TM-9-6115-671-14 Electric Power Plant III 2 x 150 Kw 400hz Manual

CHAPTER 1 INTRODUCTION - TM-9-6115-671-14_22
FIGURE 1-1. 30 kW TACTICAL QUIET GENERATOR SET
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATION (EIR)
SECTION II. EQUIPMENT DESCRIPTION AND DATA
TABLE 1-1. TABULATED DATA
TABLE 1-1. TABULATED DATA (continued) - TM-9-6115-671-14_27
FIGURE 1-2. LOCATIONS OF DATA PLATES AND ACCESS DOORS (FRONT AND RIGHT SIDE)
FIGURE 1-3. LOCATIONS OF DATA PLATES AND ACCESS DOORS (REAR AND LEFT SIDE)
FIGURE 1-4. OPERATING INSTRUCTION PLATE, MEP-805B
FIGURE 1-5. OPERATING INSTRUCTION PLATE, MEP-815B
FIGURE 1-6. IDENTIFICATION PLATE, MEP-805B AND MEP-815B
FIGURE 1-13. EXTERNAL FUEL SUPPLY PLATE
FIGURE 1-14. BATTERY CONNECTION INSTRUCTION PLATE
FIGURE 1-16. FUEL SYSTEM DIAGRAM PLATE
DIFFERENCES BETWEEN MODELS - TM-9-6115-671-14_36
SECTION III. PRINCIPLES OF OPERATION - TM-9-6115-671-14_37
FIGURE 1-19. FAULT SYSTEM FLOW DIAGRAM - TM-9-6115-671-14_38
Governor Control System
FIGURE 1-20. GOVERNOR CONTROL SYSTEM FLOW DIAGRAM
FIGURE 1-21. VOLTAGE REGULATION SYSTEM FLOW DIAGRAM
FIGURE 1-22. FUEL SYSTEM FLOW DIAGRAM
Generator Set Cooling System - TM-9-6115-671-14_43
FIGURE 1-23. GENERATOR SET COOLING SYSTEM FLOW DIAGRAM - TM-9-6115-671-14_44
Engine Cooling System - TM-9-6115-671-14_45
FIGURE 1-24. ENGINE COOLING SYSTEM FLOW DIAGRAM - TM-9-6115-671-14_46
FIGURE 1-25. LUBRICATION SYSTEM FLOW DIAGRAM
FIGURE 1-26. ENGINE AIR INTAKE AND EXHAUST SYSTEM FLOW DIAGRAM - TM-9-6115-671-14_48
Output Supply System - TM-9-6115-671-14_49
FIGURE 1-27. OUTPUT SUPPLY SYSTEM FLOW DIAGRAM
Generator Assembly
FIGURE 1-28. BRUSHLESS GENERATOR SCHEMATIC - TM-9-6115-671-14_52
Generator Set Controls - TM-9-6115-671-14_53
FIGURE 1-29. ENGINE STARTING SYSTEM FLOW DIAGRAM
Field Flash
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - TM-9-6115-671-14_56
FIGURE 1-30. 30 KW GENERATOR SET COMPONENTS
FIGURE 1-30. 30 KW GENERATOR SET COMPONENTS CONT.
Batteries
CHAPTER 2 OPERATING INSTRUCTIONS - TM-9-6115-671-14_62
FIGURE 2-1. DCS CONTROLS AND INDICATORS - TM-9-6115-671-14_63
TABLE 2-1. DCS CONTROLS AND INDICATORS - TM-9-6115-671-14_64
TABLE 2-1. DCS CONTROLS AND INDICATORS (continued)
FIGURE 2-2. CIM DISPLAY SCREEN CONTROLS AND INDICATORS - TM-9-6115-671-14_66
TABLE 2-2. CIM DISPLAY SCREEN CONTROLS AND INDICATORS
TABLE 2-3. FAULTS
TABLE 2-3. FAULTS (continued) - TM-9-6115-671-14_69
FIGURE 2-3. DIAGNOSTIC CONTROLS AND INDICATORS
FIGURE 2-3. DIAGNOSTIC CONTROLS AND INDICATORS CONT.
TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS - TM-9-6115-671-14_72
TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS (continued) - TM-9-6115-671-14_73
TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS (continued) - TM-9-6115-671-14_74
TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS (continued) - TM-9-6115-671-14_75
Procedures Column - TM-9-6115-671-14_76
TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - TM-9-6115-671-14_77
TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) CONT.
TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (continued) - TM-9-6115-671-14_79
TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (continued) - TM-9-6115-671-14_80
TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (continued) - TM-9-6115-671-14_81
TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (continued) - TM-9-6115-671-14_82
Indoor Installation - TM-9-6115-671-14_83
FIGURE 2-5. MINIMUM ENCLOSURE CLEARANCE MEASUREMENTS - TM-9-6115-671-14_84
ASSEMBLY AND PREPARATION FOR USE - TM-9-6115-671-14_85
FIGURE 2-6. GROUNDING CONNECTIONS - TM-9-6115-671-14_86
Installation of Load Cables - TM-9-6115-671-14_87
FIGURE 2-7. INSTALLATION OF LOAD CABLES - TM-9-6115-671-14_88
FIGURE 2-8. GENERATOR SET CONTROLS - TM-9-6115-671-14_89
Self Test
OPERATING PROCEDURE - TM-9-6115-671-14_91
Shut Down Generator Set
FIGURE 2-9. CIM DISPLAY SCREEN CONTROLS AND INDICATORS - TM-9-6115-671-14_93
PARALLEL UNIT OPERATION (LOAD SHARING) - TM-9-6115-671-14_94
FIGURE 2-10. PARALLEL OPERATION SETUP
Operation - TM-9-6115-671-14_96
Remove from Parallel Operation
TQG Remote Software Installation - TM-9-6115-671-14_98
TQG Remote Software Installation CONT.
PREPARATION FOR MOVEMENT - TM-9-6115-671-14_100
FIGURE 2-11. REMOTE PC DISPLAY MODES - TM-9-6115-671-14_101
FIGURE 2-12. REMOTE PC SETUP - TM-9-6115-671-14_102
OPERATION IN EXTREME HEAT ABOVE 120 F (48.8 C) - TM-9-6115-671-14_103
OPERATION UNDER RAINY OR HUMID CONDITIONS - TM-9-6115-671-14_104
OPERATION AT HIGH ALTITUDES - TM-9-6115-671-14_105
FIGURE 2-13. NATO SLAVE RECEPTACLE - TM-9-6115-671-14_106
NUCLEAR, BIOLOGICAL, AND CHEMICAL (NBC) DECONTAMINATION PROCEDURES - TM-9-6115-671-14_107
CHAPTER 2 OPERATING INSTRUCTIONS - TM-9-6115-671-14_108
FIGURE 2-1. DCS CONTROLS AND INDICATORS - TM-9-6115-671-14_109
TABLE 2-1. DCS CONTROLS AND INDICATORS - TM-9-6115-671-14_110
TABLE 2-1. DCS CONTROLS AND INDICATORS (continued)
FIGURE 2-2. CIM DISPLAY SCREEN CONTROLS AND INDICATORS
TABLE 2-2. CIM DISPLAY SCREEN CONTROLS AND INDICATORS - TM-9-6115-671-14_113
TABLE 2-3. FAULTS - TM-9-6115-671-14_114
TABLE 2-3. FAULTS (continued) - TM-9-6115-671-14_115
FIGURE 2-3. DIAGNOSTIC CONTROLS AND INDICATORS (SHEET 1 OF 2)
FIGURE 2-3. DIAGNOSTIC CONTROLS AND INDICATORS (SHEET 2 OF 2)
TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS - TM-9-6115-671-14_118
TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS (continued) - TM-9-6115-671-14_119
TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS (continued) - TM-9-6115-671-14_120
TABLE 2-4. DIAGNOSTIC CONTROLS AND INDICATORS (continued) - TM-9-6115-671-14_121
Procedures Column - TM-9-6115-671-14_122
TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - TM-9-6115-671-14_123
TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (cont)
TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (cont) - TM-9-6115-671-14_125
TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (cont) - TM-9-6115-671-14_126
TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (cont) - TM-9-6115-671-14_127
TABLE 2-5. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (cont) - TM-9-6115-671-14_128
Indoor Installation - TM-9-6115-671-14_129
FIGURE 2-5. MINIMUM ENCLOSURE CLEARANCE MEASUREMENTS - TM-9-6115-671-14_130
ASSEMBLY AND PREPARATION FOR USE - TM-9-6115-671-14_131
FIGURE 2-6. GROUNDING CONNECTIONS - TM-9-6115-671-14_132
Installation of Load Cables - TM-9-6115-671-14_133
FIGURE 2-7. INSTALLATION OF LOAD CABLES - TM-9-6115-671-14_134
FIGURE 2-8. GENERATOR SET CONTROLS
Self Test.
