CHAPTER 1 INTRODUCTION - TM-9-6115-645-24_20
FIGURE 1-1. Generator Set, 60 kW, Tactical Quiet
EQUIPMENT IMPROVEMENT RFCOMMENDATIONS (EIRs)
LEVELS OF MAINTENANCE
TABLE 1-1. Tabulated Data
TABLE 1-1. Tabulated Data - Continued - TM-9-6115-645-24_25
TABLE 1-1. Tabulated Data - Continued - TM-9-6115-645-24_26
TABLE 1-2. Performance Characteristics - Continued
FIGURE 1-2 FAULT SYSTEM
Coolant High Temperature Switch
Fuel System - TM-9-6115-645-24_30
FIGURE 1-3. Generator Set Fuel System - TM-9-6115-645-24_31
FIGURE 1-4. Generator Set Cooling System
FIGURE 1-5. Engine Cooling System
Engine Lubrication System\
FIGURE 1-6. Engine Lubrication System
FIGURE 1-7. Engine Air Intake and Exhaust System
Ermine Starting System
FIGURE 1-8. Output Supply System - TM-9-6115-645-24_38
FIGURE 1-9. Engine Starting System
Field Flash.
FIGURE 1-10. Governor Control System - TM-9-6115-645-24_41
FIGURE 1-11. Voltage Regulation System - TM-9-6115-645-24_42
Governor Control System
FIGURE 1-12. Generator Set Components - TM-9-6115-645-24_44
CONVENIENCE RECEPTACLE - TM-9-6115-645-24_45
CHAPTER 2 UNIT MAINTENANCE INSTRUCTIONS - TM-9-6115-645-24_46
TABLE 2-1. Coolant - TM-9-6115-645-24_47
Lubricating Oil
GENERATOR SET INSTALLATION - TM-9-6115-645-24_49
FIGURE 2-1. Base Mounting Measurements - TM-9-6115-645-24_50
FIGURE 2-2. Minimum Enclosure Clearance Measurements
TABLE 2-4. Fabricated/Assembled Parts
REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL).
TABLE 2-5. Unit Preventive Maintenance Checks and Services (PMCS)
TABLE 2-5. Unit Preventive Maintenance Checks and Services - Continued
SECTION V. TROUBLESHOOTING - TM-9-6115-645-24_56
SYMPTOM INDEX GENERATOR SET - TM-9-6115-645-24_57
TABLE 2-6. UNIT TROUBLESHOOTING - TM-9-6115-645-24_58
TABLE 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-645-24_59
TABLE 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-645-24_60
TABLE 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-645-24_61
TABLE 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-645-24_62
TABLE 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-645-24_63
TABLE 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-645-24_64
TABLE 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-645-24_65
TABLE 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-645-24_66
TABLE 2-6. UNIT TROUBLESHOOTING - Continued\
TABLE 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-645-24_68
TABLE 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-645-24_69
SECTION VI. RADIO INTERFERENCE SUPPRESSION - TM-9-6115-645-24_70
SECTION VIII. MAINTENANCE OF DC ELECTRICAL SYSTEM
FIGURE 2-3. Batteries and Cables
BATTFRIES
TABLE 2-7. STATE OF CHARGE WITH SPECIFIC GRAVITY CORRECTED TO 80F (27C) - TM-9-6115-645-24_74
NATO SLAVE RECEPTACLE - TM-9-6115-645-24_75
FIGURE 2-4. NATO Slave Receptacle and Cables
SECTION IX. MAINTENANCE OF HOUSING - TM-9-6115-645-24_77
FIGURE 2-5. Generator Set Access Doors - TM-9-6115-645-24_78
CONTROL BOX TOP PANEL - TM-9-6115-645-24_79
FIGURE 2-6. Control Box Top Panel
Installation - TM-9-6115-645-24_81
TOP HOUSING SECTION
FIGURE 2-7. Generator Set Top Housing Section
FIGURE 2-7. Generator Set Top Housing Section CONT.
