TM-9-6115-729-24 Generator Set Skid Mounted Tactical Quiet 100 kw 50/60 Hz MEP-807A Manual

Chapter 1. GENERAL INFORMATION, EQUIPMENT DESCRIPTION AND THEORY OF OPERATION - TM-9-6115-729-240031
WORK PACKAGE INDEX - TM-9-6115-729-240033
GENERAL INFORMATION - TM-9-6115-729-240035
MAINTENANCE FORMS, RECORDS, AND REPORTS
CORROSION PREVENTION AND CONTROL (CPC) - TM-9-6115-729-240037
MANUFACTURER WARRANTY INFORMATION
Table 1. Manufacturer's Warranties for 100kW Generator Set
NOMENCLATURE CROSS REFERENCE LIST - TM-9-6115-729-240040
LIST OF ABBREVIATIONS AND ACRONYMS - TM-9-6115-729-240041
LIST OF ABBREVIATIONS AND ACRONYMS - Continued - TM-9-6115-729-240042
LIST OF ABBREVIATIONS AND ACRONYMS - Continued - TM-9-6115-729-240043
SAFETY, CARE, AND HANDLING INFORMATION - TM-9-6115-729-240044
EQUIPMENT DESCRIPTION AND DATA - TM-9-6115-729-240045
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - TM-9-6115-729-240046
Figure 1. 100 kW Tactical Quiet Generator Location of Components (Sheet 2 of 6).
Figure 1. 100 kW Tactical Quiet Generator Location of Components (Sheet 3 of 6).
Figure 1. 100 kW Tactical Quiet Generator Location of Components (Sheet 4 of 6).
Figure 1. 100 kW Tactical Quiet Generator Location of Components (Sheet 5 of 6).
Figure 1. 100 kW Tactical Quiet Generator Location of Components (Sheet 6 of 6).
ALTERNATOR - TM-9-6115-729-240052
ELECTRONIC MODULAR CONTROL PANEL - TM-9-6115-729-240053
SKID BASE - TM-9-6115-729-240054
EQUIPMENT DATA - TM-9-6115-729-240055
Table 1. 100 kW TQG Equipment Data - TM-9-6115-729-240056
Table 1. 100 kW TQG Equipment Data - Continued.
THEORY OF OPERATION - TM-9-6115-729-240059
ENGINE SENSORS - TM-9-6115-729-240060
ENGINE STARTING SYSTEM - TM-9-6115-729-240061
FUEL SYSTEM - TM-9-6115-729-240062
HYDRAULIC ELECTRONIC UNIT INJECTOR (HEUI) FUEL SYSTEM
Figure 3. Hydraulic Electronic Unit Injector System.
Hydraulic Pump
Injection Actuation System
LUBRICATION SYSTEM - TM-9-6115-729-240067
Figure 4. Lubrication System.
ENGINE COOLING SYSTEM - TM-9-6115-729-240069
AIR INLET AND EXHAUST SYSTEM - TM-9-6115-729-240070
Turbocharger
AC POWER OUTPUT - TM-9-6115-729-240072
DC POWER DISTRIBUTION - TM-9-6115-729-240073
Batteries - TM-9-6115-729-240074
Field Flash Relay
Coolant Low Sensor Interface
BATTLE SHORT Switch (BSS) Input to ECM - TM-9-6115-729-240077
AC POWER DISTRIBUTION - TM-9-6115-729-240078
Digital Voltage Regulator (DVR) A3 - TM-9-6115-729-240079
GSC Voltage and Current Monitoring
GENERATOR SET CONTROL (GSC) - TM-9-6115-729-240081
GSC Outputs - TM-9-6115-729-240082
Table 1. GSC Display Relay Identification. - TM-9-6115-729-240083
DIGITAL VOLTAGE REGULATOR (DVR A3) MODULE OPERATION
Voltage and Current Monitoring Circuits and Field Drive Circuits
Loading and Stopping Profile - TM-9-6115-729-240086
LOAD SHARING MODULE (LSM A4) INTERNAL OPERATION - TM-9-6115-729-240087
Speed Trim Summer - TM-9-6115-729-240088
GENERATOR - TM-9-6115-729-240089
WINTERIZATION KIT - TM-9-6115-729-240090
COMMON TOOLS AND TEST EQUIPMENT - TM-9-6115-729-240091
Chapter 2. FIELD LEVEL TROUBLESHOOTING PROCEDURES - TM-9-6115-729-240093
WORK PACKAGE INDEX - TM-9-6115-729-240095
INTRODUCTION - TM-9-6115-729-240097
TQG TROUBLESHOOTING - TM-9-6115-729-240098
GSC ALARM INDICATORS AND FAULT CODE TROUBLESHOOTING - TM-9-6115-729-240099
DIAGNOSTIC EVENTS AND EVENT CODES - TM-9-6115-729-240100
GSC FAULT CODES - TM-9-6115-729-240101