OPERATING PROCEDURE - TM-9-6115-671-14_137
Start Generator Set
FIGURE 2-9. CIM DISPLAY SCREEN CONTROLS AND INDICATORS - TM-9-6115-671-14_139
PARALLEL UNIT OPERATION (LOAD SHARING).
FIGURE 2-10. PARALLEL OPERATION SETUP - TM-9-6115-671-14_141
Operation - TM-9-6115-671-14_142
REMOTE OPERATION
TQG Remote Software Installation - TM-9-6115-671-14_144
TQG Remote Software Installation (cont)
PREPARATION FOR MOVEMENT - TM-9-6115-671-14_146
FIGURE 2-11. REMOTE PC DISPLAY MODES
FIGURE 2-12. REMOTE PC SETUP - TM-9-6115-671-14_148
OPERATION IN EXTREME HEAT ABOVE 120 F (48.8 C) - TM-9-6115-671-14_149
OPERATION UNDER RAINY OR HUMID CONDITIONS - TM-9-6115-671-14_150
OPERATION AT HIGH ALTITUDES - TM-9-6115-671-14_151
FIGURE 2-13. NATO SLAVE RECEPTACLE
OPERATION WHILE CONTAMINATED
CHAPTER 3 OPERATOR MAINTENANCE INSTRUCTIONS
TABLE 3-1. OPERATOR TROUBLESHOOTING
ENGINE CRANKS BUT FAILS TO START
ENGINE STARTS BUT STOPS WHEN ENGINE CONTROL SWITCH IS RELEASED FROM START - TM-9-6115-671-14_157
ENGINE STOPS SUDDENLY - TM-9-6115-671-14_158
ENGINE KNOCKS - TM-9-6115-671-14_159
ENGINE DOES NOT DEVELOP FULL POWER - TM-9-6115-671-14_160
ENGINE EXHAUST SMOKES
ENGINE OIL PRESSURE LOW - TM-9-6115-671-14_162
ENGINE OVERHEATING - TM-9-6115-671-14_163
GENERATOR SET FAILS TO PARALLEL CORRECTLY
GENERATOR SET FAILS TO PARALLEL CORRECTLY (CONTINUED)
CIM DISPLAY SCREEN DOES NOT DISPLAY AND BACKLIGHT DOES NOT LIGHT - TM-9-6115-671-14_166
CIM DISPLAY SCREEN BATTERY VDC INDICATOR SHOWS EXCESSIVE CHARGING AFTER PROLONGED OPERATION - TM-9-6115-671-14_167
CIM DISPLAY SCREEN VOLTAGE GAGE FLUCTUATES
CIM DISPLAY SCREEN FREQ GAGE FLUCTUATES - TM-9-6115-671-14_169
CIM DISPLAY SCREEN DOES NOT RESPOND TO KEYPAD INPUT TES
SECTION III. OPERATOR MAINTENANCE PROCEDURES - TM-9-6115-671-14_171
Service. - TM-9-6115-671-14_172
Air Cleaner Assembly.
FIGURE 3-1. AIR CLEANER ELEMENT REPLACEMENT - TM-9-6115-671-14_174
Crankcase Breather Filter Assembly
FIGURE 3-2 CRANKCASE BREATHER FILTER ASSEMBLY
Engine Cooling System.
