TM-9-6115-670-14P Generator Set Diesel Engine Driven Skid Mounted 150 kw Alternating Current Manual

CHAPTER 1 INTRODUCTION - TM-9-6115-670-14P_23
NOMENCLATURE CROSS-REFERENCE LIST - TM-9-6115-670-14P_24
LIST OF ABBREVIATIONS - TM-9-6115-670-14P_25
Section II. EQUIPMENT DESCRIPTION - TM-9-6115-670-14P_26
Table 1-1. Differences Between Models
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - TM-9-6115-670-14P_28
Figure 1-1. Auxiliary Power Unit Major Components (Sheet 1 of 2)
Figure 1-1. Auxiliary Power Unit Major Components (Sheet 2)
EQUIPMENT DATA - TM-9-6115-670-14P_31
Fuel System - TM-9-6115-670-14P_32
Solder pins and jacks - TM-9-6115-670-14P_33
Figure 1-2. Instructions and Warning Plates (Sheet 1 of 3)
Figure 1-2. Instructions and Warning Plates (Sheet 2)
Figure 1-2. Instructions and Warning Plates (Sheet 3)
Figure 1-3. Combustion System
Figure 1-4. Lubrication System
Figure 1-5. Cooling System
Figure 1-6. Fuel System
Figure 1-7. Intake/Exhaust System - TM-9-6115-670-14P_41
Figure 1-8. Electrical System
Figure 1-9. Main Stator and AVR Interface
Figure 1-10. Engine Speed Control System
Figure 1-11. Current Control
CHAPTER 2 OPERATING INSTRUCTIONS - TM-9-6115-670-14P_47
Figure 2-1. APU Control Unit Front Panel
Table 2-1. APU Control Unit Controls and Indicators
Section II. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - TM-9-6115-670-14P_50
Leakage Definitions - TM-9-6115-670-14P_51
Operation of Generator Set with Minor Leaks
Table 2-2. Operator Preventative Maintenance Checks and Services (PMCS)
Table 2-2. Operator Preventive Maintenance Checks and Services (PMCS) Continued
Figure 2-2. Operator PMCS Routing Diagram (Sheet 1 of 3)
Figure 2-2. Operator PMCS Routing Diagram (Sheet 2 of 3)
Figure 2-2. Operator PMCS Routing Diagram (Sheet 3 of 3)
Section III. OPERATION UNDER USUAL CONDITIONS - TM-9-6115-670-14P_58
SHUT-DOWN
Section IV. OPERATION UNDER UNUSUAL CONDITIONS - TM-9-6115-670-14P_60
OPERATION IN TROPICAL CLIMATE
CHAPTER 3 OPERATOR MAINTENANCE INSTRUCTIONS - TM-9-6115-670-14P_63
SYMPTOM INDEX
ENGINE FAILS TO CRANK - TM-9-6115-670-14P_65
ENGINE TURNS OVER BUT FAILS TO START - TM-9-6115-670-14P_66
ENGINE STARTS, BUT STOPS WHEN START-PREHEAT SWITCH IS RELEASED.
ENGINE STOPS SUDDENLY - TM-9-6115-670-14P_68
ENGINE KNOCKS - TM-9-6115-670-14P_69
BLACK SMOKE IN EXHAUST - TM-9-6115-670-14P_70
LOW OIL PRESSURE
ENGINE OVERHEATING - TM-9-6115-670-14P_72
ENGINE COOLANT TEMPERATURE TOO LOW. - TM-9-6115-670-14P_73
AC VOLTAGE FLUCTUATES - TM-9-6115-670-14P_74
Section III. OPERATOR MAINTENANCE PROCEDURES - TM-9-6115-670-14P_75
OIL DIPSTICK
Figure 3-1. Oil Dipstick
ENGINE OIL
Figure 3-2. Engine Oil
RADIATOR CAP - TM-9-6115-670-14P_80
Figure 3-3. Radiator Cap
RADIATOR - TM-9-6115-670-14P_82
Figure 3-4. Radiator
CHAPTER 4 UNIT MAINTENANCE INSTRUCTIONS - TM-9-6115-670-14P_85
CHAPTER 4 UNIT MAINTENANCE INSTRUCTIONS (cont)
Section II. REPAIR PARTS - TM-9-6115-670-14P_87
Table 4-1. Freezing Points, Composition, and Specific Gravities of Military Antifreeze Materials
Procedure Column
Leakage Definitions - TM-9-6115-670-14P_90
WARNINGS, CAUTIONS, AND NOTES
Table 4-2. Unit Preventive Maintenance Checks and Services (PMCS) - Continued - TM-9-6115-670-14P_92
Table 4-2. Unit Preventive Maintenance Checks and Services (PMCS) - Continued - TM-9-6115-670-14P_93
Section VI. UNIT TROUBLESHOOTING PROCEDURES
ENGINE FAILS TO TURN OVER - TM-9-6115-670-14P_95
ENGINE CRANKS BUT FAILS TO START.
