Sense Input (P7-25).
Dead Bus Sense Input (P7-29).
AC Transformer Box (ATB) Sensor.
Bus Transformer Box (BTB) Sensor.
Turbo Air Inlet Pressure Sensor.
Turbo air inlet pressure sensor.
DVR FAULT CODE TROUBLESHOOTING PROCEDURES
Internal Memory Failure
Internal Watchdog Failure
Rotating Diode Defective.
Reverse VAR (Alarm Fault)
Undervoltage.
CORRECTIVE ACTION - Continued
Overvoltage.
Overexcitation
Reverse VAR (Shutdown Fault)
Instantaneous Trip
Loss of Frequency
DVR Memory Failure (Severe Fault)
FAILURES WITHOUT A FAULT CODE TROUBLESHOOTING PROCEDURES
Figure 1. SMMS Relay Location
CORRECTIVE ACTION - Continued
Setpoint Programming Error.
GSC Operation Is Erratic.
Display Of Voltage on GSC is Zero For One or More Phases.
Display of Current on GSC is Zero For One or More Phases.
Display of Voltage on GSC is Inaccurate.
Display of Current on GSC is Inaccurate.
Display of Power on GSC is Inaccurate.
Generator Produces Low Voltage Under No Load Condition.
CORRECTIVE ACTION - Continued
Generator Produces Low Voltage When Load is Applied.
Generator Produces Fluctuating Voltage.
Generator Produces High Voltage.
Generator is Overheating.
Improper Load.
Improper Engine Operation.
Load Sharing Module (LSM) A4 Erratic Operation.
Load Sharing Module Malfunction.
Starter Motor Defective.
Engine Cranks But Will Not Start.
Engine Timing Incorrect.
Ether Injection System Malfunction.
Engine Misfires, Runs Rough, or is Unstable.
ECM may not be leaving cold mode operation.
Low Power/Poor or No Response to Throttle.
ECM may not be leaving cold mode operation.
Intermittent Engine Shut Downs.
Engine Timing.
Excessive White Smoke.
Can Not Reach Operating Engine RPM.
Fuel Supply Problem.
Engine Temperature
Poor Acceleration or Response.
Electrical Connections Faulty
Poor Fuel Consumption.
Engine Stalls at Low RPM.
Fuel Supply Problem.
Auxiliary Fuel Pump Does Not Operate.
Auxiliary Fuel Pump Relay.
Engine Runs Out of Fuel With No LOW FUEL LEVEL Alarm.
Alternator Does Not Charge Batteries.
Coolant in Engine Oil.
Coolant Temperature Too High.
Air in Coolant.
Thermostat Malfunction.
ECM Will Not Communicate With Other Systems or Display Modules.
Engine Oil in Coolant.
Engine Oil in Exhaust System.
Engine Oil Temperature Too High.
Incorrect Oil Level.
Engine Vibration.
Excessive Engine Oil Consumption.
Excessive Valve Lash.
Fuel in Engine Oil.
Intermittent Low Power or Power Cutout.
Low Engine Oil Pressure.
Oil Filter Defective.
Mechanical Noise (Knock) in Engine.
Noise Coming From Cylinder.
ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING SOFTWARE INSTALLATION
Figure 1. Connecting Caterpillar Communication Adapter.
LOADING ELECTRONIC TECHNICIAN (ET) SOFTWARE
USING ELECTRONIC TECHNICIAN (ET) SOFTWARE
Figure 2. Caterpillar ET Opening Screen.
Table 1. Caterpillar ET Tool Navigation Icons.
Diagnostics Tests
Figure 3. Cat ET Diagnostic Tests.
ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING
ELECTRONIC TECHNICIAN (FIELD) LEVEL TROUBLESHOOTING
ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING
Figure 1. 24 Vdc Electrical Circuits.
ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued
Table 1. ECM Supply Voltage Test Points.
Table 2. + Battery Voltage Input to ECM Test Points.
System Operation Description
CORRECTIVE ACTION - Continued
Figure 3. Timing Sensors.