FIGURE 3-3. COOLANT RECOVERY (OVERFLOW) BOTTLE - TM-9-6115-671-14_178
TABLE 3-2. COOLANT - TM-9-6115-671-14_179
FIGURE 3-4. FUEL TANK FILLER NECK - TM-9-6115-671-14_180
Service - TM-9-6115-671-14_181
Inspection - TM-9-6115-671-14_182
FIGURE 3-5. FUEL FILTER/WATER SEPARATOR - TM-9-6115-671-14_183
FIGURE 3-6. DIPSTICK AND OIL FILL CAP
TABLE 3-4. QUICK REFERENCE GENERAL INSPECTION - TM-9-6115-671-14_185
CHAPTER 4 UNIT MAINTENANCE INSTRUCTIONS - TM-9-6115-671-14_186
Service - TM-9-6115-671-14_187
TABLE 4-1. COOLANT - TM-9-6115-671-14_188
FIGURE 4-1. FUEL DRAIN VALVE AND OIL DRAIN - TM-9-6115-671-14_189
TABLE 4-2. FUEL - TM-9-6115-671-14_190
FIGURE 4-2. DIPSTICK AND OIL FILL CAP
SECTION IV. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-9-6115-671-14_192
TABLE 4-3. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
TABLE 4-3. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) (continued)
SECTION V. TROUBLESHOOTING
SYMPTOM INDEX - TM-9-6115-671-14_196
ENGINE FAILS TO CRANK - TM-9-6115-671-14_197
ENGINE FAILS TO CRANK (CONTINUED) - TM-9-6115-671-14_198
ENGINE FAILS TO CRANK (CONTINUED) - TM-9-6115-671-14_199
ENGINE CRANKS, BUT FAILS TO START - TM-9-6115-671-14_200
ENGINE CRANKS, BUT FAILS TO START (CONTINUED)
ENGINE FAILS TO START IN COLD WEATHER - TM-9-6115-671-14_202
ENGINE FAILS TO START IN COLD WEATHER - TM-9-6115-671-14_203
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) - TM-9-6115-671-14_204
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) - TM-9-6115-671-14_205
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) - TM-9-6115-671-14_206
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) - TM-9-6115-671-14_207
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) - TM-9-6115-671-14_208
CIM DISPLAY SCREEN DOES NOT DISPLAY AND BACKLIGHT DOES NOT LIGHT - TM-9-6115-671-14_209
CIM DISPLAY SCREEN WORKS, BUT BACKLIGHT DOES NOT LIGHT OR ONLY PARTIALLY LIGHTS
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) - TM-9-6115-671-14_211
TABLE 4-4. UNIT TROUBLESHOOTING (CONTINUED) - TM-9-6115-671-14_212
CIM DISPLAY SCREEN BATTERY AMPS INDICATOR SHOWS NO CHARGE WHEN BATTERIES ARE LOW OR DISCHARGED
CIM DISPLAY SCREEN BATTERY AMPS INDICATOR SHOWS EXCESSIVE CHARGING AFTER PROLONGED OPERATION - TM-9-6115-671-14_214
CIM DISPLAY SCREEN GENERATOR VOLTAGE GAGE FLUCTUATES - TM-9-6115-671-14_215
CIM DISPLAY SCREEN FREQ GAGE FLUCTUATES - TM-9-6115-671-14_216
CIM DISPLAY SCREEN FREQ GAGE FLUCTUATES (CONTINUED) - TM-9-6115-671-14_217
HIGH OIL CONSUMPTION - TM-9-6115-671-14_218
ENGINE MISFIRING - TM-9-6115-671-14_219
CIM DISPLAY SCREEN WATER TEMP METER INDICATES COOLANT TEMPERATURE TOO LOW - TM-9-6115-671-14_220
EXCESSIVE FUEL CONSUMPTION - TM-9-6115-671-14_221
COOLANT IN CRANKCASE OR OIL IN COOLANT - TM-9-6115-671-14_222
CIM DISPLAY SCREEN VOLTAGE GAGE DOES NOT INDICATE VOLTAGE - TM-9-6115-671-14_223
CIM DISPLAY SCREEN VOLTAGE GAGE INDICATES VOLTAGE, BUT FREQ GAGE IS OFF SCALE - TM-9-6115-671-14_224
FAULT INDICATOR DISPLAYS CIRCUIT FAILURE - FUEL LEVEL - TM-9-6115-671-14_225
FAULT INDICATOR DISPLAYS CIRCUIT FAILURE - OIL PRESSURE (LOW) OR OIL PRESSURE (HIGH) - TM-9-6115-671-14_226
FAULT INDICATOR DISPLAYS CIRCUIT FAILURE - COOLANT TEMP - TM-9-6115-671-14_227
FAULT INDICATOR DISPLAYS WARNING - OVERVOLTAGE OR SHUTDOWN - OVERVOLTAGE - TM-9-6115-671-14_228
CIRCUIT INTERRUPTER WILL NOT CLOSE - TM-9-6115-671-14_229
CIRCUIT INTERRUPTER WILL NOT CLOSE Continued - TM-9-6115-671-14_230
CIRCUIT INTERRUPTER WILL NOT OPEN - TM-9-6115-671-14_231
CIRCUIT INTERRUPTER WILL NOT OPEN Continued - TM-9-6115-671-14_232
CIM DISPLAY SCREEN DOES NOT RESPOND TO KEYPAD INPUT - TM-9-6115-671-14_233
SECTION VI. UNIT MAINTENANCE PROCEDURES
Repair - TM-9-6115-671-14_235
FIGURE 4-3. BATTERIES AND CABLES
FIGURE 4-4. NATO SLAVE RECEPTACLE AND CABLES - TM-9-6115-671-14_237
Batteries BT1 and BT2
NATO SLAVE RECEPTACLE - TM-9-6115-671-14_239
Keypad Power Supply PS1
Testing - TM-9-6115-671-14_241
MAINTENANCE OF HOUSING
FIGURE 4-5. GENERATOR SET ACCESS DOORS
Repair. - TM-9-6115-671-14_244
DCS Control Box Top Panel.