Repair - TM-9-6115-645-24_85
FRONT HOUSING SECTION - TM-9-6115-645-24_86
FIGURE 2-8 GENERATOR SET FRONT HOUSING SECTION
Installation. - TM-9-6115-645-24_88
REAR HOUSING SECTION
FIGURE 2-9. Generator Set Rear Housing Section - TM-9-6115-645-24_90
Repair - TM-9-6115-645-24_91
Installation - TM-9-6115-645-24_92
SECTION X. MAINTENANCE OF CONTROL BOX ASSEMBLY
FIGURE 2-10. Control Box Assembly - TM-9-6115-645-24_94
PANEL LIGHTS
SYNCHRONIZING LIGHTS
FIGURE 2-11. Control Panel Lights - TM-9-6115-645-24_97
FUEL LEVEL INDICATOR - TM-9-6115-645-24_98
FIGURE 2-12. Control Panel Indicators
COOLANT TEMP. INDICATOR
OIL PRESSURE INDICATOR - TM-9-6115-645-24_101
TIME METER (TOTAL HOURS) - TM-9-6115-645-24_102
BATTERY CHARGE AMMETER
FREQUENCY METER (HERTZ)
AMMETER (PERCENT RATED CURRENT)
KILOWATTMETER (PERCENT POWER)
AC VOLTMETER (VOLTS AC)\
Removal - TM-9-6115-645-24_108
FIGURE 2-13. Control Panel Switches - TM-9-6115-645-24_109
ETHER SWITCH
VOLTAGE ADJUST POTENTIOMETER
FREQUENCY ADJUST POTENTIOMETER
BATTLE SHORT SWITCH
AC CIRCUIT INTERRUPTER SWITCH - TM-9-6115-645-24_114
PARALLEL-UNIT SWITCH - TM-9-6115-645-24_115
AM-VM TRANSFER SWITCH
EMERGENCY STOP SWITCH - TM-9-6115-645-24_117
REACTIVE CURRENT ADJUST RHEOSTAT
LOAD SHARING ADJUST RHEOSTAT
FIGURE 2-14. Control Box Components
OVERSPEED RESET SWITCH - TM-9-6115-645-24_121
Testing - TM-9-6115-645-24_122
CONVENIENCE RECEPTACLE - TM-9-6115-645-24_123
GROUND FAULT CIRCUIT INTERRUPTER
FIGURE 2-14.1. In-Line Fuse Installation
BATTERY CHARGER FUSE
DC CONTROL POWER CIRCUIT BREAKER - TM-9-6115-645-24_127
FREQUENCY TRANSDUCER. - TM-9-6115-645-24_128
Removal - TM-9-6115-645-24_129
Testing - TM-9-6115-645-24_130
OVER/UNDER VOLTAGE RELAY
SHORT CIRCUIT/OVERLOAD RELAY - TM-9-6115-645-24_132
Removal - TM-9-6115-645-24_133
PERMISSIVE PARALLELING RELAY
Removal - TM-9-6115-645-24_135
REVERSE POWER RELAY
VOLTAGE SENSING RELAY - TM-9-6115-645-24_137
RFLAYS
CONTROL BOX HARNESS
FIGURE 2-17. Diagnostic Connector Pin Positions
TABLE 2-9. Diagnostic Connector Connection Points - TM-9-6115-645-24_141
PARALLEL CONNECTOR
RESISTOR-DIODE ASSEMBLY - TM-9-6115-645-24_143
FIGURE 2-18. Diode Identification - TM-9-6115-645-24_144
FIGURE 2-19. Control Box Panels
CONTROL PANEL FRAME - TM-9-6115-645-24_146
CONTROL BOX SIDE PANELS - TM-9-6115-645-24_147
CONTROL BOX BOTTOM - TM-9-6115-645-24_148
SECTION XI. MAINTENANCE OF AIR INTAKE AND EXHAUST SYSTEM
FIGURE 2-20. Muffler and Exhaust Pipe
AIR RESTRICTION INDICATOR - TM-9-6115-645-24_151
FIGURE 2-21. Air Cleaner Assembly
AIR FILTER ELEMENT
Service - TM-9-6115-645-24_154
SECTION XII. MAINTENANCE OF COOLANT SYSTEM
Inspection and Cleaning - TM-9-6115-645-24_156
FIGURE 2-22. Radiator Cap
FIGURE 2-23. Coolant System
LOWER COOLANT HOSE - TM-9-6115-645-24_159
COOLAN T OVERFLOW AND DRAIN HOSES
Inspection and Cleaning
GENERATOR SET COOLING FAN
FAN BELTS
FIGURE 2-24. Fan Belts
COOLANT RECOVERY SYSTEM - TM-9-6115-645-24_165
FIGURE 2-25. Coolant Recovery System
SECTION XIII. MAINTENANCE
FIGURE 2-26. Fuel Tank Filler Neck and Low Pressure Fuel System - TM-9-6115-645-24_168
FUEL TANK FILLER NECK - TM-9-6115-645-24_169
FUEL DRAIN VALVE.
