TM-9-6115-643-24 Generator Set Skid Mounted Tactical Quiet 10 Kw 60 and 400 Hz MEP-803A (60 Hz) MEP-813A (400 Hz) Manual

CHAPTER   1 INTRODUCTION - TM-9-6115-643-24_21
FIGURE 1-1. Generator Set, 15 kw, Tactical Quiet
EQUIPMENT   IMPROVEMENT   RECOMMENDATIONS   (EIRs) - TM-9-6115-643-24_23
Section   Il.   EQUIPMENT   DESCRIPTION   AND   DATA
TABLE 1-1. Tabulated Data - Continued - TM-9-6115-643-24_25
TABLE   1-1.   Tabulated   Data   -   Continued - TM-9-6115-643-24_26
TABLE 1-1. Tabulated Data
TABLE   1-2.   Performance   Characteristics
TABLE   1-2.   Performance   Characteristics   -   Continued
Section   Ill.   PRINCIPLES   OF   OPERATION - TM-9-6115-643-24_30
FIGURE 1-2. Fualt System
Fuel System. - TM-9-6115-643-24_32
FIGURE   1-3.   Generator   Set   Fuel   System - TM-9-6115-643-24_33
Generator Set Cooling System - TM-9-6115-643-24_34
FIGURE 1-4. Generator Set Cooling System
FIGURE 1-5. Engine Cooling System - TM-9-6115-643-24_36
Engine Lubrication System - TM-9-6115-643-24_37
FIGURE   1-6.   Engine   Lubrication   System - TM-9-6115-643-24_38
FIGURE 1-7. Engine Air Intake and Exhaust System - TM-9-6115-643-24_39
Generator Set Controls - TM-9-6115-643-24_40
FIGURE 18. Output Supply System
FIGURE 1-9. Engine Starting System
NATO SLAVE RECEPTACLE - TM-9-6115-643-24_43
EMERGENCY STOP
FIGURE 1-10. Governor Control System
FIGURE   1-11.   Voltage   Regulation   System - TM-9-6115-643-24_46
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - TM-9-6115-643-24_47
CONVENIENCE RECEPTACLE
FIGURE   1-12.   Generator   Set   Components - TM-9-6115-643-24_49
NATO SLAVE RECEPTACLE - TM-9-6115-643-24_50
CHAPTER   2 UNIT   MAINTENANCE   INSTRUCTIONS - TM-9-6115-643-24_51
Fuel Tank - TM-9-6115-643-24_52
TABLE 2-3. Lubricating Oil - TM-9-6115-643-24_53
Indoor Installation - TM-9-6115-643-24_54
FIGURE   2-1.   Base   Mounting   Measurements - TM-9-6115-643-24_55
FIGURE   2-2.   Minimum   Enclosure   Clearance   Measurements
FABRICATION/ASSEMBLY OF PARTS
TABLE   2-4.   Fabricated/Assembled   Parts
Section II. REPAIR PARTS; SPECIAL TOOLS
TABLE 2-5. Unit Preventive Maintenance Checks and Services
TABLE 2-5. Unit Preventive Maintenance Checks and Services - Continued - TM-9-6115-643-24_61
Section V. TROUBLESHOOTING - TM-9-6115-643-24_62
SYMPTOM   INDEX GENERATOR   SET - TM-9-6115-643-24_63
TABLE   2-6.   UNIT   TROUBLESHOOTING - TM-9-6115-643-24_64
TABLE   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-643-24_65
TABLE   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-643-24_66
TABLE   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-643-24_67
TABLE   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-643-24_68
TABLE   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-643-24_69
TABLE   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-643-24_70
TABLE   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-643-24_71
TABLE   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-643-24_72
TABLE   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-643-24_73
TABLE   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-643-24_74
Section    VI.    RADIO    INTERFERENCE    SUPPRESSION
Section   VIII.   MAINTENANCE   OF   DC   ELECTRICAL   SYSTEM - TM-9-6115-643-24_76
lnspection - TM-9-6115-643-24_77
FIGURE   2-3.   Batteries   and   Cables - TM-9-6115-643-24_78
BATTERIES.