CORRECTIVE ACTION - Continued
Figure 4. Ether Injection System Circuit.
ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued
ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued
Injector Solenoid Circuit Test.
Figure 5. Injector Solenoid Circuit.
Cylinder 1 - 6 Injector Solenoids
CORRECTIVE ACTION - Continued
CORRECTIVE ACTION - Continued
Table 3. Injector Solenoid Harness Terminals.
CORRECTIVE ACTION - Continued
Speed Control Test.
Figure 6. Speed Control Circuits.
Table 4. Speed Control Circuit Test Points.
CORRECTIVE ACTION - Continued
Electronic Service Tool (Cat ET) will not communicate with ECM.
CORRECTIVE ACTION - Continued
Engine Timing Sensor Calibrate.
Figure 7. Timing Calibration Plug.
CORRECTIVE ACTION - Continued
Flash Programming
Engine Fuel Pressure Reading.
Engine Status
Load Injector Code.
CORRECTIVE ACTION
Chapter 3. UNIT (FIELD) LEVEL MAINTENANCE INSTRUCTIONS
WORK PACKAGE INDEX
WORK PACKAGE INDEX (cont)
SERVICE UPON RECEIPT
PRELIMINARY CHECKS AND ADJUSTMENT OF EQUIPMENT
OUTPUT VOLTAGE SETTING
PMCS INTRODUCTION
INTRODUCTION
INSPECTION
PMCS COLUMN DESCRIPTIONS (TABLE 1)
PMCS, INCLUDING LUBRICATION INSTRUCTIONS
Table 1. Preventive Maintenance Checks and Services
Table 1. Preventive Maintenance Checks and Services - Continued.
Table 1. Preventive Maintenance Checks and Services - Continued.
Table 1. Preventive Maintenance Checks and Services - Continued.
Table 2. PMCS Mandatory Replacement Parts List.
LUBRICATION INSTRUCTIONS
Table 3. Engine Oil.
Table 6. Lubrication Requirements.
GENERAL MAINTENANCE INSTRUCTIONS
CLEANING INSTRUCTIONS
INSPECTION INSTRUCTIONS
RIGHT BATTERY ACCESS DOOR ASSEMBLY MAINTENANCE
Figure 1. Right Battery Access Door Assembly.
DISASSEMBLY
LEFT BATTERY ACCESS DOOR ASSEMBLY MAINTENANCE
Figure 1. Left Battery Access Door Assembly.
ASSEMBLY
CONTROL BOX DOOR ASSEMBLY MAINTENANCE
ASSEMBLY
Figure 1. Control Box Door Assembly.
LEFT FRONT DOOR ASSEMBLY (LATCH) MAINTENANCE
Figure 1. Left Front Door Assembly (Latch).
ASSEMBLY
INSTALLATION
LEFT REAR DOOR ASSEMBLY MAINTENANCE
Figure 1. Left Rear Door Assembly (Sheet 1 of 2).
Figure 1. Left Rear Door Assembly (Sheet 2 of 2).
DISASSEMBLY
INSTALLATION
LEFT REAR DOOR ASSEMBLY (LATCH) MAINTENANCE
Figure 1. Left Rear Door Assembly (Latch) (Sheet 1 of 2).
Figure 1. Left Rear Door Assembly (Latch) (Sheet 2 of 2).
DISASSEMBLY
INSTALLATION
LOAD BOARD DOOR ASSEMBLY MAINTENANCE
Figure 1. Load Board Door Assembly.
ASSEMBLY
RIGHT FRONT DOOR ASSEMBLY (LATCH) MAINTENANCE
Figure 1. Right Front Door Assembly (Latch).
ASSEMBLY
RIGHT FRONT DOOR ASSEMBLY AND STORAGE BOX ASSEMBLY MAINTENANCE
Figure 1. Right Front Door Assembly.
DISASSEMBLY
REMOVAL
Figure 2. Storage Box Assembly.
RIGHT REAR DOOR ASSEMBLY MAINTENANCE
Figure 1. Right Rear Door Assembly.