ENGINE CRANKS BUT FAILS TO START CONTINUED.
ENGINE STARTS, BUT STOPS WHEN START-PREHEAT SWITCH IS RELEASED - TM-9-6115-670-14P_98
ENGINE STOPS SUDDENLY - TM-9-6115-670-14P_99
ENGINE RUNS ERRATICALLY OR MISFIRES - TM-9-6115-670-14P_100
ENGINE RUNS ERRATICALLY OR MISFIRES - TM-9-6115-670-14P_101
ENGINE RUNS ERRATICALLY OR MISFIRES Continued
ENGINE DOES NOT DEVELOP FULL POWER.
ENGINE KNOCKS.
BLACK SMOKE IN EXHAUST - TM-9-6115-670-14P_105
BLUE OR WHITE SMOKE IN EXHAUST
LOW OIL PRESSURE.
ENGINE OVERHEATING - TM-9-6115-670-14P_108
ENGINE COOLANT TEMPERATURE TOO LOW
DC AMMETER SHOWS NO CHARGE WHEN VEHICLE BATTERY IS LOW OR DISCHARGED
DC AMMETER SHOWS EXCESSIVE CHARGING AFTER PROLONGED APU OPERATION
EXCESSIVE OIL CONSUMPTION - TM-9-6115-670-14P_112
FUEL MIXED INTO LUBRICANT OIL
OVERSPEED FAULT INDICATOR LIGHTS. - TM-9-6115-670-14P_114
Section VII. PREPARATION FOR STORAGE OR SHIPMENT
Section VIII. UNIT MAINTENANCE INSTRUCTIONS
Figure 4-1. Engine Oil
OIL FILTER.
Figure 4-2. Oil Filter
OIL COOLER.
Figure 4-3. Oil Cooler
LOW OIL PRESSURE SWITCH. - TM-9-6115-670-14P_122
LOW OIL PRESSURE SWITCH. - TM-9-6115-670-14P_123
Figure 4-4. Low Oil Pressure Switch (Sheet 2)
FAN GUARD, FAN SHROUD, AND SHROUD HOUSING
REPLACE - TM-9-6115-670-14P_126
Figure 4-5. Fan Guard, Fan Shroud, and Shroud Housing (Sheet 1 of 2)
Figure 4-5. Fan Guard, Fan Shroud, and Shroud Housing (Sheet 2)
RADIATOR SUB-ASSEMBLY.
Figure 4-6. Radiator (Sheet 1 of 3)
Figure 4-6. Radiator (Sheet 2)
TEST - TM-9-6115-670-14P_132
Figure 4-6. Radiator (Sheet 3)
RADIATOR COOLANT DRAIN VALVE
Figure 4-7. Radiator Coolant Drain Valve
ENGINE COOLANT DRAIN VALVE
Figure 4-8. Engine Coolant Drain Valve
THERMOSTAT
Figure 4-9. Thermostat
FAN BELT.
Figure 4-10. Fan Belt
RADIATOR HOSES
Figure 4-11. Radiator Hoses
TEMPERATURE SENDER.
Figure 4-12. Temperature Sender
TEMPERATURE SWITCH
Figure 4-13. Temperature Switch
BREATHER
Figure 4-14. Breather (Sheet 1 of 2)
Figure 4-14. Breather (Sheet 2)
RADIATOR OVERFLOW TANK.
