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
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