FUEL LEVEL SENDER - TM-9-6115-645-24_171
LOW FUEL LEVEL AUXILIARY FUEL PUMP FLOAT SWITCH
FUEL PICKUP - TM-9-6115-645-24_173
FUFL FILTFRIDRAIN VALVF ASSFMBI Y
FIGURE 2-27. Ether Start System
ETHER SOLENOID VALVE
SECTION XIV. MAINTENANCE OF OUTPUT BOX ASSEMBLY
FIGURE 2-28. Output Box Assembly
CURRFNT TRANSFORMER
AC CIRCUIT INTERRUPTER RELAY - TM-9-6115-645-24_180
CRANKING RELAY - TM-9-6115-645-24_181
LOAD OUTPUT TERMINAL BOARD
FIGURE 2-29. Load Terminal Board Assembly - TM-9-6115-645-24_183
LOAD OUTPUT TERMINALS - TM-9-6115-645-24_184
VARISTORS - TM-9-6115-645-24_185
FIGURE 2-30. Engine Switches and Senders
Cleaning and Inspection - TM-9-6115-645-24_187
OIL PRESSURE SENDER
COLANT TEMPERATURE SENDER
Cleaning and Inspection - TM-9-6115-645-24_190
Cleaning and Inspection - TM-9-6115-645-24_191
MAGNETIC PICKUP
DEAD CRANK SWITCH - TM-9-6115-645-24_193
DIODE ASSEMBLY
FIGURE 2-31. Oil Drain Valve
SECTION XVII. PREPARATION FOR SHIPMENT AND STORAGE
CHAPTER 3 GENERAL MAINTENANCE INSTRUCTIONS - TM-9-6115-645-24_198
SYMPTOM INDEX GENERATOR SET - TM-9-6115-645-24_199
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-645-24_201
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-645-24_202
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-645-24_203
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-645-24_204
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-645-24_205
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-645-24_206
SECTION 3-5 GENERAL. Ill. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
FIGURE 3-1. Top Housing Panel
FIGURE 3-3. Overflow Bottle Assembly
FIGURE 3-5. Radiator Assembly
FIGURE 3-7. Fuel Filler Hoses and Panel Assembly
FIGURE 3-8. Left Side Housing Panels
Loosen clamp
FIGURE 3-12 RIGHT SIDE ENGINE
FIGURE 3-13. Load Output Terminal Board
FIGURE 3-14. Engine Assembly Removal
FIGURE 3-15. Front Fork Lift Guide
Installation\
Installation CONT.
Replacement - TM-9-6115-645-24_220
FIGURE 3-17. Engine Components (Left Side)
FIGURE 3-18 ENGINE COMPONENTS
CHAPTER 4 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS SECTION I. MAINTENANCE OF CONTROL BOX ASSEMBLY
Testing. (Regulator. P/N: 19880-002 For MFP-806A Generator Set)
TABLE 4-2. Voltage Adjustment Range (MEP-816A)
FIGURE 4-1. Test Circuit
Testing. - TM-9-6115-645-24_228
Adjustment
FIGURE 4-2. Fuel Injection Pump High Idle Speed Adjustment
CONTROI BOX HARNESS
Inspection - TM-9-6115-645-24_232
Replacement - TM-9-6115-645-24_233
FIGURE 4-3. CONTROL BOX COMPONENTS
SECTION II. MAINTENANCE OF COOLANT SYSTEM
Figure 4-4. Fuel Tank
SECTION IV. MAINTENANCE OF OUTPUT BOX ASSEMBLY
FIGURE 4-5. Output Box Assembly
VOLTAGE RECONNECTION TERMINAL BOARD - TM-9-6115-645-24_239
CURRENT TRANSFORMER - TM-9-6115-645-24_240
FIGURE 4-6. Testing Current Transformer
FIGURE 4-7. Testing Droop Current Transformer
OUTPUT BOX PANELS - TM-9-6115-645-24_243
Removal - TM-9-6115-645-24_244
SECTION V. MAINTENANCE OF ENGINE ACCESSORIES
FIGURE 4-8. Governor Actuator Assembly
instillation
FIGURE 4-9. Governor Actuator Adjustment
FIGURE 4-10. Brushless Generator Schematic
FIGURE 4-11. Generator Set Housing and Rear Forklift Guide
GFNFRATOR ASSFMBLY
FIGURE 4-13. Fuel Filler Panel Assembly
FIGURE 4-14 LOAD OUTPUT TERMINAL BOARD AND MAIN GENERATOR CABLES
Installation - TM-9-6115-645-24_254
