CHAPTER 1 INTRODUCTION - TM-9-6115-641-24_18
Figure 1-1. Generator Set, 5 kW, Tactical Quiet
EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRs)
Table 1-1. Tabulated Data
Table 1-1. Tabulated Data - Continued - TM-9-6115-641-24_22
Table 1-1. Tabulated Data - Continued - TM-9-6115-641-24_23
Table 1-2. Performance Characteristics - Continued - TM-9-6115-641-24_24
Section Ill. PRINCIPLES OF OPERATION - TM-9-6115-641-24_25
Figure 1-2. Fault System
Fuel System - TM-9-6115-641-24_27
Figure 1-3. Generator Set Fuel System - TM-9-6115-641-24_28
Generator Set Cooling System - TM-9-6115-641-24_29
Figure 1-4. Generator Set Cooling System
Figure 1-5. Engine Cooling System
Figure 1-6. Engine Lubrication System - TM-9-6115-641-24_32
Engine Air Intake and Exhaust System
Figure 1-7. Engine Air Intake and Exhaust System - TM-9-6115-641-24_34
Figure 1-8. Output Supply System - TM-9-6115-641-24_35
Generator Set Control - TM-9-6115-641-24_36
Figure 1-9. Engine Starting System - TM-9-6115-641-24_37
Shutdown. - TM-9-6115-641-24_38
Voltage Regulation System
Figure 1-10. Governor Control System - TM-9-6115-641-24_40
Figure 1-11. Voltage Regulation System - TM-9-6115-641-24_41
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - TM-9-6115-641-24_42
Figure 1-12. Generator Set Components - TM-9-6115-641-24_43
CHAPTER 2 UNIT MAINTENANCE INSTRUCTIONS - TM-9-6115-641-24_44
Table 2-1. Coolant - TM-9-6115-641-24_45
Table 2-3. Lubricating Oil - TM-9-6115-641-24_46
Outdoor Installation - TM-9-6115-641-24_47
Figure 2-1. Minimum Enclosure Clearance Measurements
Figure 2-2. Base Mounting Measurements - TM-9-6115-641-24_49
Table 2-4. Fabricated/Assembled Parts
Table 2-5. Unit Preventive Maintenance Checks and Services
Table 2-5. Unit Preventive Maintenance Checks and Services - Continued - TM-9-6115-641-24_52
Table 2-5. Unit Preventive Maintenance Checks and Services - Continued - TM-9-6115-641-24_53
SYMPTOM INDEX GENERATOR SET - TM-9-6115-641-24_54
Table 2-6. UNIT TROUBLESHOOTING - TM-9-6115-641-24_55
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_56
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_57
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_58
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_59
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_60
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_61
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_62
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_63
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_64
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_65
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_66
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_67
Section VI. RADIO INTERFERENCE SUPPRESSION - TM-9-6115-641-24_68
Section Vlll. MAINTENANCE OF DC ELECTRICAL SYSTEM
Figure 2-3. Batteries and Cables - TM-9-6115-641-24_70
Table 2-7. STATE OF CHARGE WITH SPECIFIC GRAVITY CORRECTED TO 80F (27C) - TM-9-6115-641-24_71
Table 2-8. SPECIFIC GRAVITY TEMPERATURE CORRECTIONS
Removal. - TM-9-6115-641-24_73
NATO SLAVE RECEPTACLE - TM-9-6115-641-24_74
Figure 2-4. NATO Slave receptacle and Cables
Testing - TM-9-6115-641-24_76
Figure 2-5. Battery Charging Alternation
Section IX. MAINTENANCE OF HOUSING - TM-9-6115-641-24_78
Figure 2-6. Generator Set Access Doors
CONTROL BOX TOP PANEL - TM-9-6115-641-24_80
Figure 2-7. Control Box Top Panel
TOP HOUSING PANEL
FRONT HOUSING PANEL
Figure 2-8. Generator Set front Housing Section
FRONT HOUSING SECTION - TM-9-6115-641-24_85
Installation - TM-9-6115-641-24_86
REAR HOUSING SECTION - TM-9-6115-641-24_87
Figure 2-9. Generator set rear Housing Section
Removal - TM-9-6115-641-24_89
Section X. MAINTENANCE OF CONTROL BOX ASSEMBLY
CONVENIENCE RECEPTACLE.