VIEWING FAULT LOG OP1 - TM-9-6115-729-240102
FAULT LOG CLEARING OP4 - TM-9-6115-729-240103
TRANSIENT CODES DURING TROUBLESHOOTING - TM-9-6115-729-240104
DVR FAULT CODE TROUBLESHOOTING - TM-9-6115-729-240105
TROUBLESHOOTING INDEX - TM-9-6115-729-240107
GSC FAULT CODE - TM-9-6115-729-240108
GSC FAULT CODE (cont) - TM-9-6115-729-240109
GSC FAULT CODE (cont) - TM-9-6115-729-240110
DVR FAULT CODE - TM-9-6115-729-240111
ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - TM-9-6115-729-240112
GSC ALARM INDICATORS AND FAULT CODE TROUBLESHOOTING PROCEDURES - TM-9-6115-729-240113
TROUBLESHOOTING USING DEDICATED SHUTDOWN INDICATORS - TM-9-6115-729-240114
OVERCRANK light - TM-9-6115-729-240115
FAULT ALARM light flashing yellow. - TM-9-6115-729-240116
Undiagnosed shutdown. - TM-9-6115-729-240117
SP FAULT CODE TROUBLESHOOTING PROCEDURES - TM-9-6115-729-240119
TROUBLESHOOTING USING SP FAULT CODES
Bus Voltage Fault (Paralleling Only).
AL FAULT CODE TROUBLESHOOTING PROCEDURES - TM-9-6115-729-240123
TROUBLESHOOTING USING AL FAULT CODES
Low Coolant Temperature - TM-9-6115-729-240125
Low Engine Oil Pressure
Fault Detected by Engine ECM - TM-9-6115-729-240127
Generator Over Voltage - TM-9-6115-729-240128
Generator Over Frequency - TM-9-6115-729-240129
Generator Reverse Power - TM-9-6115-729-240130
Generator Total Over Current
Phase A No Voltage Input at GSC input (P7-10) - TM-9-6115-729-240132
Incorrect Phase Sequence - Paralleling fault code - TM-9-6115-729-240133
Improper Generator or Bus Voltage - Paralleling fault code - TM-9-6115-729-240134
CORRECTIVE ACTION - Continued - TM-9-6115-729-240135
Synchronizer Time-out - Paralleling fault code - TM-9-6115-729-240136
GSC FAULT CODE TROUBLESHOOTING PROCEDURES - TM-9-6115-729-240137
TROUBLESHOOTING USING GSC FAULT CODES - TM-9-6115-729-240138
TROUBLESHOOTING USING GSC FAULT CODES - Continued - TM-9-6115-729-240139
TROUBLESHOOTING USING GSC FAULT CODES - Continued - TM-9-6115-729-240140
Injection actuator pressure valve.
Shutdown Overridden.
Throttle Position Signal. - TM-9-6115-729-240143
Fuel pressure sensor. - TM-9-6115-729-240144
Voltage Above Normal.
CORRECTIVE ACTION - Continued - TM-9-6115-729-240146
High Fuel pressure Warning. - TM-9-6115-729-240147
Oil pressure sensor. - TM-9-6115-729-240148
Oil pressure sensor. - TM-9-6115-729-240149
CORRECTIVE ACTION - Continued - TM-9-6115-729-240150
Engine low coolant sensor.
Disconnect the defective sensor connector.
Injection actuation pressure system. - TM-9-6115-729-240153
Injection actuation pressure system. - TM-9-6115-729-240154
Electrical system voltage. - TM-9-6115-729-240155
Fuel filter change required.
CORRECTIVE ACTION - TM-9-6115-729-240157
Engine oil temperature sensor.
CORRECTIVE ACTION - Continued - TM-9-6115-729-240159
Loss of engine speed signal. - TM-9-6115-729-240160
Loss of engine timing signal.
CAT data link. - TM-9-6115-729-240162
ECM self test. - TM-9-6115-729-240163
CORRECTIVE ACTION - TM-9-6115-729-240164
CORRECTIVE ACTION - Continued - TM-9-6115-729-240165
E-Stop shutdown. - TM-9-6115-729-240166
GSC electronic control. - TM-9-6115-729-240167
GSC 8V sensor power supply. - TM-9-6115-729-240168
Atmospheric pressure sensor. - TM-9-6115-729-240169
Cool Down circuit (P7-36). - TM-9-6115-729-240170
ENGINE CONTROL switch. - TM-9-6115-729-240171
Secondary (bottom) engine timing sensor.