DISASSEMBLY
RIGHT REAR DOOR ASSEMBLY (LATCH) MAINTENANCE
Figure 1. Right Rear Door Assembly (Latch).
DISASSEMBLY
ACCESS COVERS MAINTENANCE
INSTALLATION
Figure 1. Access Covers.
FRONT ROOF SECTION HOUSING ASSEMBLY MAINTENANCE
REMOVAL
Figure 1. Front Roof Section Housing Assembly (Sheet 1 of 2).
Figure 1. Front Roof Section Housing Assembly (Sheet 2 of 2).
ASSEMBLY
REAR ROOF SECTION HOUSING ASSEMBLY MAINTENANCE
Figure 1. Rear Roof Section Housing Assembly.
DISASSEMBLY
ENGINE GENERATOR COMPARTMENT CEILING ASSEMBLY MAINTENANCE
REMOVAL
Figure 1. Engine Generator Compartment Ceiling Assembly.
INSTALLATION
GENERATOR ACCESS COVER ASSEMBLY MAINTENANCE
ASSEMBLY
Figure 1. Generator Access Cover Assembly.
FRONT SECTION HOUSING ASSEMBLY MAINTENANCE
Figure 1. Front Section Housing Assembly (Sheet 1 of 2).
Figure 1. Front Section Housing Assembly (Sheet 2 of 2).
DISASSEMBLY
INSTALLATION
REAR SECTION HOUSING ASSEMBLY MAINTENANCE
Figure 1. Rear Section Housing Assembly.
DISASSEMBLY
LEFT CENTER PANEL ASSEMBLY MAINTENANCE
Figure 1. Left Center Panel Assembly.
INSTALLATION
RIGHT CENTER PANEL ASSEMBLY MAINTENANCE
Figure 1. Right Center Panel Assembly.
INSTALLATION
RIGHT REAR PANEL ASSEMBLY MAINTENANCE
INSTALLATION
Figure 1. Right Rear Panel Assembly.
LEFT REAR PANEL ASSEMBLY MAINTENANCE
Figure 1. Left Rear Panel Assembly.
DOOR SUPPORT ASSEMBLY MAINTENANCE
Figure 1. Door Support Assembly.
INSTALLATION
CONTROL BOX PANEL ASSEMBLY MAINTENANCE
Table 1. WP 0041 Guide.
Figure 1. Control Box Panel Assembly (Sheet 1 of 4).
Figure 1. Control Box Panel Assembly (Sheet 2 of 4).
Figure 1. Control Box Panel Assembly (Sheet 3 of 4).
Figure 1. Control Box Panel Assembly (Sheet 4 of 4).
DISASSEMBLY
VOLTAGE Adjust Potentiometer Test
FREQUENCY Adjust Potentiometer Test
ASSEMBLY
INSTALLATION
CONTROL BOX ASSEMBLY MAINTENANCE
Figure 1. Control Box.
Table 1. WP 0042 Guide.
Table 1. WP 0042 Guide - Continued.
Figure 2. Control Box Assembly (Sheet 1 of 5).
Figure 2. Control Box Assembly (Sheet 2 of 5).
Figure 2. Control Box Assembly (Sheet 3 of 5).
Figure 2. Control Box Assembly (Sheet 4 of 5).
Figure 2. Control Box Assembly (Sheet 5 of 5).
DISASSEMBLY
ASSEMBLY
ASSEMBLY - Continued
INSTALLATION
LSM A4 LOAD GAIN ADJUSTMENT
RESISTOR ASSEMBLY A7 MAINTENANCE
Figure 1. Resistor Assembly A7.
TEST
CONTROL BOX HARNESS ASSEMBLY MAINTENANCE
REPAIR OR REPLACEMENT
RECONNECTION TERMINAL BOARD ASSEMBLY MAINTENANCE
Figure 1. Reconnection Terminal Board Assembly.
ASSEMBLY
LOAD TERMINAL BOARD ASSEMBLY MAINTENANCE
Figure 1. Load Terminal Board Assembly (Sheet 1 of 2).