Figure 2-10. Control Box Assembly - TM-9-6115-641-24_92
GROUND FAULT CIRCUIT INTERRUPTER
MALFUNCTION INDICATOR PANEL - TM-9-6115-641-24_94
DC CONTROL POWER CIRCUIT BREAKER - TM-9-6115-641-24_95
AC VOLTAGE REGULATOR. - TM-9-6115-641-24_96
FREQUENCY TRANSDUCER. - TM-9-6115-641-24_97
FREQUENCY TRANSDUCER. (cont)
SHUNT
OVERVOLTAGE RELAY
SHORT CIRCUIT/OVERLOAD RELAY - TM-9-6115-641-24_101
Testing - TM-9-6115-641-24_102
Figure 2-11. Control Box Components
Removal.
RELAYS - TM-9-6115-641-24_105
Figure 2-12. Diode Identification
CONTROL BOX HARNESS - TM-9-6115-641-24_107
Figure 2-13. Diagnostic Connector Pin Positions (Front View)
Table 2-10. Diagnostic Connector Connection Points
PRESS TO TEST INDICATOR LIGHTS
Figure 2-14. Control Panel Indicators and Switches
FUEL LEVEL INDICATOR - TM-9-6115-641-24_112
COOLANT TEMP. INDICATOR
OIL PRESSURE INDICATOR - TM-9-6115-641-24_114
OIL PRESSURE INDICATOR (cont)
TIME METER (TOTAL HOURS) - TM-9-6115-641-24_116
FREQUENCY METER (HERTZ)
FREQUENCY METER (HERTZ) (cnot)
FREQUENCY METER (HERTZ) (cont)
AC VOLTMETER (VOLTS AC)
MASTER SWITCH
VOLTAGE ADJUST POTENTIOMETER - TM-9-6115-641-24_122
EMERGENCY STOP SWICTH
BATTLE SHORT SWICTH
CIRCUIT INTERRUPTER SWITCH.
AM - VM TRANSFER SWITCH
PANEL LIGHTS SWITCH - TM-9-6115-641-24_127
CONTROL PANEL FRAME - TM-9-6115-641-24_128
CONTROL PANEL FRAME (cont)
Figure 2-15. Control Box Housing and Control Panel
CONTROL BOX SIDE PANELS. - TM-9-6115-641-24_131
CONTROL BOX TRAY
Section XI. MAINTENANCE OF OUTPUT BOX ASSEMBLY
AC CIRCUIT INTERRUPTER RELAY - TM-9-6115-641-24_134
CRANKING RELAY - TM-9-6115-641-24_135
Figure 2-16. Output Box Assembly
PRE-HEAT RELAY
VOLTAGE RECONNECTION SWITCH
Section XII. MAINTENANCE OF AIR INTAKE AND EXHAUST SYSTEM - TM-9-6115-641-24_139
Cleaning and Inspection - TM-9-6115-641-24_140
Figure 2-18. Muffler - TM-9-6115-641-24_141
AIR RESTRICTION INDICATOR
AIR CLEANER ELEMENT
Figure 2-19. Air Cleaner Assembly - TM-9-6115-641-24_144
Section XIII. MAINTENANCE OF COOLING SYSTEM
RADIATOR - TM-9-6115-641-24_146
UPPER COOLANT HOSE.
Figure 2-20. Radiator Assembly and Cooling System
LOWER COOLANT HOSE - TM-9-6115-641-24_149
COOLANT RECOVERY SYSTEM
FAN BELT - TM-9-6115-641-24_151
FUEL LEVEL SENDER - TM-9-6115-641-24_152
LOW FUEL LEVEL/AUXILIARY FUEL PU MP FLOAT SWITCH
LOW FUEL LEVEL/AUXILIARY FUEL PU MP FLOAT SWITCH (cont)
FUEL FLOAT MODULE
FUEL TANK FILLER NECK.
Figure 2-21. Fuel Tank, Switches, and Auxiliary Fuel Pump
FUEL TANK DRAIN VALVE.
AUXILIARY FUEL PUMP.
FUEL TRANSFER PUMP.