Low engine oil pressure warning (Active & Logged). - TM-9-6115-729-240173
High engine coolant temperature warning (Active & Logged). - TM-9-6115-729-240174
Overspeed warning (active and logged). - TM-9-6115-729-240175
Fuel filter restriction warning (active and logged). - TM-9-6115-729-240176
GSC engine governor relay (EGR) output. - TM-9-6115-729-240177
GSC generator fault relay (GFR) output. - TM-9-6115-729-240178
GSC crank termination relay (CTR) output. - TM-9-6115-729-240179
GSC run relay (RR) output. - TM-9-6115-729-240180
GSC fuel control relay (FCR) output. - TM-9-6115-729-240181
GSC programmable spare relays (PSR1 and PSR2) output.
FMI 12 - Failed Component. - TM-9-6115-729-240183
Unexpected shutdown.
Engine electronic control module. - TM-9-6115-729-240185
Intake air heater.
Customer communication module (CCM) data link. - TM-9-6115-729-240187
Speed adjust 1 output P7-27 (+) and P7-28 (-).
CORRECTIVE ACTION - Continued - TM-9-6115-729-240189
K1 sense input (P7-25). - TM-9-6115-729-240190
Dead bus sense input (P7-29). - TM-9-6115-729-240191
AC transformer box (ATB) sensor. - TM-9-6115-729-240192
Bus transformer box (BTB) sensor. - TM-9-6115-729-240193
Turbocharger air inlet pressure sensor. - TM-9-6115-729-240194
Turbocharger air inlet pressure sensor. - TM-9-6115-729-240195
DVR FAULT CODE TROUBLESHOOTING PROCEDURES - TM-9-6115-729-240197
TROUBLESHOOTING USING DVR FAULT CODES
Internal Watchdog Failure.
Reverse VAR (Alarm Fault) - TM-9-6115-729-240200
Undervoltage
Overvoltage
Overexcitation - TM-9-6115-729-240203
Reverse VAR (Shutdown Fault) - TM-9-6115-729-240204
Instantaneous Trip - TM-9-6115-729-240205
Loss of Sensing
CORRECTIVE ACTION - TM-9-6115-729-240207
DVR Memory Failure (Severe Fault).
FAILURES WITHOUT A FAULT CODE TROUBLESHOOTING PROCEDURES - TM-9-6115-729-240209
TROUBLESHOOTING FAILURES WITHOUT FAULT CODES
Figure 2. SMMS Relay Location.
CORRECTIVE ACTION - TM-9-6115-729-240212
Setpoint Programming Error. - TM-9-6115-729-240213
Red Fault Shutdown Indicator Flashing.
CORRECTIVE ACTION - TM-9-6115-729-240215
GSC Malfunction.
Setpoint Incorrect. - TM-9-6115-729-240217
Setpoint Incorrect. - TM-9-6115-729-240218
DVR malfunction.
CORRECTIVE ACTION - TM-9-6115-729-240220
CORRECTIVE ACTION (cont)
Generator Produces Low Voltage When Load is Applied. - TM-9-6115-729-240222
Generator Produces Fluctuating Voltage. - TM-9-6115-729-240223
Generator Produces High Voltage. - TM-9-6115-729-240224
Improper Load. - TM-9-6115-729-240225
Undesirable Speed Decrease With Load Increase.
Load Sharing Module (LSM) A4 Erratic Operation. - TM-9-6115-729-240227
Engine Not Properly Sharing Load With Other Generator Sets (Parallel Operation).
Engine Will Not Crank (Starter Pinion Engages and Engine Does Not Turn Over).
CORRECTIVE ACTION - TM-9-6115-729-240230
Engine Cranks But Will Not Start. - TM-9-6115-729-240231
Inlet Air Heater Malfunction.
Engine Misfires, Runs Rough, or is Unstable. - TM-9-6115-729-240233
Electrical Connections Faulty.
Low Power/Poor or No Response to Throttle. - TM-9-6115-729-240235
ECM May Not Be Leaving Cold Mode Operation. - TM-9-6115-729-240236
Intermittent Engine Shut Downs. - TM-9-6115-729-240237
Excessive Black Smoke.
Excessive White Smoke. - TM-9-6115-729-240239
Can Not Reach Operating Engine RPM. - TM-9-6115-729-240240
Insufficient Inlet Air.