Figure 4-15. Radiator Overflow Tank
FUEL SYSTEM - TM-9-6115-670-14P_153
Figure 4-16. Fuel System
FUEL FILTER ASSEMBLY
REPLACE - TM-9-6115-670-14P_156
Figure 4-17. Fuel Filter Assembly
FUEL PUMP ASSEMBLY
REPLACE - TM-9-6115-670-14P_159
Figure 4-18. Fuel Pump Assembly
FUEL DAY TANK ASSEMBLY (JTACS and WIN-T)
TEST
REPAIR - TM-9-6115-670-14P_163
REPLACE - TM-9-6115-670-14P_164
REPLACE (cont) - TM-9-6115-670-14P_165
Figure 4-19. Fuel Day Tank Assembly (JTACS and WIN-T)
FUEL DAY TANK ASSEMBLY (SICPS)
SERVICE - TM-9-6115-670-14P_168
TEST - TM-9-6115-670-14P_169
REPAIR - TM-9-6115-670-14P_170
REPLACE - TM-9-6115-670-14P_171
Figure 4-20. Fuel Day Tank Assembly (SICPS)
FUEL FEEDER PUMP
REPLACE - TM-9-6115-670-14P_175
Figure 4-21. Fuel Feeder Pump
FUEL LINES AND FITTINGS (JTACS, SICPS, and WIN-T)
REPLACE - TM-9-6115-670-14P_178
Figure 4-22. Fuel Lines and Fittings (SICPS)
Figure 4-23. Fuel Lines and Fittings (JTACS and WIN-T)
BATTERY CHARGING ALTERNATOR
REPLACE - TM-9-6115-670-14P_182
Figure 4-24. Battery Charging Alternator
STARTER - TM-9-6115-670-14P_184
Figure 4-25. Starter
GLOW PLUG
REPLACE - TM-9-6115-670-14P_187
Figure 4-26. Glow Plug (Sheet 2)
MUFFLER WRAP
Figure 4-27. Muffler Wrap
MUFFLER, (JTACS) MODEL MEP-903B and (WIN-T), MODEL MEP-903C
Figure 4-28. Muffler (JTACS and WIN-T)
MUFFLER (SICPS), MODEL MEP-903A
Figure 4-29. Muffler (SICPS)
EXHAUST PIPE, (JTACS) MODEL MEP-903B and (WIN-T) MODEL MEP-903C
Figure 4-30. Exhaust Pipe (JTACS and WIN-T)
EXHAUST PIPE (SICPS), MODEL MEP-903A
Figure 4-31. Exhaust Pipe (SICPS)
ENGINE TURBOCHARGER
Figure 4-32. Engine Turbocharger
AIR FILTER (SICPS, JTACS, AND WIN-T)
Figure 4-33. Air Filter (Sheet 1 of 2)
Figure 4-33. Air Filter (Sheet 2)
AIR INTAKE PIPE.
Figure 4-35. Air Intake Pipe
GOVERNOR CONTROL ASSEMBLY
REPLACE - TM-9-6115-670-14P_208
Figure 4-36. Governor Control Assembly
ACTUATOR SOLENOID.
Figure 4-37. Actuator/Solenoid (Sheet 1 of 2)
Figure 4-37. Actuator/Solenoid (Sheet 2)
ACTUATOR LINKAGE
Figure 4-38. Actuator Linkage (Sheet 1 of 2)
REPLACE - TM-9-6115-670-14P_215
Figure 4-38. Actuator Linkage (Sheet 2)
ELECTRICAL OUTPUT TERMINAL BOARD
Figure 4-39. Electrical Output Terminal Board
CONTACTOR MOUNTING PLATE
INSTALL
Figure 4-40. Contactor Mounting Plate
MAIN AC CONTACTOR - TM-9-6115-670-14P_222
MAIN AC CONTACTOR - TM-9-6115-670-14P_223
REPLACE - TM-9-6115-670-14P_224
GROUND STRAP.
Figure 4-42. Ground Strap
CURRENT SHUNT
REPLACE - TM-9-6115-670-14P_228
Figure 4-43. Current Shunt
SPEED SENSOR
REPLACE - TM-9-6115-670-14P_231
Figure 4-44. Speed Sensor
ELECTRICAL METERS
HERTZ METER
REPLACE - TM-9-6115-670-14P_235
Figure 4-45. Electrical Meters
HOUR METER.
Figure 4-46. Hour Meter
AC VOLTAGE ADJUST POTENTIOMETER
REPLACE - TM-9-6115-670-14P_240
Figure 4-47. AC Voltage Adjust Potentiometer
EMERGENCY SHUT-DOWN SWITCH
Figure 4-48. Emergency Shut-Down Switch
TOGGLE SWITCHES
Figure 4-49. Toggle Switches
START-PREHEAT TOGGLE SWITCH
Figure 4-50. START-PREHEAT Toggle Switch
INDICATOR LAMPS - TM-9-6115-670-14P_248
INDICATOR LAMPS - TM-9-6115-670-14P_249
CYLINDER HEAD COVER (VALVE COVER)
Figure 4-52. Cylinder Head Cover (Valve Cover)
CHAPTER 5 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS
COMMON TOOLS AND EQUIPMENT - TM-9-6115-670-14P_254
SYMPTOM INDEX - TM-9-6115-670-14P_255
ENGINE FAILS TO TURN OVER - TM-9-6115-670-14P_256
ENGINE TURNS OVER BUT FAILS TO START - TM-9-6115-670-14P_257
ENGINE STARTS, BUT STOPS WHEN START-PREHEAT SWITCH IS RELEASED - TM-9-6115-670-14P_258
ENGINE STOPS SUDDENLY - TM-9-6115-670-14P_259
ENGINE RUNS ERRATICALLY OR MISFIRES - TM-9-6115-670-14P_260
ENGINE DOES NOT DEVELOP FULL POWER - TM-9-6115-670-14P_261
BLACK SMOKE IN EXHAUST.