FUEL FILTER/WATER SEPARATOR ASSEMBLY. - TM-9-6115-641-24_161
Figure 2-22. Fuel Filter/Water Separator and Transfer Pump
FUEL FILTER/WATER SEPARATOR ELEMENT - TM-9-6115-641-24_163
Section XV. MAINTENANCE OF LUBRICATION SYSTEM
Figure 2-23. Engine Oil Drain Line - TM-9-6115-641-24_165
Section XVI. MAINTENANCE OF ENGINE ACCESSORIES
LOW OIL PRESSURE SWITCH
Figure 2-25. Engine Related Switches and Senders
Testing. - TM-9-6115-641-24_169
OIL PRESSURE SENDER.
COOLANT TEMPERATURE SENDER - TM-9-6115-641-24_171
COOLANT HIGH TEMPERATURE SWITCH - TM-9-6115-641-24_172
MAGNETIC PICKUP - TM-9-6115-641-24_173
FUEL SOLENOID
DEAD CRANK SWITCH - TM-9-6115-641-24_175
Section XVII. MAINTENANCE OF LOAD OUTPUT TERMINAL BOARD ASSEMBLY - TM-9-6115-641-24_176
Figure 2-26. Load Output Terminal Board Assembly
LOAD OUTPUT TERMINALS - TM-9-6115-641-24_178
VARISTORS - TM-9-6115-641-24_179
MARKING
CHAPTER 3 GENERAL MAINTENANCE INSTRUCTIONS
SYMPTOM INDEX GENERATOR SET - TM-9-6115-641-24_183
Table 3-1. DIRECT SUPPORT TROUBLESHOOTING - TM-9-6115-641-24_184
Table 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-641-24_185
Table 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-641-24_186
Table 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-641-24_187
Table 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-641-24_188
Section Ill. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS - TM-9-6115-641-24_189
ENGINE AND GENERATOR ASSEMBLY - TM-9-6115-641-24_190
Removal - TM-9-6115-641-24_191
Installation - TM-9-6115-641-24_192
Figure 3-1. Engine and Generator Assembly Removal - TM-9-6115-641-24_193
Installation
Installation - Continued
ENGINE REPLACEMENT - TM-9-6115-641-24_196
CHAPTER 4 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS - TM-9-6115-641-24_198
Figure 4-2. Brush Test
Figure 4-5. Stator Winding Test
Figure 4-6. Rotor Test
Figure 4-7. Alternator Assembly
Figure 4-8. Assembling Front Housing to Rotor
Figure 4-9. Performance Test Circuit
Section Il. MAINTENANCE OF CONTROL BOX ASSEMBLY
Figure 4-10. Control Box Harness - TM-9-6115-641-24_206
Section Ill. MAINTENANCE OF OUTPUT BOX ASSEMBLY - TM-9-6115-641-24_207
OUTPUT BOX ASSEMBLY
OUTPUT BOX/ENGINE HARNESS - TM-9-6115-641-24_209
Figure 4-11. Output Box Assembly - TM-9-6115-641-24_210
Installation - TM-9-6115-641-24_211
Figure 4-12. Testing Current Transformer - TM-9-6115-641-24_212
Section V. MAINTENANCE OF ENGINE ACCESSORIES
Figure 4-13. Frequency Droop Adjustment
lnspection
Figure 4-14. Skid Base
Figure 4-16. Excitation Block Diagram
ADJUSTMENTS AND TESTS - TM-9-6115-641-24_218
Figure 4-17. Testing Rotating Rectifiers
Figure 4-19. Testing Exciter Armature
Figure 4-21. Testing Rotor for Grounds - TM-9-6115-641-24_221
Figure 4-22. Testing Stator Windings - TM-9-6115-641-24_223
Figure 4-23. Support of Rotor Assembly
Assembly/lnstallation
GENERATOR ASSEMBLY (MEP-812A)
Figure 4-24. Generator Assembly (MEP-802A)
Disassembly - TM-9-6115-641-24_228
Assembly. - TM-9-6115-641-24_229
Figure 4-25. Generator Assembly (MEP-812A)
Appendix A. REFERENCE
Appendix B. MAINTENANCE ALLOCATION CHART (MAC)
EXPLANATION OF COLU MNS IN THE MAC, SECTION Il
Section Il. MAINTENANCE ALLOCATION CHART - TM-9-6115-641-24_236
Section Il. MAINTENANCE ALLOCATION CHART - Continued
Section Il. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-641-24_238
Section Il. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-641-24_239
Section Il. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-641-24_240
Section Il. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-641-24_241