Engine Temperature.
Poor Acceleration or Response. - TM-9-6115-729-240243
Engine Temperature Low.
Poor Fuel Consumption. - TM-9-6115-729-240245
Engine Stalls at Low RPM. - TM-9-6115-729-240246
Auxiliary Fuel Pump Does Not Operate. - TM-9-6115-729-240247
Fuel Level Switch Assembly.
Engine Runs Out of Fuel With No LOW FUEL LEVEL Alarm. - TM-9-6115-729-240249
Alternator Does Not Charge Batteries. - TM-9-6115-729-240250
Coolant in Engine Oil. - TM-9-6115-729-240251
Coolant Temperature Too High. - TM-9-6115-729-240252
Air in Coolant. - TM-9-6115-729-240253
Thermostat Malfunction. - TM-9-6115-729-240254
ECM Will Not Communicate With Other Systems or Display Modules. - TM-9-6115-729-240255
Cat Data Link Circuitry Short Circuit.
Engine Oil in Coolant. - TM-9-6115-729-240257
Engine Oil in Exhaust System. - TM-9-6115-729-240258
Engine Oil Temperature Too High. - TM-9-6115-729-240259
Engine Vibration. - TM-9-6115-729-240260
Excessive Engine Oil Consumption. - TM-9-6115-729-240261
Excessive Valve Lash. - TM-9-6115-729-240262
Exhaust Temperature is Too High.
Fuel in Engine Oil. - TM-9-6115-729-240264
Intermittent Low Power or Power Cutout. - TM-9-6115-729-240265
Low Engine Oil Pressure. - TM-9-6115-729-240266
Mechanical Noise (Knock) in Engine. - TM-9-6115-729-240267
Noise Coming From Cylinder. - TM-9-6115-729-240268
ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING SOFTWARE INSTALLATION - TM-9-6115-729-240269
TROUBLESHOOTING USING MAINTENANCE SUPPORT DEVICE (MSD) AND ELECTRONIC TECHNICIAN (ET) TOOL - TM-9-6115-729-240270
LOADING ELECTRONIC TECHNICIAN (ET) SOFTWARE - TM-9-6115-729-240271
USING ELECTRONIC TECHNICIAN (ET) SOFTWARE - TM-9-6115-729-240272
Figure 2. Caterpillar ET Opening Screen. - TM-9-6115-729-240273
Table 1. Caterpillar ET Tool Navigation Icons. - TM-9-6115-729-240274
USING ELECTRONIC TECHNICIAN (ET) SOFTWARE - Continued
Figure 3. Cat ET Diagnostic Tests. - TM-9-6115-729-240276
ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING PROCEDURES
ELECTRONIC TECHNICIAN (FIELD) LEVEL TROUBLESHOOTING - TM-9-6115-729-240278
CORRECTIVE ACTION - TM-9-6115-729-240279
Figure 2. Air Inlet Heater Relay.
CORRECTIVE ACTION - Continued - TM-9-6115-729-240281
CORRECTIVE ACTION - Continued - TM-9-6115-729-240282
CORRECTIVE ACTION - Continued - TM-9-6115-729-240283
CORRECTIVE ACTION - Continued - TM-9-6115-729-240284
CORRECTIVE ACTION - Continued - TM-9-6115-729-240285
CORRECTIVE ACTION - Continued - TM-9-6115-729-240286
Electrical Connectors Wiggle Test.
Electrical Power Supply Circuit Test.
Figure 3. 24 Vdc Electrical Circuits.
ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued - TM-9-6115-729-240290
Table 1. ECM Supply Voltage Test Points. - TM-9-6115-729-240291
Table 2. Battery Voltage Input to ECM Test Points.
Engine Timing Sensor Circuit Test.
CORRECTIVE ACTION - Continued - TM-9-6115-729-240294
Figure 5. Timing Sensor Troubleshooting.
CORRECTIVE ACTION - Continued - TM-9-6115-729-240296
Injection Actuation Pressure Test.
Table 3. Injection Actuation Pressure Test Results.
Perform the Injection Actuation Pressure Test
Table 4. Injection Actuation Pressure Output Results.
Table 5. Injection Actuation Pressure Test at Low Idle and Operating RPM.
Injection Actuation Pressure signal erratic, intermittent, or incorrect.
Injection Actuation Pressure signal incorrect
CORRECTIVE ACTION - Continued - TM-9-6115-729-240304
CORRECTIVE ACTION - Continued - TM-9-6115-729-240305
System Operation Description - TM-9-6115-729-240306
Perform the Injection Actuation Pressure Test using the Cat ET.