BLUE OR WHITE SMOKE IN EXHAUST.
ENGINE OVERHEATING - TM-9-6115-670-14P_264
ENGINE COOLANT TEMPERATURE TOO LOW. - TM-9-6115-670-14P_265
ENGINE COOLANT TEMPERATURE TOO LOW. - TM-9-6115-670-14P_266
EXCESSIVE OIL CONSUMPTION - TM-9-6115-670-14P_267
FUEL MIXED INTO LUBRICANT OIL.
AC VOLTMETER DOES NOT INDICATE VOLTAGE
AC VOLTMETER INDICATES VOLTAGE BUT FREQUENCY METER IS OFF SCALE
AC VOLTAGE FLUCTUATES - TM-9-6115-670-14P_271
AC VOLTAGE FLUCTUATES - TM-9-6115-670-14P_272
MAIN AC CONTACTOR WILL NOT CLOSE
OVERSPEED FAULT INDICATOR LIGHTS. - TM-9-6115-670-14P_274
OVER-VOLTAGE FAULT INDICATOR LIGHTS
Section III. DIRECT SUPPORT MAINTENANCE PROCEDURES - TM-9-6115-670-14P_276
OIL PAN COVER
Figure 5-1. Oil Pan Cover
OIL PAN
Figure 5-2. Oil Pan
OIL PAN STRAINER
Figure 5-3. Oil Pan Strainer
RELIEF VALVE
RADIATOR CAP - TM-9-6115-670-14P_284
WATER PUMP
Figure 5-6. Water Pump
INJECTION NOZZLE ASSEMBLY - TM-9-6115-670-14P_287
INJECTION NOZZLE ASSEMBLY - TM-9-6115-670-14P_288
REPLACE - TM-9-6115-670-14P_289
Figure 5-7. Injection Nozzles (Sheet 2)
INJECTION PUMP - TM-9-6115-670-14P_291
INJECTION PUMP - TM-9-6115-670-14P_292
Figure 5-8. Injection Pump (Sheet 1 of 3)
REPLACE - TM-9-6115-670-14P_294
Figure 5-8. Injection Pump (Sheet 2)
Figure 5-8. Injection Pump (Sheet 3)
CURRENT TRANSFORMER - TM-9-6115-670-14P_297
OVERLOAD RELAY
REPLACE - TM-9-6115-670-14P_299
CONTACTOR PLATE
Figure 5-11. Contactor Plate
RELAY BOARD
REPLACE - TM-9-6115-670-14P_303
Figure 5-12. Relay Board
DC BOX SUBASSEMBLY
Figure 5-13. DC Box Subassembly - TM-9-6115-670-14P_306
Figure 5-13. DC Box Subassembly - TM-9-6115-670-14P_307
REPLACE - TM-9-6115-670-14P_308
Figure 5-14. Electromagnetic Safety Relays
RELAY SOCKETS
Figure 5-15. Relay Sockets
AUTOMATIC VOLTAGE REGULATOR
Figure 5-16. Automatic Voltage Regulator (Sheet 1 of 2)
REPLACE - TM-9-6115-670-14P_314
Figure 5-16. Automatic Voltage Regulator (Sheet 2) - TM-9-6115-670-14P_315
Figure 5-16. Automatic Voltage Regulator (Sheet 2) - TM-9-6115-670-14P_316
REPLACE - TM-9-6115-670-14P_317
Figure 5-17. Regulator Box - TM-9-6115-670-14P_318
Figure 5-17. Regulator Box - TM-9-6115-670-14P_319
REPLACE - TM-9-6115-670-14P_320
REPLACE (cont) - TM-9-6115-670-14P_321
REPLACE (cont) - TM-9-6115-670-14P_322
Figure 5-18. Generator, 10 kW, 60 Hz (Sheet 1 of 5)
Figure 5-18. Generator, 10 kW, 60 Hz (Sheet 2)
Figure 5-18. Generator, 10 kW, 60 Hz (Sheet 3)
Figure 5-18. Generator, 10 kW, 60 Hz (Sheet 4)
Figure 5-18. Generator, 10 kW, 60 Hz (Sheet 5)
WIRING HARNESS REPAIR
Solder pins and jacks - TM-9-6115-670-14P_329
APU DC BOX WIRING HARNESS J3
Table 5-1. APU DC Box Wiring Harness J3 Continuity Test
REPLACE - TM-9-6115-670-14P_332
Figure 5-19. APU DC Box Wiring Harness J3 - TM-9-6115-670-14P_333