FIGURE 4-15 GENERATOR ASSEMBLY REMOVAL
ROTATING RECTIFIER DIODES
FIGURE 4-16. Rectifier Assembly
END BELL AND MAIN BEARING - TM-9-6115-645-24_258
ROTATING RECTIFIER - TM-9-6115-645-24_259
FIGURE 4-17. Generator Assembly
EXCITER STATOR - TM-9-6115-645-24_261
TABLE 4-3. GENERATOR RESISTANCE VALUES AT 25C (770F)
FIGURE 4-18. Rotor Assembly Lifting Device (Typical)
FIGURE 4-19 Belleville Washer Mounting
SECTION VII. MAINTENANCE OF SKID BASE
FIGURE 4-21. Skid Base
APPENDIX A REFERENCES - TM-9-6115-645-24_268
APPENDIX B MAINTENANCE ALLOCATION CHART SECTION 1. INTRODUCTION
EXPLANATION OF COLUMNS IN THE MAC, SECTION II - TM-9-6115-645-24_271
EXPLANATION OF COLUMNS IN REMARKS, SECTION IV - TM-9-6115-645-24_272
SECTION II. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-645-24_273
SECTION II. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-645-24_274
SECTION II. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-645-24_275
SECTION II. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-645-24_276
SECTION II. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-645-24_277
SECTION Ill. TOOLS AND TEST EQUIPMENT REQUIREMENTS FOR MEP-806A AND MEP-816A
APPENDIX C EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST SECTION 1. INTRODUCTION
SECTION II. TABULAR LIST
APPENDIX D FABRICATION/ASSEMBLY D-1 INTRODUCTION. OF PARTS
FIGURE D-2. Cable Assembly, Battery (P/N: 88-22206)
FIGURE D-3. Cable Assembly, Battery (P/N: 88-22127)
FIGURE D-4. Cable Assembly, Battery (P/N: 88-22208)
FIGURE D-5. Cable Assembly, Battery (P/N: 88-22179)
FIGURE D-6. Cable Assembly, Battery (P/N: 88-22207)
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: 88-2241 8-2)
FIGURE D-10. Holder, Control Panel (P/N: 88-22120)
FIGURE D-11. Hose Assembly (P/N: 88-201 91)
FIGURE D-1 2. Insulation$ D-12 Air Baffle (P/N: 88-2261 6)
FIGURE D-13. Insulation, Baffle (P/N: 88-22769)
FIGURE D-14. Insulation, Door (P/N: 88-22610)
FIGURE D-15. Insulation, Baffle (P/N: 88-22615)
FIGURE D-16. Insulation, Baffle (P/N: 88-22612)
FIGURE D-17 INSULATION
FIGURE D-18. Insulation, Duct Floor (P/N: 88-22599)
FIGURE D-19. Insulation, Duct Floor (P/N: 88-22600)
FIGURE D-20. Insulation, Baffle (P/N: 88-22592)
FIGURE D-21. Insulation, Panel RS (P/N: 88-22614)
FIGURE D-22. Insulation, Rear Panel (P/N: 88-22598)
FIGURE D-23. Insulation, Rear LS (P/N: 88-22637)
FIGURE D-24. Insulation, Top Front (P/N: 88-22602)
FIGURE D-25. Insulation, Door (P/N: 88-22609)
FIGURE D-26. Insulation, Door (P/N: 88-22770)
FIGURE D-27 INSULATION
FIGURE D-28. Insulation, Center, Front (P/N: 88-22604)
FIGURE D-29. Insulation, Top Center (P/N: 88-22605)
FIGURE D-30 INSULATION, PANEL, TOP
FIGURE D-31. Insulation, Housing, Front (P/N: 88-22596)
FIGURE D-32. Pump Assembly, Fuel (P/N: 88-22546)
FIGURE D-33. Resistor Assembly (P/Ns: 122-3066-1 and 122-3066-2)
FIGURE D-34. Resistor Assembly, Volt (P/N: 88-22631)
FIGURE D-35. Resistor-Diode Assembly (P/N: 88-22106)
FIGURE D-36. Solenoid Assembly (P/N: 88-22553)
FIGURE D-37. Switch Assembly, Fuel Level (P/N: 8822549)
FIGURE D-38. Transducer Assembly (P/N: 88-22550)
FIGURE D-39. FWire Varistor (P/Ns: 88-20305-6 through 88-20305-9)
PART Il. Inches to Centimeters - TM-9-6115-645-24_321
FO-1 ELECTRICAL SCHEMATIC
FO-2 WIRING DIAGRAM
FO-2 WIRING DIAGRAM CONT.