Figure 1. Load Terminal Board Assembly (Sheet 2 of 2).
DISASSEMBLY
ASSEMBLY
BATTERY CABLE ASSEMBLIES MAINTENANCE
REMOVAL
Figure 1. Battery Cable Assemblies (Sheet 1 of 2).
Figure 1. Battery Cable Assemblies (Sheet 2 of 2).
INSTALLATION
INSTALLATION - Continued
POWER CABLE ASSEMBLIES MAINTENANCE
Figure 1. Power Cable Assemblies.
REMOVAL
INSTALLATION
MAIN LOAD CONTACTOR MAINTENANCE
Figure 1. Main Load Contactor.
INSTALLATION
BATTERIES MAINTENANCE
REMOVAL
Figure 1. Batteries.
TEST AND INSPECTION
INSTALLATION
BATTERY DISCONNECT SWITCH MAINTENANCE
REMOVAL
Figure 1. Battery Disconnect Switch.
CURRENT TRANSFORMERS MAINTENANCE
REMOVAL
Figure 1. Current Transformers (Sheet 1 of 2).
Figure 1. Current Transformers (Sheet 2 of 2).
INSTALLATION
POTENTIAL TRANSFORMER MAINTENANCE
Figure 1. Potential Transformer.
INSTALLATION
SLAVE RECEPTACLE MAINTENANCE
REMOVAL
Figure 1. Slave Receptacle.
INSTALLATION
ELECTRICAL INSTALLATION MAINTENANCE
Table 1. WP 0055 Guide.
Figure 1. Electrical Installation (Sheet 1 of 2).
Figure 1. Electrical Installation (Sheet 2 of 2).
REMOVAL
INSTALLATION
INSTALLATION - Continued
FUEL LEVEL SWITCH ASSEMBLY MAINTENANCE
Figure 1. Fuel Level Switch Assembly.
INSTALLATION
FUEL HOSES MAINTENANCE
REMOVAL
Figure 1. Fuel Hoses (Sheet 1 of 4).
Figure 1. Fuel Hoses (Sheet 2 of 4).
Figure 1. Fuel Hoses (Sheet 3 of 4).
Figure 1. Fuel Hoses (Sheet 4 of 4).
INSTALLATION
INSTALLATION - Continued
FUEL PICKUP TUBE ASSEMBLY MAINTENANCE
Figure 1. Fuel Pickup Tube Assembly.
INSTALLATION
AUXILIARY FUEL PUMP ASSEMBLY MAINTENANCE
SERVICING
Figure 1. Auxiliary Fuel Pump Assembly.
INSTALLATION
FUEL COOLER MAINTENANCE
REMOVAL
Figure 1. Fuel Cooler (Sheet 1 of 2).
Figure 1. Fuel Cooler (Sheet 2 of 2).
WATER SEPARATOR FILTER AND BRACKET MAINTENANCE
DRAINING
Figure 1. Water Separator Filter and Bracket.
WATER SEPARATOR FILTER REMOVAL
FUEL LEVEL SENDER MAINTENANCE
Figure 1. Fuel Level Sender (Sheet 1 of 2).
Figure 1. Fuel Level Sender (Sheet 2 of 2).
TEST AND INSPECTION
INSTALLATION
FUEL TANK MAINTENANCE
REMOVAL
Figure 1. Fuel Tank Maintenance.
INSTALLATION
COOLANT RECOVERY SYSTEM MAINTENANCE
REMOVAL
Figure 1. Coolant Recovery System.
SURGE TANK MAINTENANCE
REMOVAL
Figure 1. Surge Tank.
INSTALLATION
FAN AND FAN GUARDS MAINTENANCE
Table 1. WP 0066 Guide.
Figure 1. Fan and Fan Guards (Sheet 1 of 3).
Figure 1. Fan and Fan Guards (Sheet 2 of 3).
Figure 1. Fan and Fan Guards (Sheet 3 of 3).