Figure 5-19. APU DC Box Wiring Harness J3 - TM-9-6115-670-14P_334
Table 5-2. Engine Wiring Harness P1 Continuity Test
REPLACE - TM-9-6115-670-14P_336
REPLACE - TM-9-6115-670-14P_337
WIRING HARNESS J1
Table 5-3. Wiring Harness J1 Continuity Test
REPLACE - TM-9-6115-670-14P_340
Figure 5-21. Wiring Harness J1
WIRING HARNESS CONTROL CABLE - TM-9-6115-670-14P_342
WIRING HARNESS CONTROL CABLE - TM-9-6115-670-14P_343
WIRING HARNESS CONTROL CABLE - TM-9-6115-670-14P_344
REPLACE - TM-9-6115-670-14P_345
Figure 5-22. Water Temperature Gauge
WIRING HARNESS J2
Table 5-5. Wiring Harness J2 Continuity Test
REPLACE - TM-9-6115-670-14P_349
Figure 5-23. Wiring Harness J2
FRAME ASSEMBLY
REPLACE - TM-9-6115-670-14P_352
REPLACE (cont) - TM-9-6115-670-14P_353
REPAIR - TM-9-6115-670-14P_354
REPAIR (cont)
Figure 5-24. Frame Assembly and Vibration Isolator Mount Assembly (Sheet 1 of 6)
Figure 5-24. Frame Assembly and Vibration Isolator Mount Assembly (Sheet 2 of 6)
Figure 5-24. Frame Assembly and Vibration Isolator Mount Assembly (Sheet 3 of 6)
Figure 5-24. Frame Assembly and Vibration Isolator Mount Assembly (Sheet 4 of 6)
Figure 5-24. Frame Assembly and Vibration Isolator Mount Assembly (Sheet 5 of 6)
Figure 5-24. Frame Assembly and Vibration Isolator Mount Assembly (Sheet 6 of 6)
DIESEL ENGINE
Figure 5-25. Diesel Engine (Sheet 1 of 11) - TM-9-6115-670-14P_363
Figure 5-25. Diesel Engine (Sheet 1 of 11) - TM-9-6115-670-14P_364
Figure 5-25. Diesel Engine (Sheet 1 of 11) - TM-9-6115-670-14P_365
Figure 5-25. Diesel Engine (Sheet 3 of 11)
Figure 5-25. Diesel Engine (Sheet 4 of 11)
Figure 5-25. Diesel Engine (Sheet 5 of 11)
Figure 5-25. Diesel Engine (Sheet 6 of 11)
Figure 5-25. Diesel Engine (Sheet 7 of 11)
Figure 5-25. Diesel Engine (Sheet 8 of 11)
Figure 5-25. Diesel Engine (Sheet 9 of 11)
Figure 5-25. Diesel Engine (Sheet 10 of 11)
Figure 5-25. Diesel Engine (Sheet 11 of 11)
INSTALL
INSTALL (cont)
EXHAUST MANIFOLD
Figure 5-26. Exhaust Manifold
INTAKE MANIFOLD
Figure 5-27. Intake Manifold
ROCKER ARM ASSEMBLY
REPLACE - TM-9-6115-670-14P_382
VALVE CLEARANCE
ADJUST
Figure 5-29. Valve Clearance
FLYWHEEL
Figure 5-30. Flywheel
CHAPTER 6 GENERAL SUPPORT MAINTENANCE INSTRUCTIONS - TM-9-6115-670-14P_389
Section I. REPAIR PARTS
PUSH RODS.
Figure 6-1. Push Rods - TM-9-6115-670-14P_392
Figure 6-1. Push Rods - TM-9-6115-670-14P_393
Figure 6-1. Push Rods - TM-9-6115-670-14P_394
REPAIR - TM-9-6115-670-14P_395
Figure 6-2. Cylinder Head (Sheet 2) - TM-9-6115-670-14P_396
Figure 6-2. Cylinder Head (Sheet 2) - TM-9-6115-670-14P_397
Figure 6-2. Cylinder Head (Sheet 4)
TAPPETS
VALVES.
Figure 6-4. Valves (Sheet 1 of 3)
Figure 6-4. Valves (Sheet 2)
Figure 6-4. Valves (Sheet 3)
REPLACE - TM-9-6115-670-14P_404
VALVE GUIDE.