FO-2 WIRING DIAGRAM CONT. - TM-9-6115-645-24_354
FO-2 WIRING DIAGRAM CONT. - TM-9-6115-645-24_355
FIGURE 1-1. Generator Set, 60 kW, Tactical Quiet
EQUIPMENT IMPROVEMENT RFCOMMENDATIONS (EIRs)
LEVELS OF MAINTENANCE
TABLE 1-1. Tabulated Data
TABLE 1-1. Tabulated Data - Continued - TM-9-6115-645-24_25
TABLE 1-1. Tabulated Data - Continued - TM-9-6115-645-24_26
TABLE 1-2. Performance Characteristics - Continued
FIGURE 1-2 FAULT SYSTEM
Coolant High Temperature Switch
Fuel System - TM-9-6115-645-24_30
FIGURE 1-3. Generator Set Fuel System - TM-9-6115-645-24_31
FIGURE 1-4. Generator Set Cooling System
FIGURE 1-5. Engine Cooling System
Engine Lubrication System\
FIGURE 1-6. Engine Lubrication System
FIGURE 1-7. Engine Air Intake and Exhaust System
Ermine Starting System
FIGURE 1-8. Output Supply System - TM-9-6115-645-24_38
FIGURE 1-9. Engine Starting System
Field Flash.
FIGURE 1-10. Governor Control System - TM-9-6115-645-24_41
FIGURE 1-11. Voltage Regulation System - TM-9-6115-645-24_42
Governor Control System
FIGURE 1-12. Generator Set Components - TM-9-6115-645-24_44
CONVENIENCE RECEPTACLE - TM-9-6115-645-24_45
CHAPTER 2 UNIT MAINTENANCE INSTRUCTIONS - TM-9-6115-645-24_46
TABLE 2-1. Coolant - TM-9-6115-645-24_47
Lubricating Oil
GENERATOR SET INSTALLATION - TM-9-6115-645-24_49
FIGURE 2-1. Base Mounting Measurements - TM-9-6115-645-24_50
FIGURE 2-2. Minimum Enclosure Clearance Measurements
TABLE 2-4. Fabricated/Assembled Parts
REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL).
TABLE 2-5. Unit Preventive Maintenance Checks and Services (PMCS)
TABLE 2-5. Unit Preventive Maintenance Checks and Services - Continued
SECTION V. TROUBLESHOOTING - TM-9-6115-645-24_56
SYMPTOM INDEX GENERATOR SET - TM-9-6115-645-24_57
TABLE 2-6. UNIT TROUBLESHOOTING - TM-9-6115-645-24_58
TABLE 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-645-24_59
TABLE 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-645-24_60
TABLE 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-645-24_61
TABLE 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-645-24_62
TABLE 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-645-24_63
TABLE 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-645-24_64
TABLE 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-645-24_65
TABLE 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-645-24_66
TABLE 2-6. UNIT TROUBLESHOOTING - Continued\
TABLE 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-645-24_68
TABLE 2-6. UNIT TROUBLESHOOTING - Continued - TM-9-6115-645-24_69
SECTION VI. RADIO INTERFERENCE SUPPRESSION - TM-9-6115-645-24_70
SECTION VIII. MAINTENANCE OF DC ELECTRICAL SYSTEM
FIGURE 2-3. Batteries and Cables
BATTFRIES
TABLE 2-7. STATE OF CHARGE WITH SPECIFIC GRAVITY CORRECTED TO 80F (27C) - TM-9-6115-645-24_74
NATO SLAVE RECEPTACLE - TM-9-6115-645-24_75
FIGURE 2-4. NATO Slave Receptacle and Cables
SECTION IX. MAINTENANCE OF HOUSING - TM-9-6115-645-24_77
FIGURE 2-5. Generator Set Access Doors - TM-9-6115-645-24_78
CONTROL BOX TOP PANEL - TM-9-6115-645-24_79
FIGURE 2-6. Control Box Top Panel
Installation - TM-9-6115-645-24_81
TOP HOUSING SECTION
FIGURE 2-7. Generator Set Top Housing Section
FIGURE 2-7. Generator Set Top Housing Section CONT.