TABLE 2-7.   STATE   OF   CHARGE   WITH   SPECIFIC   GRAVITY   CORRECT   TO   80F   (27C)
Inspection - TM-9-6115-643-24_81
FIGURE 2-4. NATO Slave Receptacle and Cables
Section   IX.   MAINTENANCE   OF   HOUSING - TM-9-6115-643-24_83
Inspection - TM-9-6115-643-24_84
FIGURE   2-5.   Generator   Set   Access   Doors
CONTROL   BOX   TOP   PANEL
FIGURE 2-6. Control Box Top Panel\
TOP HOUSING  SECTION
FIGURE 27. Generator Set Top Housing Section
Inspection - TM-9-6115-643-24_90
FRONT HOUSING SECTION - TM-9-6115-643-24_91
Installation - TM-9-6115-643-24_92
FIGURE 2-8. Generator Set front Housing Section - TM-9-6115-643-24_93
REAR HOUSING SECTION.
Inspection - TM-9-6115-643-24_95
FIGURE 2-9. Generator Set Rear Housing Section - TM-9-6115-643-24_96
Installation - TM-9-6115-643-24_97
Removal. - TM-9-6115-643-24_98
FIGURE   2-10.   Control   Box   Assembly - TM-9-6115-643-24_99
PRESS TO TEST LIGHTS
FIGURE 2-11. Control Panel Lights
SYNCHRONIZING   LIGHTS
COOLANT TEMP. INDICATOR
Testing. - TM-9-6115-643-24_104
OIL PRESSURE INDICATOR - TM-9-6115-643-24_105
TIME METERS
BATTERY CHARGE AMMETER
FIGURE   2-12.   Control   Panel   Indicators
FREQUENCY METER (HERTZ). - TM-9-6115-643-24_109
AMMETER   (PERCENT   RATED   CURRENT).
KILOWATTMFTER    (PERCENT    POWER).
AC   VOLTMETER   (VOLTS   AC).
MASTER   SWITCH - TM-9-6115-643-24_113
VOLTAGE   ADJUST   POTENTIOMETER.
Testing - TM-9-6115-643-24_115
Installation - TM-9-6115-643-24_116
AC CIRCUIT INTERRUPTER SWITCH - TM-9-6115-643-24_117
FIGURE   2-13.   Control   Panel   Switches - TM-9-6115-643-24_118
PARALLEL-UNIT SWITCH - TM-9-6115-643-24_119
AM-VM TRANSFER SWITCH - TM-9-6115-643-24_120
PANEL LIGHTS SWITCH - TM-9-6115-643-24_121
EMERGENCY STOP SWITCH - TM-9-6115-643-24_122
Removal. - TM-9-6115-643-24_123
LOAD SHARING ADJUST RHEOSTAT
OVERSPEED RESET SWITCH - TM-9-6115-643-24_125
FREQUENCY SELECT SWITCH
CONVENIENCE   RECEPTACLE - TM-9-6115-643-24_127
GROUND   FAULT   CIRCUIT   INTERRUPTER.
FIGURE 2-13.1. In-Line Fuse Installation
BATTERY CHARGER FUSE.
Inspection - TM-9-6115-643-24_132
FREQUENCY   TRANSDUCER
FIGURE   2-14.   Control   Box   Components
Testing   (MEP   814A).