FIGURE 4-6. DCS CONTROL BOX TOP PANEL - TM-9-6115-671-14_246
Top Housing Section
WARNING - TM-9-6115-671-14_248
FIGURE 4-7. TOP HOUSING SECTION (SHEET 1 OF 3)
FIGURE 4-7. TOP HOUSING SECTION (SHEET 2 OF 3) - TM-9-6115-671-14_250
FIGURE 4-7. TOP HOUSING SECTION (SHEET 3 OF 3) - TM-9-6115-671-14_251
Installation - TM-9-6115-671-14_252
Front Housing Section - TM-9-6115-671-14_253
FIGURE 4-8. FRONT HOUSING SECTION (SHEET 1 OF 2) - TM-9-6115-671-14_254
FIGURE 4-8. FRONT HOUSING SECTION (SHEET 2 OF 2) - TM-9-6115-671-14_255
Installation - TM-9-6115-671-14_256
Rear Housing Section - TM-9-6115-671-14_257
Inspection. - TM-9-6115-671-14_258
FIGURE 4-9. REAR HOUSING SECTION (SHEET 1 OF 2)
FIGURE 4-9. REAR HOUSING SECTION (SHEET 2 OF 2)
Installation - TM-9-6115-671-14_261
MAINTENANCE OF DCS CONTROL BOX ASSEMBLY - TM-9-6115-671-14_262
FIGURE 4-10. DCS CONTROL BOX
Panel Lights DS1 through DS3
Replacement. - TM-9-6115-671-14_265
FIGURE 4-11. DCS CONTROL BOX PANEL LIGHTS DS1 THROUGH DS3 AND NETWORK FAILURE LIGHT DS5
NETWORK FAILURE Light DS5
Replacement - TM-9-6115-671-14_268
FIGURE 4-12. TIME METER AND SWITCHES - TM-9-6115-671-14_269
Replacement. - TM-9-6115-671-14_270
ETHER START Switch S9
AC CIRCUIT INTERRUPT Switch S5.
FAULT RESET Switch S4.
MASTER CONTROL Switch S3.
Testing - TM-9-6115-671-14_275
FIGURE 4-13. DCS CONTROL PANEL COMPONENTS - TM-9-6115-671-14_276
VOLTAGE ADJUST Switch S18
FREQUENCY ADJUST Switch S19
Replacement. - TM-9-6115-671-14_279
Testing. - TM-9-6115-671-14_280
BATTLE SHORT Switch S7
EMERGENCY STOP Switch S17
GROUND FAULT CIRCUIT INTERRUPTER CB3
Replacement. - TM-9-6115-671-14_284
Computer Interface Module (CIM)
Removal. - TM-9-6115-671-14_286
Keypad Assembly KP
COMMUNICATION RECEPTACLE
PARALLELING RECEPTACLE J2.
CONVENIENCE RECEPTACLE J1
DCS Load Sharing Synchronizer A2.
Removal.
FIGURE 4-15. DCS CONTROL BOX BACK PANEL COMPONENTS
DCS Speed Control Unit A3
Removal. - TM-9-6115-671-14_295
Automatic Voltage Regulator A4.
Removal - TM-9-6115-671-14_297
Backplane Module A1
Replacement - TM-9-6115-671-14_299
I/O Interface Module A5
Replacement
DC CONTROL POWER Fuse
FREQUENCY SELECT Switch S12
FIGURE 4-16. DCS CONTROL BOX FLOOR COMPONENTS (SHEET 1 OF 2) - TM-9-6115-671-14_304
Replacement - TM-9-6115-671-14_305
Testing. - TM-9-6115-671-14_306
Diode CR1-CR10
FIGURE 4-17. DIODE IDENTIFICATION
Resistor R1.