Repair - TM-9-6115-645-24_85
FRONT HOUSING SECTION - TM-9-6115-645-24_86
FIGURE 2-8 GENERATOR SET FRONT HOUSING SECTION
Installation. - TM-9-6115-645-24_88
REAR HOUSING SECTION
FIGURE 2-9. Generator Set Rear Housing Section - TM-9-6115-645-24_90
Repair - TM-9-6115-645-24_91
Installation - TM-9-6115-645-24_92
SECTION X. MAINTENANCE OF CONTROL BOX ASSEMBLY
FIGURE 2-10. Control Box Assembly - TM-9-6115-645-24_94
PANEL LIGHTS
SYNCHRONIZING LIGHTS
FIGURE 2-11. Control Panel Lights - TM-9-6115-645-24_97
FUEL LEVEL INDICATOR - TM-9-6115-645-24_98
FIGURE 2-12. Control Panel Indicators
COOLANT TEMP. INDICATOR
OIL PRESSURE INDICATOR - TM-9-6115-645-24_101
TIME METER (TOTAL HOURS) - TM-9-6115-645-24_102
BATTERY CHARGE AMMETER
FREQUENCY METER (HERTZ)
AMMETER (PERCENT RATED CURRENT)
KILOWATTMETER (PERCENT POWER)
AC VOLTMETER (VOLTS AC)\
Removal - TM-9-6115-645-24_108
FIGURE 2-13. Control Panel Switches - TM-9-6115-645-24_109
ETHER SWITCH
VOLTAGE ADJUST POTENTIOMETER
FREQUENCY ADJUST POTENTIOMETER
BATTLE SHORT SWITCH
AC CIRCUIT INTERRUPTER SWITCH - TM-9-6115-645-24_114
PARALLEL-UNIT SWITCH - TM-9-6115-645-24_115
AM-VM TRANSFER SWITCH
EMERGENCY STOP SWITCH - TM-9-6115-645-24_117
REACTIVE CURRENT ADJUST RHEOSTAT
LOAD SHARING ADJUST RHEOSTAT
FIGURE 2-14. Control Box Components
OVERSPEED RESET SWITCH - TM-9-6115-645-24_121
Testing - TM-9-6115-645-24_122
CONVENIENCE RECEPTACLE - TM-9-6115-645-24_123
GROUND FAULT CIRCUIT INTERRUPTER
FIGURE 2-14.1. In-Line Fuse Installation
BATTERY CHARGER FUSE
DC CONTROL POWER CIRCUIT BREAKER - TM-9-6115-645-24_127
FREQUENCY TRANSDUCER. - TM-9-6115-645-24_128
Removal - TM-9-6115-645-24_129
Testing - TM-9-6115-645-24_130
OVER/UNDER VOLTAGE RELAY
SHORT CIRCUIT/OVERLOAD RELAY - TM-9-6115-645-24_132
Removal - TM-9-6115-645-24_133
PERMISSIVE PARALLELING RELAY
Removal - TM-9-6115-645-24_135
REVERSE POWER RELAY
VOLTAGE SENSING RELAY - TM-9-6115-645-24_137
RFLAYS
CONTROL BOX HARNESS
FIGURE 2-17. Diagnostic Connector Pin Positions
TABLE 2-9. Diagnostic Connector Connection Points - TM-9-6115-645-24_141
PARALLEL CONNECTOR
RESISTOR-DIODE ASSEMBLY - TM-9-6115-645-24_143
FIGURE 2-18. Diode Identification - TM-9-6115-645-24_144
FIGURE 2-19. Control Box Panels
CONTROL PANEL FRAME - TM-9-6115-645-24_146
CONTROL BOX SIDE PANELS - TM-9-6115-645-24_147
CONTROL BOX BOTTOM - TM-9-6115-645-24_148
SECTION XI. MAINTENANCE OF AIR INTAKE AND EXHAUST SYSTEM
FIGURE 2-20. Muffler and Exhaust Pipe
AIR RESTRICTION INDICATOR - TM-9-6115-645-24_151
FIGURE 2-21. Air Cleaner Assembly
AIR FILTER ELEMENT
Service - TM-9-6115-645-24_154
SECTION XII. MAINTENANCE OF COOLANT SYSTEM
Inspection and Cleaning - TM-9-6115-645-24_156
FIGURE 2-22. Radiator Cap
FIGURE 2-23. Coolant System
LOWER COOLANT HOSE - TM-9-6115-645-24_159
COOLAN T OVERFLOW AND DRAIN HOSES
Inspection and Cleaning
GENERATOR SET COOLING FAN
FAN BELTS
FIGURE 2-24. Fan Belts
COOLANT RECOVERY SYSTEM - TM-9-6115-645-24_165
FIGURE 2-25. Coolant Recovery System
SECTION XIII. MAINTENANCE
FIGURE 2-26. Fuel Tank Filler Neck and Low Pressure Fuel System - TM-9-6115-645-24_168
FUEL TANK FILLER NECK - TM-9-6115-645-24_169
FUEL DRAIN VALVE.