REMOVAL
INSTALLATION
INSTALLATION - Continued
INSTALLATION - Continued
COOLANT HOSE ASSEMBLIES MAINTENANCE
REMOVAL
Figure 1. Coolant Hose Assemblies (Sheet 1 of 4).
Figure 1. Coolant Hose Assemblies (Sheet 2 of 4).
Figure 1. Coolant Hose Assemblies (Sheet 3 of 4).
Figure 1. Coolant Hose Assemblies (Sheet 4 of 4).
REMOVAL
INSTALLATION
RADIATOR ASSEMBLY MAINTENANCE
REMOVAL
Figure 1. Radiator Assembly (Sheet 1 of 2).
Figure 1. Radiator Assembly (Sheet 2 of 2).
REPAIR OR REPLACEMENT
INSTALLATION
INSTALLATION - Continued
EXHAUST SYSTEM MAINTENANCE
REMOVAL
Figure 1. Exhaust System.
INSTALLATION
CRANKCASE VENTILATION FILTER MAINTENANCE
REMOVAL
Figure 1. Crankcase Ventilation Filter.
AIR CLEANER FILTER MAINTENANCE
REMOVAL
Figure 1. Air Cleaner Filter.
AIR CLEANER SYSTEM MAINTENANCE
REMOVAL
Figure 1. Air Cleaner System (Sheet 1 of 2).
Figure 1. Air Cleaner System (Sheet 2 of 2).
INSTALLATION
ETHER INJECTION ASSEMBLY MAINTENANCE
REMOVAL
Figure 1. Ether Injection Assembly.
ALTERNATOR MAINTENANCE
REMOVAL
Figure 1. Alternator.
ALTERNATOR BELT MAINTENANCE
REMOVAL
Figure 1. Alternator Belt.
BELT TENSION ADJUSTMENT
STARTER MAINTENANCE
REMOVAL
Figure 1. Starter.
TENSIONER MAINTENANCE
REMOVAL
Figure 1. Tensioner.
FUEL PRIMING PUMP MAINTENANCE
REMOVAL
Figure 1. Fuel Priming Pump.
OIL FILTER MAINTENANCE AND OIL CHANGE
FILTER REMOVAL AND OIL DRAIN
Figure 1. Oil Filter Maintenance and Oil Change.
OIL SAMPLING
FUEL FILTER MAINTENANCE
Figure 1. Fuel Filter.
INSTALLATION
THERMOSTAT MAINTENANCE
REMOVAL
Figure 1. Thermostat.
ENGINE CONTROL MODULE MAINTENANCE
REMOVAL
Figure 1. Engine Control Module.
REPROGRAMMING
REPROGRAMMING DVR PARAMETERS FOR VOLTAGE AND FREQUENCY CHANGE
REPROGRAMMING OR VERIFYING DVR PARAMETERS
Table 2. 200 kW TQG DVR Programming Parameters.
Table 2. 200 kW TQG DVR Programming Parameters - Continued.
Table 2. 200 kW TQG DVR Programming Parameters - Continued.
REPROGRAMMING GSC SETPOINTS FOR VOLTAGE AND FREQUENCY CHANGE
REPROGRAMMING GSC SETPOINTS FOR VOLTAGE AND FREQUENCY CHANGE - Continued
REPROGRAMMING OR VERIFYING GSC SETPOINTS
REPROGRAMMING OR VERIFYING GSC SETPOINTS - Continued
Table 4. 200 kW OP5-0 Engine/Generator Setpoint Programming.
Table 4. 200 kW OP5-0 Engine/Generator Setpoint Programming - Continued.
Table 4. 200 kW OP5-0 Engine/Generator Setpoint Programming - Continued.
Table 4. 200 kW OP5-0 Engine/Generator Setpoint Programming - Continued.
Table 4. 200 kW OP5-0 Engine/Generator Setpoint Programming - Continued.
Table 5. OP5-1 Protective Relaying Setpoint Programming.
Table 5. OP5-1 Protective Relaying Setpoint Programming - Continued.