Resistor R2
VOLTAGE SELECTION Switch S20
Replacement - TM-9-6115-671-14_312
Relays K15, K17, K19, K22, K23
Resistors R16 and R17
Resistor R6
DCS Control Box Wiring Harness
CIM Wiring Harness
Inspection. - TM-9-6115-671-14_318
DCS Control Panel Assembly
DCS Control Panel Frame
Repair - TM-9-6115-671-14_321
FIGURE 4-18. DCS CONTROL BOX PANELS
DCS Control Box Side Panels
DCS Control Box Bottom
DCS Data Plates
MAINTENANCE OF AIR INTAKE AND EXHAUST SYSTEM
Muffler and Exhaust Pipe
FIGURE 4-19. MUFFLER AND EXHAUST PIPE
Air Cleaner Assembly - TM-9-6115-671-14_329
FIGURE 4-20. AIR CLEANER ASSEMBLY - TM-9-6115-671-14_330
Restriction Indicator
Air Cleaner Filter Element
Removal - TM-9-6115-671-14_333
Service - TM-9-6115-671-14_334
FIGURE 4-21. CRANKCASE BREATHER FILTER ASSEMBLY
Removal - TM-9-6115-671-14_336
MAINTENANCE OF ENGINE COOLING SYSTEM
FIGURE 4-22. COOLING SYSTEM CONT. - TM-9-6115-671-14_338
FIGURE 4-22. COOLING SYSTEM CONT. - TM-9-6115-671-14_339
Filler Hose and Panel
Fan Guards - TM-9-6115-671-14_341
FIGURE 4-23. FAN GUARDS
Coolant Hoses, Upper
Inspection - TM-9-6115-671-14_344
Coolant Hose, Lower
Coolant Overflow and Drain Hoses
Radiator - TM-9-6115-671-14_347
Service - TM-9-6115-671-14_348
Fan.
FIGURE 4-24. FAN BELT - TM-9-6115-671-14_350
Fan Belt
Replacement - TM-9-6115-671-14_352
Coolant Recovery System
FIGURE 4-25. COOLANT RECOVERY SYSTEM
MAINTENANCE OF FUEL SYSTEM - TM-9-6115-671-14_355
FIGURE 4-26. FUEL TANK FILLER NECK AND LOW PRESSURE FUEL SYSTEM CONT. - TM-9-6115-671-14_356
FIGURE 4-26. FUEL TANK FILLER NECK AND LOW PRESSURE FUEL SYSTEM CONT. - TM-9-6115-671-14_357
Replacement - TM-9-6115-671-14_358
Fuel Tank Filler Neck - TM-9-6115-671-14_359
Fuel Drain Valve
Fuel Level Sender MT5
Fuel Pickup
Ether Cylinder Assembly
FIGURE 4-27. ETHER START SYSTEM - TM-9-6115-671-14_364
Ether Solenoid Valve L6
Ether Solenoid Valve L6 CONT.
Ether Solenoid Relay
MAINTENANCE OF OUTPUT BOX ASSEMBLY - TM-9-6115-671-14_368
Output Box Wiring Harness - TM-9-6115-671-14_369
FIGURE 4-28. OUTPUT BOX ASSEMBLY
Current Transformer CT1, CT2, CT3 - TM-9-6115-671-14_371
Droop Current Transformer CT5
AC Circuit Interrupter K1
Cranking Relay K2
Load Output Terminal Board TB2
Inspection - TM-9-6115-671-14_376
IGURE 4-29. LOAD OUTPUT TERMINAL BOARD ASSEMBLY
IGURE 4-29. LOAD OUTPUT TERMINAL BOARD ASSEMBLY CONT.
MAINTENANCE OF ENGINE ACCESSORIES - TM-9-6115-671-14_379
FIGURE 4-30. ENGINE SWITCHES AND SENDERS - TM-9-6115-671-14_380
Removal. - TM-9-6115-671-14_381
Coolant Temperature Sender MT6
Service - TM-9-6115-671-14_383
Magnetic Pickup MPU
Installation - TM-9-6115-671-14_385
DEAD CRANK Switch S10
Inspection. - TM-9-6115-671-14_387
FIGURE 4-31. BATTERY CURRENT TRANSDUCER\
MAINTENANCE OF LUBRICATION SYSTEM
Replacement - TM-9-6115-671-14_390
FIGURE 4-32. OIL DRAIN VALVE - TM-9-6115-671-14_391
SECTION VII. PREPARATION FOR SHIPMENT AND STORAGE - TM-9-6115-671-14_392
CIM CONFIGURATION SWITCH
CHAPTER 5 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS - TM-9-6115-671-14_394
SECTION III. TROUBLESHOOTING - TM-9-6115-671-14_395
TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING - TM-9-6115-671-14_396
TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED) - TM-9-6115-671-14_397
TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED) - TM-9-6115-671-14_398
TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED) - TM-9-6115-671-14_399
TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED) - TM-9-6115-671-14_400
TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED) - TM-9-6115-671-14_401
TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED) - TM-9-6115-671-14_402
TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED) - TM-9-6115-671-14_403
TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED) - TM-9-6115-671-14_404
TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED) - TM-9-6115-671-14_405
TABLE 5-1. DIRECT SUPPORT TROUBLESHOOTING (CONTINUED) - TM-9-6115-671-14_406
SECTION IV. DIRECT SUPPORT MAINTENANCE PROCEDURES - TM-9-6115-671-14_407
REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
REMOVAL AND INSTALLATION OF MAJOR COMPONENTS CONT.