FUEL LEVEL SENDER - TM-9-6115-645-24_171
LOW FUEL LEVEL AUXILIARY FUEL PUMP FLOAT SWITCH
FUEL PICKUP - TM-9-6115-645-24_173
FUFL FILTFRIDRAIN VALVF ASSFMBI Y
FIGURE 2-27. Ether Start System
ETHER SOLENOID VALVE
SECTION XIV. MAINTENANCE OF OUTPUT BOX ASSEMBLY
FIGURE 2-28. Output Box Assembly
CURRFNT TRANSFORMER
AC CIRCUIT INTERRUPTER RELAY - TM-9-6115-645-24_180
CRANKING RELAY - TM-9-6115-645-24_181
LOAD OUTPUT TERMINAL BOARD
FIGURE 2-29. Load Terminal Board Assembly - TM-9-6115-645-24_183
LOAD OUTPUT TERMINALS - TM-9-6115-645-24_184
VARISTORS - TM-9-6115-645-24_185
FIGURE 2-30. Engine Switches and Senders
Cleaning and Inspection - TM-9-6115-645-24_187
OIL PRESSURE SENDER
COLANT TEMPERATURE SENDER
Cleaning and Inspection - TM-9-6115-645-24_190
Cleaning and Inspection - TM-9-6115-645-24_191
MAGNETIC PICKUP
DEAD CRANK SWITCH - TM-9-6115-645-24_193
DIODE ASSEMBLY
FIGURE 2-31. Oil Drain Valve
SECTION XVII. PREPARATION FOR SHIPMENT AND STORAGE
CHAPTER 3 GENERAL MAINTENANCE INSTRUCTIONS - TM-9-6115-645-24_198
SYMPTOM INDEX GENERATOR SET - TM-9-6115-645-24_199
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-645-24_201
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-645-24_202
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-645-24_203
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-645-24_204
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-645-24_205
TABLE 3-1. DIRECT SUPPORT TROUBLESHOOTING - Continued - TM-9-6115-645-24_206
SECTION 3-5 GENERAL. Ill. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
FIGURE 3-1. Top Housing Panel
FIGURE 3-3. Overflow Bottle Assembly
FIGURE 3-5. Radiator Assembly
FIGURE 3-7. Fuel Filler Hoses and Panel Assembly
FIGURE 3-8. Left Side Housing Panels
Loosen clamp
FIGURE 3-12 RIGHT SIDE ENGINE
FIGURE 3-13. Load Output Terminal Board
FIGURE 3-14. Engine Assembly Removal
FIGURE 3-15. Front Fork Lift Guide
Installation\
Installation CONT.
Replacement - TM-9-6115-645-24_220
FIGURE 3-17. Engine Components (Left Side)
FIGURE 3-18 ENGINE COMPONENTS
CHAPTER 4 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS SECTION I. MAINTENANCE OF CONTROL BOX ASSEMBLY
Testing. (Regulator. P/N: 19880-002 For MFP-806A Generator Set)
TABLE 4-2. Voltage Adjustment Range (MEP-816A)
FIGURE 4-1. Test Circuit
Testing. - TM-9-6115-645-24_228
Adjustment
FIGURE 4-2. Fuel Injection Pump High Idle Speed Adjustment
CONTROI BOX HARNESS
Inspection - TM-9-6115-645-24_232
Replacement - TM-9-6115-645-24_233
FIGURE 4-3. CONTROL BOX COMPONENTS
SECTION II. MAINTENANCE OF COOLANT SYSTEM
Figure 4-4. Fuel Tank
SECTION IV. MAINTENANCE OF OUTPUT BOX ASSEMBLY
FIGURE 4-5. Output Box Assembly
VOLTAGE RECONNECTION TERMINAL BOARD - TM-9-6115-645-24_239
CURRENT TRANSFORMER - TM-9-6115-645-24_240
FIGURE 4-6. Testing Current Transformer
FIGURE 4-7. Testing Droop Current Transformer
OUTPUT BOX PANELS - TM-9-6115-645-24_243
Removal - TM-9-6115-645-24_244
SECTION V. MAINTENANCE OF ENGINE ACCESSORIES
FIGURE 4-8. Governor Actuator Assembly
instillation
FIGURE 4-9. Governor Actuator Adjustment
FIGURE 4-10. Brushless Generator Schematic
FIGURE 4-11. Generator Set Housing and Rear Forklift Guide
GFNFRATOR ASSFMBLY
FIGURE 4-13. Fuel Filler Panel Assembly
FIGURE 4-14 LOAD OUTPUT TERMINAL BOARD AND MAIN GENERATOR CABLES
Installation - TM-9-6115-645-24_254
FIGURE 4-15 GENERATOR ASSEMBLY REMOVAL