Table 5. OP5-1 Protective Relaying Setpoint Programming - Continued.
Table 5. OP5-1 Protective Relaying Setpoint Programming - Continued.
Table 5. OP5-1 Protective Relaying Setpoint Programming - Continued.
Table 5. OP5-1 Protective Relaying Setpoint Programming - Continued.
Table 6. OP5-3 Synchronization Setpoint Programming.
Table 6. OP5-3 Synchronization Setpoint Programming - Continued.
Table 7. OP6 Spare Input/Output Setpoint Programming.
Table 7. OP6 Spare Input/Output Setpoint Programming - Continued.
Table 7. OP6 Spare Input/Output Setpoint Programming - Continued.
Table 8. OP8 Voltmeter Ammeter Programming.
INSTALLATION OF GENERATOR SET ON TRAILER
Figure 1. Installation of Generator Set on Trailer.
INSTALLATION
PREPARATION FOR STORAGE OR SHIPMENT
PREPARATION FOR STORAGE OR SHIPMENT
Figure 1. Preparation for Storage or Shipment.
LONG TERM STORAGE
ILLUSTRATED LIST OF MANUFACTURED ITEMS
TORQUE LIMITS
Table 1. Standard Dry Torque Limits.
Table 2. Metric Dry Torque Limits.
Table 2. Metric Dry Torque Limits - Continued.
WIRE LISTS
INTRODUCTION
HARNESS INSPECTION PROCEDURES
Wire Insulation Damage Inspection
Terminal Retention into Socket Inspection
Figure 1. Engine Sensors (Sheet 1 of 2).
Figure 1. Engine Sensors (Sheet 2 of 2).
Figure 2. Wire Harness Connectors (Sheet 1 of 3).
Figure 2. Wire Harness Connectors (Sheet 2 of 3).
Figure 2. Wire Harness Connectors (Sheet 3 of 3).
Table 1. Control Panel Wire List.
Table 1. Control Panel Wire List - Continued.
Table 1. Control Panel Wire List - Continued.
Table 1. Control Panel Wire List - Continued.
Table 1. Control Panel Wire List - Continued.
Table 1. Control Panel Wire List - Continued.
Table 1. Control Panel Wire List - Continued.
Table 1. Control Panel Wire List - Continued.
Table 1. Control Panel Wire List - Continued.
Table 1. Control Panel Wire List - Continued.
Table 1. Control Panel Wire List - Continued.
Table 1. Control Panel Wire List - Continued.
Table 1. Control Panel Wire List - Continued.
Table 1. Control Panel Wire List - Continued.
Table 1. Control Panel Wire List - Continued.
Table 1. Control Panel Wire List - Continued.
Table 1. Control Panel Wire List - Continued.
Table 1. Control Panel Wire List - Continued.
Table 1. Control Panel Wire List - Continued.
Table 1. Control Panel Wire List - Continued.
Table 1. Control Panel Wire List - Continued.
Table 1. Control Panel Wire List - Continued.
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List.
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued.
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued.
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued.
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued.
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued.
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued.
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued.
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued.
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued.
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued.
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued.
Table 3. ECM to EMCP Harness Wire List.
Table 3. ECM to EMCP Harness Wire List - Continued.
Table 3. ECM to EMCP Harness Wire List - Continued.
Table 3. ECM to EMCP Harness Wire List - Continued.
Table 3. ECM to EMCP Harness Wire List - Continued.
Table 3. ECM to EMCP Harness Wire List - Continued.
Table 4. Engine Harness Wire List.
Table 4. Engine Harness Wire List - Continued.
Table 4. Engine Harness Wire List - Continued.
Table 4. Engine Harness Wire List - Continued.
Table 4. Engine Harness Wire List - Continued.
Table 4. Engine Harness Wire List - Continued.
Table 5. Engine Harness to Unit Injectors Wire List.
Table 5. Engine Harness to Unit Injectors Wire List - Continued.
Table 6. Winterization Control Panel Wire List.