Installation
FIGURE 5-1. ENGINE AND GENERATOR ASSEMBLY
FIGURE 5-1. ENGINE AND GENERATOR ASSEMBLY CONT.
ENGINE AND GENERATOR ASSEMBLY - TM-9-6115-671-14_413
Engine/Generator Disassembly
Removal - TM-9-6115-671-14_415
MAINTENANCE OF DCS CONTROL BOX ASSEMBLY - TM-9-6115-671-14_416
Resistor R1
MAINTENANCE OF COOLING SYSTEM
MAINTENANCE OF FUEL SYSTEM - TM-9-6115-671-14_419
Installation - TM-9-6115-671-14_420
FIGURE 5-2. FUEL TANK - TM-9-6115-671-14_421
MAINTENANCE OF OUTPUT BOX ASSEMBLY - TM-9-6115-671-14_422
Output Box Assembly
FIGURE 5-3. OUTPUT BOX ASSEMBLY
FIGURE 5-3. OUTPUT BOX ASSEMBLY CONT.
Output Box Wiring Harness - TM-9-6115-671-14_426
Output Box Wiring Harness CONT.
Current Transformer CT1, CT2, CT3 - TM-9-6115-671-14_428
Current Transformer CT1, CT2, CT3 CONT.
FIGURE 5-4. OUTPUT BOX COMPONENTS
FIGURE 5-5. TESTING CURRENT TRANSFORMER
Power Potential Transformer T1
Power Potential Transformer T1 CONT.
Output Box Panels - TM-9-6115-671-14_434
Output Box Panels CONT.
MAINTENANCE OF ENGINE ACCESSORIES - TM-9-6115-671-14_436
FIGURE 5-7. ELECTRIC ACTUATOR - TM-9-6115-671-14_437
Replacement - TM-9-6115-671-14_438
MAINTENANCE OF GENERATOR ASSEMBLY
Installation - TM-9-6115-671-14_440
FIGURE 5-8. GENERATOR ASSEMBLY REMOVAL - TM-9-6115-671-14_441
End Bell and Main Bearing - TM-9-6115-671-14_442
FIGURE 5-9. GENERATOR ASSEMBLY
FIGURE 5-10. END BELL REMOVAL
Rotating Rectifier - TM-9-6115-671-14_445
Replacement of Rotating Rectifier Diodes
FIGURE 5-11. RECTIFIER ASSEMBLY
Exciter Stator.
TABLE 5-2. GENERATOR RESISTANCE VALUES AT 25 C (77 F)
Exciter Rotor
Generator Rotor Assembly.
Generator Rotor Assembly. CONT.