Figure 6-5. Valve Guide
VALVE SPRING
Figure 6-6. Valve Spring
VALVE SEAT
Figure 1-7. Intake/Exhaust System - TM-9-6115-670-14P_410
Figure 6-7. Valve Seat (Sheet 2)
SPEED CONTROL PLATE
Figure 6-8. Speed Control Plate
GEAR CASE
REPLACE - TM-9-6115-670-14P_415
Figure 6-9. Gear Case (Sheet 1 of 2)
Figure 6-9. Gear Case (Sheet 2 of 2)
IDLE GEAR
Figure 6-10. Idle Gear (Sheet 1 of 2)
Figure 6-10. Idle Gear (Sheet 2)
IDLE GEAR BUSHING - TM-9-6115-670-14P_421
IDLE GEAR BUSHING - TM-9-6115-670-14P_422
Figure 6-12. Idle Gear Shaft - TM-9-6115-670-14P_423
Figure 6-12. Idle Gear Shaft - TM-9-6115-670-14P_424
TM-9-6115-670-14P_425
Figure 6-13. Camshaft (Sheet 2 of 4)
Figure 6-13. Camshaft (Sheet 3 of 4)
Figure 6-13. Camshaft (Sheet 4 of 4)
CAMSHAFT GEAR
Figure 6-14. Camshaft Gear
FUEL CAMSHAFT
Figure 6-15. Fuel Camshaft
INJECTION PUMP GEAR
Figure 6-16. Injection Pump Gear
CRANKSHAFT GEAR
Figure 6-17. Crankshaft Gear
OIL PUMP GEAR
PISTONS
Figure 6-19. Piston (Sheet 1 of 2)
REPLACE - TM-9-6115-670-14P_440
Figure 6-19. Piston (Sheet 2 of 2)
CONNECTING ROD
Figure 6-20. Connecting Rod (Sheet 1 of 4)
Figure 6-20. Connecting Rod (Sheet 2 of 4)
Figure 6-20. Connecting Rod (Sheet 3)
Figure 6-20. Connecting Rod (Sheet 4)
PISTON RINGS
Figure 6-21. Piston Rings (Sheet 1 of 4)
Figure 6-21. Piston Rings (Sheet 2 of 4)
Figure 6-21. Piston Rings (Sheet 3 of 4)
Figure 6-21. Piston Rings (Sheet 4 of 4)
BEARING CASE COVER.
Figure 6-22. Bearing Case Cover
CRANKSHAFT.
REPLACE - TM-9-6115-670-14P_455
Figure 6-23. Crankshaft
CONNECTING ROD BEARING
Figure 6-24. Connecting Rod Bearing
CRANKSHAFT BEARING 1
Figure 6-25. Crankshaft Bearing 1 (Sheet 1 of 2)
Figure 6-25. Crankshaft Bearing 1 (Sheet 2)
CRANKSHAFT BEARINGS 2 AND 3
Figure 6-26. Crankshaft Bearings 2 and 3
CYLINDER
Figure 6-27. Cylinder
OIL PUMP ASSEMBLY
Figure 6-28. Oil Pump Assembly (Sheet 1 of 2)
RADIATOR SEAL FARING
Figure 6-29. Radiator Seal Faring
WATER FLANGE
Figure 6-30. Water Flange
EXCITER STATOR - TM-9-6115-670-14P_472
Figure 6-31. Exciter Stator (Sheet 1 of 4)
Figure 6-31. Exciter Stator (Sheet 3 of 4)
Figure 6-31. Exciter Stator (Sheet 4 of 4)
MAIN RECTIFIER ASSEMBLY
Figure 6-32. Main Rectifier Assembly
GENERATOR BEARING
ROTOR.
Figure 6-34. Rotor
APPENDIX A REFERENCES - TM-9-6115-670-14P_481
APPENDIX B MAINTENANCE ALLOCATION CHART - TM-9-6115-670-14P_483
EXPLANATION OF COLUMNS IN THE MAC, SECTION II - TM-9-6115-670-14P_484
EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS, SECTION III - TM-9-6115-670-14P_485
MAINTENANCE ALLOCATION CHART - TM-9-6115-670-14P_486
MAINTENANCE ALLOCATION CHART - TM-9-6115-670-14P_487
MAINTENANCE ALLOCATION CHART - TM-9-6115-670-14P_488
Section III. TOOLS AND TEST EQUIPMENT REQUIREMENTS - TM-9-6115-670-14P_489
Section III. TOOLS AND TEST EQUIPMENT REQUIREMENTS - TM-9-6115-670-14P_490
Section IV. REMARKS - TM-9-6115-670-14P_491
Section IV. REMARKS (cont)
Section I. Introduction - TM-9-6115-670-14P_493
Source code - TM-9-6115-670-14P_494
Maintenance code - TM-9-6115-670-14P_495
Recoverability code. - TM-9-6115-670-14P_496
EXPLANATION OF COLUMNS - TM-9-6115-670-14P_497
HOW TO LOCATE REPAIR PARTS - TM-9-6115-670-14P_498
Figure C-1. Auxiliary Power Unit, 10 kW, 120/208 VAC, 60 Hz
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_501
Figure C-2. Generator 10 kW, APU (Sheet 1 of 8)
Figure C-2. Generator 10 kW, APU (Sheet 2 of 8)
Figure C-2. Generator 10 kW, APU (Sheet 3 of 8)
Figure C-2. Generator 10 kW, APU (Sheet 4 of 8)
Figure C-2. Generator 10 kW, APU (Sheet 5 of 8)
Figure C-2. Generator 10 kW, APU (Sheet 6 of 8)
Figure C-2. Generator 10 kW, APU (Sheet 7 of 8)
Figure C-2. Generator 10 kW, APU (Sheet 8 of 8)
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_511
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_512
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_513
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_514
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_515
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_516
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_517
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_518
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_519
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_520
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_521
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_522
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_523
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_524
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_525
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_526
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_527
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_528
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_529
Figure C-3. Frame Assembly, SICPS
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_531