Section Il. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-641-24_242
Section Ill. TOOL AND TEST EQUIPMENT REQUIREMENTS
Appendix C. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
Section II. TABULAR LIST - TM-9-6115-641-24_245
Appendix D. FABRICATION/ASSEMBLY OF PARTS
Figure D-1. Cable Assembly, Battery (P/N: 88-20312)
Figure D-2. Cable Assembly, Battery (P/N: 88-20313) - TM-9-6115-641-24_248
Figure D-3. Cable Assembly, (P/N: 88-20314)
Figure D-4. Cable Assembly, Battery (P/N: 88-20315)
Figure D-5. Cable Assembly, Battery (P/N: 88-20316)
Figure D-7. Diode Assembly (P/N: 88-22418-1)
Figure D-8. Holder, Control Panel (P/N: 88-20134)
Figure D-9. Insulation,Skid (P/N: 88-20296)
Figure D-10. Pump Assembly, Fuel (P/N: 88-20479)
Figure D-11. Pump Assembly, Fuel (P/N: 88-22546)
Figure D-12. Solenoid Assembly, Fuel (P/N: 88-20482)
Figure D-13. Transducer Assembly (P/N: 88-20480)
Figure D-14. Wire, Varistor (P/Ns: 88-20305-1 through 88-203054)
Table D-1. INCHES TO METRIC CONVERSION
PART Il. Inches to Centimeters - TM-9-6115-641-24_261
ALPHABETICAL INDEX
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_263
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_264
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_265
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_266
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_267
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_268
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_269
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_270
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_271
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_272
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_273
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_274
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_275
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_276
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_277
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_278
fo-1. electrical schematic
fo-2. wiring diagram (sheet 1 of 5)
fo-2. wiring diagram (sheet 2 of 5)
fo-2. wiring diagram (sheet 3 of 5)
fo-2. wiring diagram (sheet 4 of 5)
fo-2. wiring diagram (sheet 5 of 5)
Figure 1-1. Generator Set, 5 kW, Tactical Quiet
EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRs)
Table 1-1. Tabulated Data
Table 1-1. Tabulated Data - Continued - TM-9-6115-641-24_22
Table 1-1. Tabulated Data - Continued - TM-9-6115-641-24_23
Table 1-2. Performance Characteristics - Continued - TM-9-6115-641-24_24
Section Ill. PRINCIPLES OF OPERATION - TM-9-6115-641-24_25
Figure 1-2. Fault System
Fuel System - TM-9-6115-641-24_27
Figure 1-3. Generator Set Fuel System - TM-9-6115-641-24_28
Generator Set Cooling System - TM-9-6115-641-24_29
Figure 1-4. Generator Set Cooling System
Figure 1-5. Engine Cooling System
Figure 1-6. Engine Lubrication System - TM-9-6115-641-24_32
Engine Air Intake and Exhaust System
Figure 1-7. Engine Air Intake and Exhaust System - TM-9-6115-641-24_34
Figure 1-8. Output Supply System - TM-9-6115-641-24_35
Generator Set Control - TM-9-6115-641-24_36
Figure 1-9. Engine Starting System - TM-9-6115-641-24_37
Shutdown. - TM-9-6115-641-24_38
Voltage Regulation System
Figure 1-10. Governor Control System - TM-9-6115-641-24_40
Figure 1-11. Voltage Regulation System - TM-9-6115-641-24_41
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - TM-9-6115-641-24_42
Figure 1-12. Generator Set Components - TM-9-6115-641-24_43
CHAPTER 2 UNIT MAINTENANCE INSTRUCTIONS - TM-9-6115-641-24_44