Table 6. Winterization Control Panel Wire List - Continued.
Table 6. Winterization Control Panel Wire List - Continued.
Table 7. Winterization Kit Heater Cable Wire List.
Table 7. Winterization Kit Heater Cable Wire List - Continued.
Table 8. Winterization Kit Power Cable Wire List.
Chapter 4. UNIT (FIELD) LEVEL MAINTENANCE INSTRUCTIONS WINTERIZATION KIT
WORK PACKAGE INDEX
WINTERIZATION HEATER CONTROL BOX ASSEMBLY MAINTENANCE
Figure 1. Winterization Heater Control Box Assembly.
DISASSEMBLY
ASSEMBLY
WINTERIZATION HEATER ASSEMBLY MAINTENANCE
REMOVAL
Figure 1. Winterization Heater Assembly.
INSTALLATION
WINTERIZATION HEATER HOSES MAINTENANCE
REMOVAL
Figure 1. Winterization Heater Hoses.
INSTALLATION
WINTERIZATION THERMOSTAT, RESISTORS, AND DIODE MAINTENANCE
REMOVAL
Figure 1. Winterization Thermostat, Resistors, and Diode.
INSTALLATION
WINTERIZATION WIRING HARNESSES MAINTENANCE
REMOVAL
Figure 1. Winterization Wiring Harnesses.
Chapter 5. DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE INSTRUCTIONS
WORK PACKAGE INDEX
GENERATOR REPAIR
DISASSEMBLY
Figure 1. Generator Repair.
CLEANING
ASSEMBLY
ASSEMBLY - Continued
ASSEMBLY - Continued
GENERATOR REPLACEMENT
REMOVAL
Figure 1. Generator.
INSTALLATION
ENGINE REPLACEMENT
REMOVAL
Figure 1. Engine.
INSTALLATION
INSTALLATION - Continued
ENGINE/GENERATOR BASE ASSEMBLY REPAIR
REPAIR OR REPLACEMENT
ENGINE ELECTRICAL SYSTEM REPAIR
Table 1. WP 0098 Guide.
Figure 1. Engine Electrical System Repair (Sheet 1 of 3).
Figure 1. Engine Electrical System Repair (Sheet 2 of 3).
Figure 1. Engine Electrical System Repair (Sheet 3 of 3).
REMOVAL - Continued
INSTALLATION
INSTALLATION - Continued
FAN PULLEY MAINTENANCE
Figure 1. Fan Pulley.
INSTALLATION
VALVE COVER AND BASE MAINTENANCE
REMOVAL
Figure 1. Valve Cover and Base (Sheet 1 of 3).
Figure 1. Valve Cover and Base (Sheet 2 of 3).
Figure 1. Valve Cover and Base (Sheet 3 of 3).
FUEL FILTER BASE AND MANIFOLD MAINTENANCE
REMOVAL
Figure 1. Fuel Filter Base and Manifold.
FUEL TRANSFER PUMP MAINTENANCE
Figure 1. Fuel Transfer Pump.
INSTALLATION
TURBOCHARGER MAINTENANCE
REMOVAL
Figure 1. Turbocharger.
INSTALLATION
CRANKSHAFT VIBRATION DAMPER AND PULLEY MAINTENANCE
REMOVAL
Figure 1. Crankshaft Vibration Damper and Pulley.
CRANKSHAFT FRONT SEAL MAINTENANCE
REMOVAL
Figure 1. Crankshaft Front Seal.
FRONT COVER MAINTENANCE
REMOVAL
Figure 1. Front Cover.
OIL FILTER BASE MAINTENANCE
REMOVAL
Figure 1. Oil Filter Base.
ASSEMBLY
OIL COOLER MAINTENANCE
REMOVAL
Figure 1. Oil Cooler.
INSTALLATION
OIL PUMP MAINTENANCE
Figure 1. Oil Pump.
DISASSEMBLY
ASSEMBLY
WATER PUMP MAINTENANCE
Figure 1. Water Pump.