KILOWATT TRANSDUCER
SHUNT. - TM-9-6115-643-24_137
OVER/UNDER VOLTAGE RELAY
SHORT CIRCUIT/OVERLOAD RELAY - TM-9-6115-643-24_139
Removal. - TM-9-6115-643-24_140
FIGURE   2-15.   Permissive   Paralleling   Relay   Test   Set-up
REVERSE POWER RELAY
FIGURE 2-16. Reverse Power Relay Test   Set-up
VOLTAGE SENSING RELAY - TM-9-6115-643-24_144
RELAYS - TM-9-6115-643-24_145
CONTROL BOX HARNESS - TM-9-6115-643-24_146
FIGURE   2-17.   Diagnostic   Connector Pin   Positions
PARALLEL    CONNECTOR
TABLE 2-9. Diagnostic Connector Connection Points
RESISTOR-DIODE ASSEMBLY - TM-9-6115-643-24_150
FIGURE   2-18. Diode   Identification
CONTROL   PANEL   FRAME
CONTROL BOX SIDE PANELS. - TM-9-6115-643-24_153
CONTROL BOX BOTTOM - TM-9-6115-643-24_154
FIGURE   2-19.   Control   Box   Panels
Installation - TM-9-6115-643-24_156
Section   XI.   MAINTENANCE   OF   AIR   INTAKE   AND   EXHAUST   SYSTEM
FIGURE 2-20. Muffler and Exhaust Pipe
AIR CLEANER ASSEMBLY - TM-9-6115-643-24_159
AIR FILTER ELEMENT
FIGURE 2-21. Air Cleaner Assembly
Installation - TM-9-6115-643-24_162
Section XII. MAINTENANCE OF COOLANT SYSTEM
Inspection    and    Cleaning.
FIGURE 2-22. radiator cap
FIGURE   2-23.   Coolant   System
FAN GUARDS - TM-9-6115-643-24_167
LOWER COOLANT HOSE - TM-9-6115-643-24_168
FIGURE 2-24. Fan Guards
Inspection and Cleaning - TM-9-6115-643-24_170
RADIATOR - TM-9-6115-643-24_171
Repair. - TM-9-6115-643-24_172
GENERATOR SET COOLING FAN
Test   and   Adjustment
FIGURE 2-25. Fan Belt
Installation - TM-9-6115-643-24_176
FIGURE   2-26.   Coolant   Recovery   System
Section XIII. MAINTENANCE OF FUEL SYSTEM
Removal. - TM-9-6115-643-24_179
FIGURE   2-27.   Fuel   Tank   Filler   Neck   and   Low   Pressure   Fuel   System
Inspection - TM-9-6115-643-24_181
FUEL LEVEL SENDER
LOW LEVEL/AUXILIARY FUEL PUMP FLOAT SWITCH
FUEL PICKUP
FUEL FLOAT MODULE
FUEL FILTER/WATER SEPARATOR ELEMENT
FIGURE   2-28.   Fuel   Filter/Water   Separator
Installation - TM-9-6115-643-24_188
Section   XIV.   MAINTENANCE   OF   OUTPUT   BOX   ASSEMBLY
FIGURE 2-29. Output Box Assembly
CURRENT TRANSFORMER - TM-9-6115-643-24_191
POWER POTENTIAL TRANSFORMER
CRANKING RELAY
LOAD OUTPUT TERMINAL BOARD
LOAD OUTPUT TERMINALS - TM-9-6115-643-24_195
FIGURE 2-30. Load Terminal Board Assembly - TM-9-6115-643-24_196
FIGURE 2-30. Load Terminal Board Assembly - TM-9-6115-643-24_197
Section   XV.   MAINTENANCE   OF   ENGINE   ACCESSORIES
OIL PRESSURE SENDER - TM-9-6115-643-24_199
Removal. - TM-9-6115-643-24_200
FIGURE 2-31. Engine Switches and Senders, Right Side
Removal. - TM-9-6115-643-24_202
COOLANT HIGH TEMPERATURE SWITCH - TM-9-6115-643-24_203
FIGURE 2-32. Engine Switches and Senders, Left Side
MAGNETIC PICKUP.