Figure C-4. Frame Assembly, JTACS/WIN-T (Sheet 1 of 2)
Figure C-4. Frame Assembly, JTACS/WIN-T (Sheet 2 of 2)
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_535
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_536
Figure C-5. Fuel Day Tank Assembly, SICPS
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_539
Figure C-6. Fuel Day Tank Assembly, JTACS/WIN-T
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_541
Figure C-7. Engine Assembly
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_543
Figure C-8. Engine, Diesel, Turbo, 3 Cylinder, Liquid Cooled (Sheet 1 of 8)
Figure C-8. Engine, Diesel, Turbo, 3 Cylinder, Liquid Cooled (Sheet 2 of 8)
Figure C-8. Engine, Diesel, Turbo, 3 Cylinder, Liquid Cooled (Sheet 3 of 8)
Figure C-8. Engine, Diesel, Turbo, 3 Cylinder, Liquid Cooled (Sheet 4 of 8)
Figure C-8. Engine, Diesel, Turbo, 3 Cylinder, Liquid Cooled (Sheet 5 of 8)
Figure C-8. Engine, Diesel, Turbo, 3 Cylinder, Liquid Cooled (Sheet 6 of 8)
Figure C-8. Engine, Diesel, Turbo, 3 Cylinder, Liquid Cooled (Sheet 7 of 8)
Figure C-8. Engine, Diesel, Turbo, 3 Cylinder, Liquid Cooled (Sheet 8 of 8)
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_553
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_554
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_555
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_556
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_557
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_558
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_559
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_560
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_561
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_562
Figure C-9. Lubricating System (Sheet 1 of 2)
Figure C-9. Lubricating System (Sheet 2 of 2)
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_565
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_566
Figure C-10. Cooling System
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_569
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_570
Figure C-11. Electrical System
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_573
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_574
Figure C-12. Fuel System
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_577
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_578
Figure C-13. Injector Pump
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_581
Figure C-14. Fuel Filter Assembly
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_583
Figure C-15. Cylinder Head Assembly
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_585
Figure C-16. Connecting Rod
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_587
Figure C-17. Fuel Pump Assembly
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_589
Figure C-18. Radiator Subassembly
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_591
Figure C-19. Speed Sensor Assembly
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_593
Figure C-20. Wiring Harness, J3, DC Box, APU (Sheet 1 of 2)
Figure C-20. Wiring Harness, J3, DC Box, APU (Sheet 2 of 2)
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_597
Figure C-21. Wiring Harness, Engine, P1 (Sheet 1 of 3)
Figure C-21. Wiring Harness, Engine, P1 (Sheet 2 of 3)
Figure C-21. Wiring Harness, Engine, P1 (Sheet 3 of 3)
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_601
Figure C-22. Wiring Harness, J1 (Sheet 1 of 2)
Figure C-22. Wiring Harness, J1 (Sheet 2 of 2)
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_605
Figure C-23. Governor Control Assembly
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_607
Figure C-24. Generator, 10 kW, 60 Hz
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_609
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_610
Figure C-25. Main Rectifier Assembly
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_613
Figure C-26. Control Cable
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_615
Figure C-27. APU Control Box Assembly (Sheet 1 of 3)
Figure C-27. APU Control Box Assembly (Sheet 2 of 3)
Figure C-27. APU Control Box Assembly (Sheet 3 of 3)
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_619
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_620
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_621
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_622
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_623
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_624
Figure C-28. Wiring Harness, J2 (Sheet 1 of 2)
Figure C-28. Wiring Harness, J2 (Sheet 2 of 2)
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_627
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_629
Figure C-29. Special Tools (Sheet 1 of 6)
Figure C-29. Special Tools (Sheet 2 of 6)
Figure C-29. Special Tools (Sheet 3 of 6)
Figure C-29. Special Tools (Sheet 4 of 6)
