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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






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