Installation - TM-9-6115-643-24_206
Removal. - TM-9-6115-643-24_207
Installation - TM-9-6115-643-24_208
Section   XVI.   MAINTENANCE   OF   LUBRICATION   SYSTEM - TM-9-6115-643-24_209
FIGURE 2-33. Oil Drain Line
Section   XVII.   PREPARATION   FOR   SHIPMENT   AND   STORAGE - TM-9-6115-643-24_211
CHAPTER   3 GENERAL   MAINTENANCE   INSTRUCTIONS - TM-9-6115-643-24_213
Section   Il.   TROUBLESHOOTING
SYMPTOM INDEX GENERATOR SET
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-643-24_217
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-643-24_218
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-643-24_219
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-643-24_220
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-643-24_221
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-643-24_222
Section   III.   REMOVAL   AND   INSTALLATION   OF   MAJOR   COMPONENTS
Installation. - TM-9-6115-643-24_224
FIGURE 3-1. Engine and Generator Assembly - TM-9-6115-643-24_225
ENGINE ASSEMBLY
FIGURE 3-2. Generator Set Top Housing Panel
Removal - TM-9-6115-643-24_228
FIGURE   3-4.   Overflow   Bottle   Assembly
EQUIPMENT   IMPROVEMENT   RECOMMENDATIONS   (EIRs) - TM-9-6115-643-24_230
FIGURE 3-8. Fuel Filler Panel Assembly
FIGURE 3-10. Left Side Housing Panels
FIGURE   3-11.   Air   Cleaner   Assembly
FIGURE   3-13.   Right   Side   Engine   Components
FIGURE   3-14.   Left   Side   Engine   Components
Installation - TM-9-6115-643-24_236
Installation (cont) - TM-9-6115-643-24_237
Installation (cont) - TM-9-6115-643-24_238
Replacement. - TM-9-6115-643-24_239
FIGURE 3-16. Engine Components
CHAPTER   4 DIRECT   SUPPORT   MAINTENANCE   INSTRUCTIONS - TM-9-6115-643-24_241
Testing. (Regulator. PIN: 19870 For MEP-804A Generator Set).
TABLE   4-2.   Voltage   Adjustment   Range   (MEP-814A)
Internal Crank Relay Test.
Adjustment. - TM-9-6115-643-24_245
Adjustment. (cont) - TM-9-6115-643-24_246
Adjustment. (cont) - TM-9-6115-643-24_247
CONTROL BOX HARNESS - TM-9-6115-643-24_248
FIGURE   4-1.   Control   Box   Components
Inspection. - TM-9-6115-643-24_250
LOAD MEASURING UNIT
Section   Il.   MAINTENANCE   OF   COOLANT   SYSTEM - TM-9-6115-643-24_252
FIGURE 4-2. Fuel Tank
Section   IV.   MAINTENANCE   Of   OUTPUT   BOX   ASSEMBLY
FIGURE 4-3. Output Box Assembly
VOLTAGE RECONNECTION TERMINAL BOARD - TM-9-6115-643-24_256
Installation - TM-9-6115-643-24_257
Repair - TM-9-6115-643-24_258
FIGURE   4-4.   Testing   Current   Transformer
DROOP CURRENT TRANSFORMER
FIGURE   4-5.   Testing   Droop   Current   Transformer
POWER POTENTIAL TRANSFORMER - TM-9-6115-643-24_262
OUTPUT BOX PANELS - TM-9-6115-643-24_263
Installation - TM-9-6115-643-24_264
Section V. MAINTENANCE OF ENGINE ACCESSORIES
FIGURE   4-8.   Governor   Actuator   Assembly - TM-9-6115-643-24_266
Installation and Adjustment
FIGURE 4-7. Brushless Generator Schematic
GENERATOR ASSEMBLY
Installation. - TM-9-6115-643-24_270
FIGURE 4-8. Generator Assembly Removal
ROTATING RECTIFIER DIODES (MEP-804A)
FIGURE 4-9. Rectifier Assembly (MEP-804A)
END   BELL   AND   MAIN   BEARING   (MEP-804A).
FIGURE   4-10.   Generator   Assembly   (MEP-804A)
EXCITER STATOR (MEP-804A).
Installation - TM-9-6115-643-24_277
FIGURE 4-11. Generator Housing Rib Locations
EXCITER ROTOR MEP-804A)
TABLE 4-3. Generator Resistance Values At 25C (77F)
GENERATOR ROTOR ASSEMBLY (MEP-804A).
FIGURE   4-12.   Rotor   Assembly   Lifting   Device   (Typical)
GENERATOR MAIN STATOR (MEP-804A).