Table 2-1. Coolant - TM-9-6115-641-24_45
Table 2-3. Lubricating Oil - TM-9-6115-641-24_46
Outdoor Installation - TM-9-6115-641-24_47
Figure 2-1. Minimum Enclosure Clearance Measurements
Figure 2-2. Base Mounting Measurements - TM-9-6115-641-24_49
Table 2-4. Fabricated/Assembled Parts
Table 2-5. Unit Preventive Maintenance Checks and Services
Table 2-5. Unit Preventive Maintenance Checks and Services - Continued - TM-9-6115-641-24_52
Table 2-5. Unit Preventive Maintenance Checks and Services - Continued - TM-9-6115-641-24_53
SYMPTOM INDEX GENERATOR SET - TM-9-6115-641-24_54
Table 2-6. UNIT TROUBLESHOOTING - TM-9-6115-641-24_55
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_56
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_57
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_58
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_59
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_60
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_61
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_62
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_63
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_64
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_65
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_66
Table 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-641-24_67
Section VI. RADIO INTERFERENCE SUPPRESSION - TM-9-6115-641-24_68
Section Vlll. MAINTENANCE OF DC ELECTRICAL SYSTEM
Figure 2-3. Batteries and Cables - TM-9-6115-641-24_70
Table 2-7. STATE OF CHARGE WITH SPECIFIC GRAVITY CORRECTED TO 80F (27C) - TM-9-6115-641-24_71
Table 2-8. SPECIFIC GRAVITY TEMPERATURE CORRECTIONS
Removal. - TM-9-6115-641-24_73
NATO SLAVE RECEPTACLE - TM-9-6115-641-24_74
Figure 2-4. NATO Slave receptacle and Cables
Testing - TM-9-6115-641-24_76
Figure 2-5. Battery Charging Alternation
Section IX. MAINTENANCE OF HOUSING - TM-9-6115-641-24_78
Figure 2-6. Generator Set Access Doors
CONTROL BOX TOP PANEL - TM-9-6115-641-24_80
Figure 2-7. Control Box Top Panel
TOP HOUSING PANEL
FRONT HOUSING PANEL
Figure 2-8. Generator Set front Housing Section
FRONT HOUSING SECTION - TM-9-6115-641-24_85
Installation - TM-9-6115-641-24_86
REAR HOUSING SECTION - TM-9-6115-641-24_87
Figure 2-9. Generator set rear Housing Section
Removal - TM-9-6115-641-24_89
Section X. MAINTENANCE OF CONTROL BOX ASSEMBLY
CONVENIENCE RECEPTACLE.
Figure 2-10. Control Box Assembly - TM-9-6115-641-24_92
GROUND FAULT CIRCUIT INTERRUPTER
MALFUNCTION INDICATOR PANEL - TM-9-6115-641-24_94
DC CONTROL POWER CIRCUIT BREAKER - TM-9-6115-641-24_95
AC VOLTAGE REGULATOR. - TM-9-6115-641-24_96
FREQUENCY TRANSDUCER. - TM-9-6115-641-24_97
FREQUENCY TRANSDUCER. (cont)
SHUNT
OVERVOLTAGE RELAY
SHORT CIRCUIT/OVERLOAD RELAY - TM-9-6115-641-24_101
Testing - TM-9-6115-641-24_102
Figure 2-11. Control Box Components
Removal.
RELAYS - TM-9-6115-641-24_105
Figure 2-12. Diode Identification
CONTROL BOX HARNESS - TM-9-6115-641-24_107
Figure 2-13. Diagnostic Connector Pin Positions (Front View)
Table 2-10. Diagnostic Connector Connection Points
PRESS TO TEST INDICATOR LIGHTS
Figure 2-14. Control Panel Indicators and Switches
FUEL LEVEL INDICATOR - TM-9-6115-641-24_112
COOLANT TEMP. INDICATOR
OIL PRESSURE INDICATOR - TM-9-6115-641-24_114
OIL PRESSURE INDICATOR (cont)
TIME METER (TOTAL HOURS) - TM-9-6115-641-24_116
FREQUENCY METER (HERTZ)
FREQUENCY METER (HERTZ) (cnot)
FREQUENCY METER (HERTZ) (cont)
AC VOLTMETER (VOLTS AC)
MASTER SWITCH
VOLTAGE ADJUST POTENTIOMETER - TM-9-6115-641-24_122
EMERGENCY STOP SWICTH
BATTLE SHORT SWICTH
CIRCUIT INTERRUPTER SWITCH.