FIGURE 5-12. ROTOR ASSEMBLY LIFTING DEVICE (TYPICAL)
MAINTENANCE OF SKID BASE
Skid Base - TM-9-6115-671-14_455
FIGURE 5-13. SKID BASE - TM-9-6115-671-14_456
CHAPTER 6 GENERAL SUPPORT MAINTENANCE INSTRUCTIONS - TM-9-6115-671-14_458
APPENDIX A REFERENCES - TM-9-6115-671-14_460
APPENDIX B MAINTENANCE ALLOCATION CHART (MAC) - TM-9-6115-671-14_462
EXPLANATION OF COLUMNS IN THE MAC, SECTION II
EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS, SECTION III - TM-9-6115-671-14_464
SECTION II. MAINTANANCE ALLOCATION CHART FOR MEP-805B AND 815B (continued) - TM-9-6115-671-14_465
SECTION II. MAINTANANCE ALLOCATION CHART FOR MEP-805B AND 815B (continued) - TM-9-6115-671-14_466
SECTION II. MAINTANANCE ALLOCATION CHART FOR MEP-805B AND 815B (continued) - TM-9-6115-671-14_467
SECTION II. MAINTANANCE ALLOCATION CHART FOR MEP-805B AND 815B (continued) - TM-9-6115-671-14_468
SECTION II. MAINTANANCE ALLOCATION CHART FOR MEP-805B AND 815B (continued) - TM-9-6115-671-14_469
SECTION II. MAINTANANCE ALLOCATION CHART FOR MEP-805B AND 815B (continued) - TM-9-6115-671-14_470
SECTION II. MAINTANANCE ALLOCATION CHART FOR MEP-805B AND 815B (continued) - TM-9-6115-671-14_471
SECTION II. MAINTANANCE ALLOCATION CHART FOR MEP-805B AND 815B (continued) - TM-9-6115-671-14_472
SECTION II. MAINTANANCE ALLOCATION CHART FOR MEP-805B AND 815B (continued) - TM-9-6115-671-14_473
SECTION III. TOOLS AND TEST EQUIPMENT FOR MEP-805B AND MEP-815B
APPENDIX C COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LIST - TM-9-6115-671-14_476
SECTION III. BASIC ISSUE ITEMS - TM-9-6115-671-14_477
Warranty Technical Bulletin
Grounding Rod
CIM Software
APPENDIX D ADDITIONAL AUTHORIZATION LIST (AAL) - TM-9-6115-671-14_481
APPENDIX E EXPENDABLE AND DURABLE ITEMS LIST - TM-9-6115-671-14_483
SECTION II. EXPENDABLE AND DURABLE ITEMS LIST (continued) - TM-9-6115-671-14_484
APPENDIX F OPERATORS LUBRICATION INSTRUCTIONS
APPENDIX G ILLUSTRATED LIST OF MANUFACTURED ITEMS - TM-9-6115-671-14_487
Figure G-1. Cable Assembly, AC Power (P/Ns 88-22126-1 through 88-22126-7)
Figure G-2. Cable Assembly, Battery (P/N 88-22178)
Figure G-3. Cable Assembly, Battery (P/N 88-22127)
Figure G-4. Cable Assembly, Battery (P/N 88-22181)
Figure G-5. Cable Assembly, Battery (P/N 88-22179)
Figure G-6. Cable Assembly, Battery (P/N 88-22207)
Figure G-7. Holder, Control Panel (P/N 88-22120)
Figure G-8. Hose Assembly (P/N 88-20191-6)
Figure G-9. Insulation, Panel, Top (P/N 88-22582)
Figure G-10. Insulation, Baffle (P/N 88-22592)
Figure G-11. Insulation, Panel, Top (P/N 88-22593)
Figure G-12. Insulation, Top, Center (P/N 88-22584)
Figure G-13. Insulation, Top, Rear (P/N 88-22585)
Figure G-14. Insulation, Front Housing (P/N 88-22591)
Figure G-15. Insulation, Top, Front (P/N 88-22586)
Figure G-16. Insulation, Top, Center (P/N 88-22587)
Figure G-17. Insulation, Top, Center (P/N 88-22588)
Figure G-18. Insulation, Top, Front (P/N 88-22583)
Figure G-19. Pump Assembly, Fuel (P/N 88-22546)
Figure G-20. Solenoid Assembly (P/N 88-22553)
Figure G-21. Switch Assembly (P/N 88-22548)
Figure G-22. Wire, Varistor (P/Ns 88-20305-1 through 88-20305-3 and 88-20305-5)
TABLE G-1. METRIC CONVERSION
TABLE H-1. TORQUE LIMITS FOR DRY FASTENERS - TM-9-6115-671-14_511
TABLE H-1. TORQUE LIMITS FOR DRY FASTENERS (CONTINUED) - TM-9-6115-671-14_512
TABLE H-3. TORQUE LIMITS FOR DRY FASTENERS (METRIC) - TM-9-6115-671-14_513
APPENDIX I MANDATORY REPLACEMENT PARTS - TM-9-6115-671-14_515
SECTION II. MANDATORY REPLACEMENT PARTS
SCHEMATIC DIAGRAM - TM-9-6115-671-14_538
WIRING DIAGRAM - TM-9-6115-671-14_539
WIRING DIAGRAM - TM-9-6115-671-14_540
WIRE HARNESS - TM-9-6115-671-14_541

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