ROTATING RECTIFIER DIODES
FIGURE 4-16. Rectifier Assembly
END BELL AND MAIN BEARING - TM-9-6115-645-24_258
ROTATING RECTIFIER - TM-9-6115-645-24_259
FIGURE 4-17. Generator Assembly
EXCITER STATOR - TM-9-6115-645-24_261
TABLE 4-3. GENERATOR RESISTANCE VALUES AT 25C (770F)
FIGURE 4-18. Rotor Assembly Lifting Device (Typical)
FIGURE 4-19 Belleville Washer Mounting
SECTION VII. MAINTENANCE OF SKID BASE
FIGURE 4-21. Skid Base
APPENDIX A REFERENCES - TM-9-6115-645-24_268
APPENDIX B MAINTENANCE ALLOCATION CHART SECTION 1. INTRODUCTION
EXPLANATION OF COLUMNS IN THE MAC, SECTION II - TM-9-6115-645-24_271
EXPLANATION OF COLUMNS IN REMARKS, SECTION IV - TM-9-6115-645-24_272
SECTION II. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-645-24_273
SECTION II. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-645-24_274
SECTION II. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-645-24_275
SECTION II. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-645-24_276
SECTION II. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-645-24_277
SECTION Ill. TOOLS AND TEST EQUIPMENT REQUIREMENTS FOR MEP-806A AND MEP-816A
APPENDIX C EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST SECTION 1. INTRODUCTION
SECTION II. TABULAR LIST
APPENDIX D FABRICATION/ASSEMBLY D-1 INTRODUCTION. OF PARTS
FIGURE D-2. Cable Assembly, Battery (P/N: 88-22206)
FIGURE D-3. Cable Assembly, Battery (P/N: 88-22127)
FIGURE D-4. Cable Assembly, Battery (P/N: 88-22208)
FIGURE D-5. Cable Assembly, Battery (P/N: 88-22179)
FIGURE D-6. Cable Assembly, Battery (P/N: 88-22207)
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: 88-2241 8-2)
FIGURE D-10. Holder, Control Panel (P/N: 88-22120)
FIGURE D-11. Hose Assembly (P/N: 88-201 91)
FIGURE D-1 2. Insulation$ D-12 Air Baffle (P/N: 88-2261 6)
FIGURE D-13. Insulation, Baffle (P/N: 88-22769)
FIGURE D-14. Insulation, Door (P/N: 88-22610)
FIGURE D-15. Insulation, Baffle (P/N: 88-22615)
FIGURE D-16. Insulation, Baffle (P/N: 88-22612)
FIGURE D-17 INSULATION
FIGURE D-18. Insulation, Duct Floor (P/N: 88-22599)
FIGURE D-19. Insulation, Duct Floor (P/N: 88-22600)
FIGURE D-20. Insulation, Baffle (P/N: 88-22592)
FIGURE D-21. Insulation, Panel RS (P/N: 88-22614)
FIGURE D-22. Insulation, Rear Panel (P/N: 88-22598)
FIGURE D-23. Insulation, Rear LS (P/N: 88-22637)
FIGURE D-24. Insulation, Top Front (P/N: 88-22602)
FIGURE D-25. Insulation, Door (P/N: 88-22609)
FIGURE D-26. Insulation, Door (P/N: 88-22770)
FIGURE D-27 INSULATION
FIGURE D-28. Insulation, Center, Front (P/N: 88-22604)
FIGURE D-29. Insulation, Top Center (P/N: 88-22605)
FIGURE D-30 INSULATION, PANEL, TOP
FIGURE D-31. Insulation, Housing, Front (P/N: 88-22596)
FIGURE D-32. Pump Assembly, Fuel (P/N: 88-22546)
FIGURE D-33. Resistor Assembly (P/Ns: 122-3066-1 and 122-3066-2)
FIGURE D-34. Resistor Assembly, Volt (P/N: 88-22631)
FIGURE D-35. Resistor-Diode Assembly (P/N: 88-22106)
FIGURE D-36. Solenoid Assembly (P/N: 88-22553)
FIGURE D-37. Switch Assembly, Fuel Level (P/N: 8822549)
FIGURE D-38. Transducer Assembly (P/N: 88-22550)
FIGURE D-39. FWire Varistor (P/Ns: 88-20305-6 through 88-20305-9)
PART Il. Inches to Centimeters - TM-9-6115-645-24_321
FO-1 ELECTRICAL SCHEMATIC
FO-2 WIRING DIAGRAM
FO-2 WIRING DIAGRAM CONT.
FO-2 WIRING DIAGRAM CONT. - TM-9-6115-645-24_354
FO-2 WIRING DIAGRAM CONT. - TM-9-6115-645-24_355