Injection Actuation Pressure Sensor Test.
CORRECTIVE ACTION - Continued - TM-9-6115-729-240309
Table 6. Cat ET Injection Actuation Pressure vs. Pressure Gauge Readings.
Injector Solenoid Circuit Test. - TM-9-6115-729-240311
Injector Solenoid Test
Run the Cylinder Cutout Test.
Use the Injector Solenoid Test to test the injector solenoids.
CORRECTIVE ACTION - Continued - TM-9-6115-729-240315
CORRECTIVE ACTION - Continued - TM-9-6115-729-240316
Table 7. Injector Harness Injector Solenoid Terminals.
CORRECTIVE ACTION - Continued - TM-9-6115-729-240318
CORRECTIVE ACTION - Continued - TM-9-6115-729-240319
Speed Control Test. - TM-9-6115-729-240320
Throttle Position Signal
Table 8. Speed Control Test Voltage Measurement Points.
CORRECTIVE ACTION - Continued - TM-9-6115-729-240323
Electronic Service Tool (Cat ET) will not communicate with ECM. - TM-9-6115-729-240324
CORRECTIVE ACTION - Continued - TM-9-6115-729-240325
Engine Timing Sensor Calibrate. - TM-9-6115-729-240326
Figure 10. Timing Calibration Plugs.
CORRECTIVE ACTION - Continued - TM-9-6115-729-240328
Flash Programming - TM-9-6115-729-240329
Engine Fuel Pressure Reading. - TM-9-6115-729-240330
Engine Status.
Copy Configuration/ECM Replacement.
CORRECTIVE ACTION - Continued - TM-9-6115-729-240333
Chapter 3. UNIT (FIELD) LEVEL MAINTENANCE INSTRUCTIONS - TM-9-6115-729-240335
WORK PACKAGE INDEX - TM-9-6115-729-240337
WORK PACKAGE INDEX (cont) - TM-9-6115-729-240338
SERVICE UPON RECEIPT - TM-9-6115-729-240339
PRELIMINARY CHECKS AND ADJUSTMENT OF EQUIPMENT - TM-9-6115-729-240340
OUTPUT VOLTAGE SETTING - TM-9-6115-729-240341
PMCS INTRODUCTION - TM-9-6115-729-240343
FLUID LEAKAGE - TM-9-6115-729-240344
INSPECTION - TM-9-6115-729-240345
PMCS, INCLUDING LUBRICATION INSTRUCTIONS - TM-9-6115-729-240347
Table 1. Preventive Maintenance Checks and Services - TM-9-6115-729-240348
Table 1. Preventive Maintenance Checks and Services - Continued. - TM-9-6115-729-240349
Table 1. Preventive Maintenance Checks and Services - Continued. - TM-9-6115-729-240350
Table 1. Preventive Maintenance Checks and Services - Continued. - TM-9-6115-729-240351
Table 2. PMCS Mandatory Replacement Parts List. - TM-9-6115-729-240352
LUBRICATION INSTRUCTIONS - TM-9-6115-729-240353
Table 3. Engine Oil. - TM-9-6115-729-240354
Table 6. Lubrication Requirements. - TM-9-6115-729-240355
GENERAL MAINTENANCE INSTRUCTIONS - TM-9-6115-729-240357
CLEANING INSTRUCTIONS - TM-9-6115-729-240358
INSPECTION INSTRUCTIONS
RIGHT BATTERY ACCESS DOOR ASSEMBLY MAINTENANCE - TM-9-6115-729-240361
Figure 1. Right Battery Access Door Assembly. - TM-9-6115-729-240362
DISASSEMBLY - TM-9-6115-729-240363
LEFT BATTERY ACCESS DOOR ASSEMBLY MAINTENANCE - TM-9-6115-729-240365
Figure 1. Left Battery Access Door Assembly. - TM-9-6115-729-240366
ASSEMBLY - TM-9-6115-729-240367
CONTROL BOX DOOR ASSEMBLY MAINTENANCE - TM-9-6115-729-240369
ASSEMBLY - TM-9-6115-729-240370
Figure 1. Control Box Door Assembly. - TM-9-6115-729-240371
LEFT FRONT DOOR ASSEMBLY (LATCH) MAINTENANCE - TM-9-6115-729-240373
Figure 1. Left Front Door Assembly (Latch). - TM-9-6115-729-240374
DISASSEMBLY - TM-9-6115-729-240375
INSTALLATION - TM-9-6115-729-240376
LEFT REAR DOOR ASSEMBLY MAINTENANCE - TM-9-6115-729-240377
Figure 1. Left Rear Door Assembly.