Installation - TM-9-6115-643-24_284
GENERATOR   HOUSING   (MEP-804A).
Testing. - TM-9-6115-643-24_286
FIGURE   4-13.   Rectifier   Assembly   (MEP-814A)
FIGURE 4-14. End Bell Removal (MEP-814A)
Installation. - TM-9-6115-643-24_289
FIGURE   4-15.   Generator   Assembly   (MEP-814A)
EXCITER STATOR (MEP-814A).
EXCITER ROTOR (MEP-814A).
Installation - TM-9-6115-643-24_293
Testing - TM-9-6115-643-24_294
GENERATOR MAIN STATOR (MEP-814A)
GENERATOR HOUSING (MEP-814A)
Section   VII.   MAINTENANCE   OF   SKID   BASE
FIGURE 4-16. Skid Base
APPENDIX A REFERENCES - TM-9-6115-643-24_299
APPENDIX A REFERENCES - Continued
APPENDIX B MAINTENANCE ALLOCATION CHART
Explanation of Columns in the MAC. Section II
Explanation of Columns in Tool and Test Equipment Requirements. Section Ill
SECTION Il. MAINTENANCE ALLOCATION CHART - TM-9-6115-643-24_304
SECTION Il. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-643-24_305
SECTION Il. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-643-24_306
SECTION Il. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-643-24_307
SECTION Il. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-643-24_308
SECTION Il. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-643-24_309
SECTION   II. MAINTENANCE   ALLOCATION   CHART   -   Continued
SECTION   Ill.   TOOL   AND   TEST   EQUIPMENT   REQUIREMENTS
SECTION   IV.   REMARKS
APPENDIX   C EXPENDABLE/DURABLE   SUPPLIES   AND   MATERIALS   LIST - TM-9-6115-643-24_313
SECTION   Il.   TABULAR   LIST
FIGURE   D-1.   Cable   Assembly,   AC   Power   (P/Ns:   88-22126-1   through   88-22126-7)
FIGURE   D-2.   Cable   Assembly,   Battery   (P/N:   88-22123)
FIGURE   D-3.   Cable   Assembly,   Battery   (P/N:   88-22179)
FIGURE   D-4.   Cable   Assembly,   Battery   (P/N:   88-22309)
FIGURE   D-5.   Cable   Assembly,   Battery   (P/N:   88-22310)
FIGURE   D-6.   Cable   Assembly,   Battery   (P/N:   88-22311)
FIGURE   D-7.   Capacitor   Assembly,   EMI   (P/N:   88-22758)
FIGURE D-8. Cord, Load Wrench (P/N: 88-22469)
FIGURE   D-9.   Diode   Assembly   (P/N:   88-22418-2)
FIGURE   D-10.   Holder,   Control   Panel   (P/N:   88-22120)
FIGURE D-11.   Insulation,   Baffle   (P/N:   88-22594)
FIGURE   D-12.   Insulation,   Front   Housing   (P/N:   88-22595)
FIGURE D-13. Pump Assembly, Fuel (P/N: 88-22546)
FIGURE   D-14.   Resistor   Assembly   (P/Ns:   122-3066-1   and   122-3066-2)
FIGURE   D-15.   Resistor   Assembly,   Volt   (P/N:   88-22631)
FIGURE   D-16.   Resistor-Diode   Assembly   (P/N:   88-22106)
FIGURE   D-17.   Switch   Assembly,   Fuel   Level   (P/N:   88-22547)
FIGURE   D-18.   Transducer   Assembly   (P/N:   88-22550)
FIGURE   D-19.   Wire,   Varistor   (P/Ns:   88-20305-1   through   88-20305-3,   and   88-20305-5)
TABLE   D-1.   INCHES   TO   METRIC   CONVERSION
fo-1 electrical schematic
fo-2. wiring diagram (sheet 1 of 4) - TM-9-6115-643-24_336
fo-2. wiring diagram (sheet 3 of 4) - TM-9-6115-643-24_338
fo-2. wiring diagram (sheet 4 of 4) - TM-9-6115-643-24_339

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