AM - VM TRANSFER SWITCH
PANEL LIGHTS SWITCH - TM-9-6115-641-24_127
CONTROL PANEL FRAME - TM-9-6115-641-24_128
CONTROL PANEL FRAME (cont)
Figure 2-15. Control Box Housing and Control Panel
CONTROL BOX SIDE PANELS. - TM-9-6115-641-24_131
CONTROL BOX TRAY
Section XI. MAINTENANCE OF OUTPUT BOX ASSEMBLY
AC CIRCUIT INTERRUPTER RELAY - TM-9-6115-641-24_134
CRANKING RELAY - TM-9-6115-641-24_135
Figure 2-16. Output Box Assembly
PRE-HEAT RELAY
VOLTAGE RECONNECTION SWITCH
Section XII. MAINTENANCE OF AIR INTAKE AND EXHAUST SYSTEM - TM-9-6115-641-24_139
Cleaning and Inspection - TM-9-6115-641-24_140
Figure 2-18. Muffler - TM-9-6115-641-24_141
AIR RESTRICTION INDICATOR
AIR CLEANER ELEMENT
Figure 2-19. Air Cleaner Assembly - TM-9-6115-641-24_144
Section XIII. MAINTENANCE OF COOLING SYSTEM
RADIATOR - TM-9-6115-641-24_146
UPPER COOLANT HOSE.
Figure 2-20. Radiator Assembly and Cooling System
LOWER COOLANT HOSE - TM-9-6115-641-24_149
COOLANT RECOVERY SYSTEM
FAN BELT - TM-9-6115-641-24_151
FUEL LEVEL SENDER - TM-9-6115-641-24_152
LOW FUEL LEVEL/AUXILIARY FUEL PU MP FLOAT SWITCH
LOW FUEL LEVEL/AUXILIARY FUEL PU MP FLOAT SWITCH (cont)
FUEL FLOAT MODULE
FUEL TANK FILLER NECK.
Figure 2-21. Fuel Tank, Switches, and Auxiliary Fuel Pump
FUEL TANK DRAIN VALVE.
AUXILIARY FUEL PUMP.
FUEL TRANSFER PUMP.
FUEL FILTER/WATER SEPARATOR ASSEMBLY. - TM-9-6115-641-24_161
Figure 2-22. Fuel Filter/Water Separator and Transfer Pump
FUEL FILTER/WATER SEPARATOR ELEMENT - TM-9-6115-641-24_163
Section XV. MAINTENANCE OF LUBRICATION SYSTEM
Figure 2-23. Engine Oil Drain Line - TM-9-6115-641-24_165
Section XVI. MAINTENANCE OF ENGINE ACCESSORIES
LOW OIL PRESSURE SWITCH
Figure 2-25. Engine Related Switches and Senders
Testing. - TM-9-6115-641-24_169
OIL PRESSURE SENDER.
COOLANT TEMPERATURE SENDER - TM-9-6115-641-24_171
COOLANT HIGH TEMPERATURE SWITCH - TM-9-6115-641-24_172
MAGNETIC PICKUP - TM-9-6115-641-24_173
FUEL SOLENOID
DEAD CRANK SWITCH - TM-9-6115-641-24_175
Section XVII. MAINTENANCE OF LOAD OUTPUT TERMINAL BOARD ASSEMBLY - TM-9-6115-641-24_176
Figure 2-26. Load Output Terminal Board Assembly
LOAD OUTPUT TERMINALS - TM-9-6115-641-24_178
VARISTORS - TM-9-6115-641-24_179
MARKING
CHAPTER 3 GENERAL MAINTENANCE INSTRUCTIONS
SYMPTOM INDEX GENERATOR SET - TM-9-6115-641-24_183
Table 3-1. DIRECT SUPPORT TROUBLESHOOTING - TM-9-6115-641-24_184
Table 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-641-24_185
Table 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-641-24_186
Table 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-641-24_187
Table 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-641-24_188
Section Ill. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS - TM-9-6115-641-24_189
ENGINE AND GENERATOR ASSEMBLY - TM-9-6115-641-24_190
Removal - TM-9-6115-641-24_191
Installation - TM-9-6115-641-24_192
Figure 3-1. Engine and Generator Assembly Removal - TM-9-6115-641-24_193
Installation
Installation - Continued
ENGINE REPLACEMENT - TM-9-6115-641-24_196
CHAPTER 4 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS - TM-9-6115-641-24_198
Figure 4-2. Brush Test
Figure 4-5. Stator Winding Test
Figure 4-6. Rotor Test
Figure 4-7. Alternator Assembly
Figure 4-8. Assembling Front Housing to Rotor
Figure 4-9. Performance Test Circuit
Section Il. MAINTENANCE OF CONTROL BOX ASSEMBLY
Figure 4-10. Control Box Harness - TM-9-6115-641-24_206
Section Ill. MAINTENANCE OF OUTPUT BOX ASSEMBLY - TM-9-6115-641-24_207
OUTPUT BOX ASSEMBLY
OUTPUT BOX/ENGINE HARNESS - TM-9-6115-641-24_209