INSTALLATION - TM-9-6115-729-240379
LEFT REAR DOOR ASSEMBLY (LATCH) MAINTENANCE - TM-9-6115-729-240381
Figure 1. Left Rear Door Assembly (Latch).
ASSEMBLY - TM-9-6115-729-240383
LOAD BOARD DOOR ASSEMBLY MAINTENANCE - TM-9-6115-729-240385
Figure 1. Load Board Door Assembly. - TM-9-6115-729-240386
DISASSEMBLY - TM-9-6115-729-240387
RIGHT FRONT DOOR ASSEMBLY (LATCH) MAINTENANCE - TM-9-6115-729-240389
Figure 1. Right Front Door Assembly (Latch). - TM-9-6115-729-240390
DISASSEMBLY - TM-9-6115-729-240391
RIGHT REAR DOOR ASSEMBLY MAINTENANCE - TM-9-6115-729-240393
Figure 1. Right Rear Door Assembly. - TM-9-6115-729-240394
ASSEMBLY - TM-9-6115-729-240395
RIGHT REAR DOOR ASSEMBLY (LATCH) MAINTENANCE - TM-9-6115-729-240397
Figure 1. Right Rear Door Assembly (Latch). - TM-9-6115-729-240398
DISASSEMBLY - TM-9-6115-729-240399
ACCESS COVERS MAINTENANCE - TM-9-6115-729-240401
INSTALLATION - TM-9-6115-729-240402
Figure 1. Access Covers. - TM-9-6115-729-240403
FRONT ROOF SECTION HOUSING ASSEMBLY MAINTENANCE - TM-9-6115-729-240405
REMOVAL - TM-9-6115-729-240406
Figure 1. Front Roof Section Housing Assembly (Sheet 1 of 2). - TM-9-6115-729-240407
Figure 1. Front Roof Section Housing Assembly (Sheet 2 of 2). - TM-9-6115-729-240408
ASSEMBLY - TM-9-6115-729-240409
REAR ROOF SECTION HOUSING ASSEMBLY MAINTENANCE - TM-9-6115-729-240411
Figure 1. Rear Roof Section Housing Assembly (Sheet 1 of 2).
Figure 1. Rear Roof Section Housing Assembly (Sheet 2 of 2).
REMOVAL - TM-9-6115-729-240414
INSTALLATION - TM-9-6115-729-240415
ENGINE GENERATOR COMPARTMENT CEILING ASSEMBLY MAINTENANCE - TM-9-6115-729-240417
REMOVAL - TM-9-6115-729-240418
Figure 1. Engine Generator Compartment Ceiling Assembly. - TM-9-6115-729-240419
INSTALLATION - TM-9-6115-729-240420
GENERATOR ACCESS COVER ASSEMBLY MAINTENANCE - TM-9-6115-729-240421
ASSEMBLY - TM-9-6115-729-240422
Figure 1. Generator Access Cover Assembly. - TM-9-6115-729-240423
FRONT SECTION HOUSING ASSEMBLY MAINTENANCE - TM-9-6115-729-240425
Figure 1. Front Section Housing Assembly (Sheet 1 of 2). - TM-9-6115-729-240426
Figure 1. Front Section Housing Assembly (Sheet 2 of 2). - TM-9-6115-729-240427
DISASSEMBLY - TM-9-6115-729-240428
INSTALLATION - TM-9-6115-729-240429
REAR SECTION HOUSING ASSEMBLY MAINTENANCE - TM-9-6115-729-240431
Figure 1. Rear Section Housing Assembly. - TM-9-6115-729-240432
DISASSEMBLY - TM-9-6115-729-240433
LEFT CENTER PANEL ASSEMBLY MAINTENANCE - TM-9-6115-729-240435
Figure 1. Left Center Panel Assembly. - TM-9-6115-729-240436
DISASSEMBLY - TM-9-6115-729-240437
RIGHT CENTER PANEL ASSEMBLY MAINTENANCE - TM-9-6115-729-240439
Figure 1. Right Center Panel Assembly. - TM-9-6115-729-240440
ASSEMBLY - TM-9-6115-729-240441
RIGHT REAR PANEL ASSEMBLY MAINTENANCE - TM-9-6115-729-240443
ASSEMBLY - TM-9-6115-729-240444
Figure 1. Right Rear Panel Assembly. - TM-9-6115-729-240445
LEFT REAR PANEL ASSEMBLY MAINTENANCE - TM-9-6115-729-240447
Figure 1. Left Rear Panel Assembly. - TM-9-6115-729-240448
INSTALLATION - TM-9-6115-729-240449
DOOR SUPPORT ASSEMBLY MAINTENANCE - TM-9-6115-729-240451
Figure 1. Door Support Assembly. - TM-9-6115-729-240452
INSTALLATION - TM-9-6115-729-240453
CONTROL BOX PANEL ASSEMBLY MAINTENANCE - TM-9-6115-729-240455
Table 1. WP 0040 Guide.