INSTALLATION
FLYWHEEL MAINTENANCE
REMOVAL
Figure 1. Flywheel.
CRANKSHAFT REAR SEAL MAINTENANCE
Figure 1. Crankshaft Rear Seal.
INSTALLATION
FLYWHEEL HOUSING MAINTENANCE
REMOVAL
Figure 1. Flywheel Housing.
CRANKSHAFT REAR SEAL CARRIER MAINTENANCE
REMOVAL
Figure 1. Crankshaft Rear Seal Carrier.
EXHAUST MANIFOLD MAINTENANCE
REMOVAL
Figure 1. Exhaust Manifold.
INLET MANIFOLD MAINTENANCE
REMOVAL
Figure 1. Inlet Manifold.
OIL PAN MAINTENANCE
REMOVAL
Figure 1. Oil Pan.
UNIT INJECTOR MAINTENANCE
REMOVAL
Figure 1. Unit Injector.
ROCKER SHAFT AND PUSHROD MAINTENANCE
REMOVAL
Figure 1. Rocker Shaft and Pushrod Removal and Installation.
INSPECTION OF INSTALLED ITEMS
ASSEMBLY
VALVE LASH CHECK
Table 1. Crankshaft Positions for Valve Lash Setting.
VALVE LASH ADJUSTMENT
VALVE LASH ADJUSTMENT - Continued
CYLINDER HEAD MAINTENANCE
REMOVAL
Figure 1. Cylinder Head.
INSTALLATION
INSTALLATION - Continued
Chapter 6. GENERAL SUPPORT Moved to Sustainment (NMWR)
Chapter 7. SUPPORTING INFORMATION
WORK PACKAGE INDEX
REFERENCES
MISCELLANEOUS PUBLICATIONS
DETAIL SPECIFICATION
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
Maintenance Functions
Explanation of Columns in the MAC
Explanation of Columns in the Remarks
Table 1. MAC.
Table 1. MAC - Continued.
Table 1. MAC - Continued.
Table 1. MAC - Continued.
Table 2. Tools and Test Equipment Requirements.
Table 3. Remarks.
Table 3. Remarks - Continued.
EXPENDABLE AND DURABLE ITEMS LIST
Table 1. Expendable and Durable Items List
Table 1. Expendable and Durable Items List - Continued.
Table 1. Expendable and Durable Items List - Continued.
Table 1. Expendable and Durable Items List - Continued.
GLOSSARY
GLOSSARY - Continued
INDEX
INDEX - Continued
INDEX - Continued
INDEX - Continued
Figure FO-2. 200kW TQG Electrical Power Schematic Diagram (sheet 1 of 6)
Figure FO-2. 200kW TQG Electrical Power Schematic Diagram (sheet 2 of 6)
Figure FO-2. 200kW TQG Electrical Power Schematic Diagram (sheet 3 of 6)
Figure FO-2. 200kW TQG Electrical Power Schematic Diagram (sheet 4 of 6)
Figure FO-2. 200kW TQG Electrical Power Schematic Diagram (sheet 5 of 6)
Figure FO-2. 200kW TQG Electrical Power Schematic Diagram (sheet 6 of 6)
Figure FO-2. 200kW Engine Wiring Harnesses - Schematic Digram (sheet 1 of 2)
Figure FO-2. 200kW Engine Wiring Harnesses - Schematic Digram (sheet 2 of 2)
Figure FO-3. Generator Set Wiring digram (sheet 1 of 2)
Figure FO-3. Generator Set Wiring digram (sheet 2 of 2)
Figure FO-4. Control Box Wiring Diagram (sheet 1 of 5)
Figure FO-4. Control Box Wiring Diagram (sheet 2 of 5)
Figure FO-4. Control Box Wiring Diagram (sheet 3 of 5)
Figure FO-4. Control Box Wiring Diagram (sheet 4 of 5)
Figure FO-4. Control Box Wiring Diagram (sheet 5 of 5)
The Metric System and Equivalents
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TM-9-6115-730-24
RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS
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By Order of the Secretary of the Army
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