Figure 4-11. Output Box Assembly - TM-9-6115-641-24_210
Installation - TM-9-6115-641-24_211
Figure 4-12. Testing Current Transformer - TM-9-6115-641-24_212
Section V. MAINTENANCE OF ENGINE ACCESSORIES
Figure 4-13. Frequency Droop Adjustment
lnspection
Figure 4-14. Skid Base
Figure 4-16. Excitation Block Diagram
ADJUSTMENTS AND TESTS - TM-9-6115-641-24_218
Figure 4-17. Testing Rotating Rectifiers
Figure 4-19. Testing Exciter Armature
Figure 4-21. Testing Rotor for Grounds - TM-9-6115-641-24_221
Figure 4-22. Testing Stator Windings - TM-9-6115-641-24_223
Figure 4-23. Support of Rotor Assembly
Assembly/lnstallation
GENERATOR ASSEMBLY (MEP-812A)
Figure 4-24. Generator Assembly (MEP-802A)
Disassembly - TM-9-6115-641-24_228
Assembly. - TM-9-6115-641-24_229
Figure 4-25. Generator Assembly (MEP-812A)
Appendix A. REFERENCE
Appendix B. MAINTENANCE ALLOCATION CHART (MAC)
EXPLANATION OF COLU MNS IN THE MAC, SECTION Il
Section Il. MAINTENANCE ALLOCATION CHART - TM-9-6115-641-24_236
Section Il. MAINTENANCE ALLOCATION CHART - Continued
Section Il. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-641-24_238
Section Il. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-641-24_239
Section Il. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-641-24_240
Section Il. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-641-24_241
Section Il. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-641-24_242
Section Ill. TOOL AND TEST EQUIPMENT REQUIREMENTS
Appendix C. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
Section II. TABULAR LIST - TM-9-6115-641-24_245
Appendix D. FABRICATION/ASSEMBLY OF PARTS
Figure D-1. Cable Assembly, Battery (P/N: 88-20312)
Figure D-2. Cable Assembly, Battery (P/N: 88-20313) - TM-9-6115-641-24_248
Figure D-3. Cable Assembly, (P/N: 88-20314)
Figure D-4. Cable Assembly, Battery (P/N: 88-20315)
Figure D-5. Cable Assembly, Battery (P/N: 88-20316)
Figure D-7. Diode Assembly (P/N: 88-22418-1)
Figure D-8. Holder, Control Panel (P/N: 88-20134)
Figure D-9. Insulation,Skid (P/N: 88-20296)
Figure D-10. Pump Assembly, Fuel (P/N: 88-20479)
Figure D-11. Pump Assembly, Fuel (P/N: 88-22546)
Figure D-12. Solenoid Assembly, Fuel (P/N: 88-20482)
Figure D-13. Transducer Assembly (P/N: 88-20480)
Figure D-14. Wire, Varistor (P/Ns: 88-20305-1 through 88-203054)
Table D-1. INCHES TO METRIC CONVERSION
PART Il. Inches to Centimeters - TM-9-6115-641-24_261
ALPHABETICAL INDEX
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_263
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_264
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_265
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_266
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_267
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_268
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_269
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_270
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_271
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_272
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_273
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_274
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_275
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_276
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_277
ALPHABETICAL INDEX - Continued - TM-9-6115-641-24_278
fo-1. electrical schematic
fo-2. wiring diagram (sheet 1 of 5)
fo-2. wiring diagram (sheet 2 of 5)
fo-2. wiring diagram (sheet 3 of 5)
fo-2. wiring diagram (sheet 4 of 5)
fo-2. wiring diagram (sheet 5 of 5)