Figure 1. Control Box Panel Assembly (Sheet 1 of 4). - TM-9-6115-729-240457
Figure 1. Control Box Panel Assembly (Sheet 2 of 4). - TM-9-6115-729-240458
Figure 1. Control Box Panel Assembly (Sheet 3 of 4). - TM-9-6115-729-240459
Figure 1. Control Box Panel Assembly (Sheet 4 of 4). - TM-9-6115-729-240460
DISASSEMBLY - TM-9-6115-729-240461
VOLTAGE Adjust Potentiometer Test - TM-9-6115-729-240462
FREQUENCY Adjust Potentiometer Test - TM-9-6115-729-240463
ASSEMBLY - TM-9-6115-729-240464
INSTALLATION - TM-9-6115-729-240465
CONTROL BOX ASSEMBLY MAINTENANCE - TM-9-6115-729-240467
Table 1. WP 0041 Guide. - TM-9-6115-729-240468
Figure 1. Control Box. - TM-9-6115-729-240469
REMOVAL - TM-9-6115-729-240470
Figure 2. Control Box Assembly (Sheet 1 of 5). - TM-9-6115-729-240471
Figure 2. Control Box Assembly Maintenance (Sheet 2 of 5).
Figure 2. Control Box Assembly Maintenance (Sheet 3 of 5).
Figure 2. Control Box Assembly Maintenance (Sheet 4 of 5).
Figure 2. Control Box Assembly Maintenance (Sheet 5 of 5).
DISASSEMBLY - TM-9-6115-729-240476
ASSEMBLY - TM-9-6115-729-240477
ASSEMBLY - Continued - TM-9-6115-729-240478
LSAM A4 LOAD GAIN ADJUSTMENT
INSTALLATION - TM-9-6115-729-240480
RESISTOR ASSEMBLY A7 MAINTENANCE - TM-9-6115-729-240481
Figure 1. Resistor Assembly A7. - TM-9-6115-729-240482
TEST - TM-9-6115-729-240483
CONTROL BOX HARNESS ASSEMBLY MAINTENANCE - TM-9-6115-729-240485
REPAIR OR REPLACEMENT - TM-9-6115-729-240486
RECONNECTION TERMINAL BOARD ASSEMBLY MAINTENANCE - TM-9-6115-729-240487
Figure 1. Reconnection Terminal Board Assembly. - TM-9-6115-729-240488
DISASSEMBLY - TM-9-6115-729-240489
LOAD TERMINAL BOARD ASSEMBLY MAINTENANCE - TM-9-6115-729-240491
Figure 1. Load Terminal Board Assembly.
DISASSEMBLY - TM-9-6115-729-240493
BATTERY CABLE ASSEMBLIES MAINTENANCE - TM-9-6115-729-240495
REMOVAL - TM-9-6115-729-240496
Figure 1. Battery Cable Assemblies (Sheet 1 of 2). - TM-9-6115-729-240497
Figure 1. Battery Cable Assemblies (Sheet 2 of 2). - TM-9-6115-729-240498
INSTALLATION - TM-9-6115-729-240499
POWER CABLE ASSEMBLIES MAINTENANCE - TM-9-6115-729-240501
Figure 1. Power Cable Assemblies. - TM-9-6115-729-240502
REMOVAL - TM-9-6115-729-240503
INSTALLATION - TM-9-6115-729-240504
MAIN LOAD CONTACTOR K1 MAINTENANCE
Figure 1. Main Load Contactor K1.
INSTALLATION - TM-9-6115-729-240507
BATTERIES MAINTENANCE - TM-9-6115-729-240509
REMOVAL - TM-9-6115-729-240510
TESTING AND CHARGING
INSTALLATION - TM-9-6115-729-240512
BATTERY DISCONNECT SWITCH MAINTENANCE - TM-9-6115-729-240513
Figure 1. Battery Disconnect Switch. - TM-9-6115-729-240514
INSTALLATION - TM-9-6115-729-240515
CURRENT TRANSFORMER MAINTENANCE
REMOVAL - TM-9-6115-729-240518
Figure 1. Current Transformer (Sheet 1 of 2).