Figure C-29. Special Tools (Sheet 5 of 6)
Figure C-29. Special Tools (Sheet 6 of 6)
DESCRIPTION AND USABLE ON CODE (UOC) - TM-9-6115-670-14P_637
CROSS-REFERENCE INDEXES    NATIONAL STOCK NUMBER INDEX
NATIONAL STOCK NUMBER INDEX - TM-9-6115-670-14P_640
NATIONAL STOCK NUMBER INDEX - TM-9-6115-670-14P_641
NATIONAL STOCK NUMBER INDEX - TM-9-6115-670-14P_642
NATIONAL STOCK NUMBER INDEX - TM-9-6115-670-14P_643
NATIONAL STOCK NUMBER INDEX - TM-9-6115-670-14P_644
PART NUMBER INDEX - TM-9-6115-670-14P_645
PART NUMBER INDEX - TM-9-6115-670-14P_646
PART NUMBER INDEX - TM-9-6115-670-14P_647
PART NUMBER INDEX - TM-9-6115-670-14P_648
PART NUMBER INDEX - TM-9-6115-670-14P_649
PART NUMBER INDEX - TM-9-6115-670-14P_650
PART NUMBER INDEX - TM-9-6115-670-14P_651
PART NUMBER INDEX - TM-9-6115-670-14P_652
PART NUMBER INDEX - TM-9-6115-670-14P_653
PART NUMBER INDEX - TM-9-6115-670-14P_654
PART NUMBER INDEX - TM-9-6115-670-14P_655
PART NUMBER INDEX - TM-9-6115-670-14P_656
PART NUMBER INDEX - TM-9-6115-670-14P_657
PART NUMBER INDEX - TM-9-6115-670-14P_658
PART NUMBER INDEX - TM-9-6115-670-14P_659
PART NUMBER INDEX - TM-9-6115-670-14P_660
PART NUMBER INDEX - TM-9-6115-670-14P_661
PART NUMBER INDEX - TM-9-6115-670-14P_662
PART NUMBER INDEX - TM-9-6115-670-14P_663
PART NUMBER INDEX - TM-9-6115-670-14P_664
PART NUMBER INDEX - TM-9-6115-670-14P_665
PART NUMBER INDEX - TM-9-6115-670-14P_666
PART NUMBER INDEX - TM-9-6115-670-14P_667
PART NUMBER INDEX - TM-9-6115-670-14P_668
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_669
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_670
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_671
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_672
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_673
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_674
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_675
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_676
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_677
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_678
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_679
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_680
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_681
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_682
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_683
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_684
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_685
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_686
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_687
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_688
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_689
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_690
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_691
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_692
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_693
FIGURE AND ITEM NUMBER INDEX - TM-9-6115-670-14P_694
APPENDIX D COMPONENTS OF END ITEM AND BASIC ISSUES ITEMS LIST
EXPLANATION OF COLUMNS - TM-9-6115-670-14P_696
Figure D-1. Auxiliary Power Unit, 10 kW, 120/240 VAC, 60 Hz
Figure D-2. Operators, Unit, Direct Support, and General Support Maintenance Manual
APPENDIX E ADDITIONAL AUTHORIZATION LIST
Section II. ADDITIONAL AUTHORIZATION LIST - TM-9-6115-670-14P_700
APPENDIX F EXPENDABLE AND DURABLE PARTS ITEMS LIST
Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST - TM-9-6115-670-14P_702
Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST - TM-9-6115-670-14P_703
APPENDIX G OPERATOR'S LUBRICATION INSTRUCTIONS
Table G1. Lubricant Table for the APU
APPENDIX H ILLUSTRATED LIST OF MANUFACTURED ITEMS
Figure H-1. Valve Guide Replacing Tool
Table H-1. Materials and Specifications
Figure H-2. Crankshaft Bearing 1 Replacing Tool - TM-9-6115-670-14P_710
Figure H-2. Crankshaft Bearing 1 Replacing Tool - TM-9-6115-670-14P_711
Figure H-3. Connecting Rod Small End Bushing Replacing Tool
Table H-5. Materials and Specifications
Figure H-4. Idle Gear Bushing Replacing Tool
Table H-7. Materials and Specifications
Figure H-5. Injection Pump Pressure Tester
Table H-9. Parts, Materials, and Specifications
APPENDIX I TORQUE LIMITS
Torque Values for General Use Screws, Bolts, and Nuts
APPENDIX J MANDATORY REPLACEMENT PARTS
Section II. MANDATORY REPLACEMENT PARTS LIST
Section II. MANDATORY REPLACEMENT PARTS LIST
Figure FO-1.   APU Wiring Diagram (SICPS and WIN-T)
Figure FO-2. Wiring Harness, Engine P, Wiring Diagram
Figure FO-3.   Wiring Harness, APU DC Box J3, Wiring Diagram
Figure FO-4.   Wiring Harness, J1, Wiring Diagram
Figure FO-5.   Wiring Harness, J2, APU, Control Box, Wiring Diagram
Figure FO-6.   Wiring Harness, Control Cable
Figure FO-7.   APU Wiring Diagram (JTACS)

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