Figure 1. Current Transformer (Sheet 2 of 2).
INSTALLATION - TM-9-6115-729-240521
POTENTIAL TRANSFORMER MAINTENANCE - TM-9-6115-729-240523
REMOVAL - TM-9-6115-729-240524
Figure 1. Potential Transformer. - TM-9-6115-729-240525
SLAVE RECEPTACLE MAINTENANCE - TM-9-6115-729-240527
REMOVAL - TM-9-6115-729-240528
Figure 1. Slave Receptacle. - TM-9-6115-729-240529
ELECTRICAL INSTALLATION MAINTENANCE - TM-9-6115-729-240531
Table 1. WP 0054 Guide.
Figure 1. Electrical Installation (Sheet 1 of 3).
Figure 1. Electrical Installation (Sheet 2 of 3).
Figure 1. Electrical Installation (Sheet 3 of 3).
REMOVAL - TM-9-6115-729-240536
INSTALLATION - TM-9-6115-729-240537
INSTALLATION - Continued - TM-9-6115-729-240538
FUEL LEVEL SWITCH ASSEMBLY MAINTENANCE - TM-9-6115-729-240539
REMOVAL - TM-9-6115-729-240540
Figure 1. Fuel Level Switch Assembly. - TM-9-6115-729-240541
FUEL HOSES MAINTENANCE - TM-9-6115-729-240543
REMOVAL - TM-9-6115-729-240544
Figure 1. Fuel Hoses (Sheet 1 of 3).
Figure 1. Fuel Hoses (Sheet 2 of 3).
Figure 1. Fuel Hoses (Sheet 3 of 3).
REMOVAL - TM-9-6115-729-240548
INSTALLATION - TM-9-6115-729-240549
FUEL PICKUP TUBE ASSEMBLY MAINTENANCE - TM-9-6115-729-240551
REMOVAL - TM-9-6115-729-240552
Figure 1. Fuel Pickup Tube Assembly. - TM-9-6115-729-240553
AUXILIARY FUEL PUMP ASSEMBLY AND SOLENOID VALVE MAINTENANCE
SERVICING - TM-9-6115-729-240556
Figure 1. Auxiliary Fuel Pump Assembly and Solenoid Valve.
INSTALLATION - TM-9-6115-729-240558
FUEL COOLER MAINTENANCE - TM-9-6115-729-240559
REMOVAL - TM-9-6115-729-240560
Figure 1. Fuel Cooler (Sheet 1 of 2). - TM-9-6115-729-240561
Figure 1. Fuel Cooler (Sheet 2 of 2). - TM-9-6115-729-240562
INSTALLATION - TM-9-6115-729-240563
WATER SEPARATOR FILTER AND BRACKET MAINTENANCE - TM-9-6115-729-240565
FILTER ELEMENT REPLACEMENT
Figure 1. Water Separator Filter and Bracket. - TM-9-6115-729-240567
WATER SEPARATOR FILTER REMOVAL - TM-9-6115-729-240568
WATER SEPARATOR FILTER INSTALLATION - Continued
FUEL LEVEL SENDER MAINTENANCE - TM-9-6115-729-240571
REMOVAL - TM-9-6115-729-240572
Figure 1. Fuel Level Sender (Sheet 1 of 2). - TM-9-6115-729-240573
Figure 1. Fuel Level Sender (Sheet 2 of 2). - TM-9-6115-729-240574
INSTALLATION - TM-9-6115-729-240575
FUEL TANK MAINTENANCE - TM-9-6115-729-240577
REMOVAL - TM-9-6115-729-240578
Figure 1. Fuel Tank Maintenance. - TM-9-6115-729-240579
INSTALLATION - TM-9-6115-729-240580
COOLANT RECOVERY SYSTEM MAINTENANCE - TM-9-6115-729-240581
REMOVAL - TM-9-6115-729-240582
Figure 1. Coolant Recovery System. - TM-9-6115-729-240583
SURGE TANK MAINTENANCE - TM-9-6115-729-240585
REMOVAL - TM-9-6115-729-240586
Figure 1. Surge Tank. - TM-9-6115-729-240587
INSTALLATION - TM-9-6115-729-240588
FAN AND FAN GUARDS MAINTENANCE - TM-9-6115-729-240589
Table 1. WP 0065 Guide.
Figure 1. Fan and Fan Guards (Sheet 1 of 3). - TM-9-6115-729-240591
Figure 1. Fan and Fan Guards (Sheet 2 of 3). - TM-9-6115-729-240592
Figure 1. Fan and Fan Guards (Sheet 3 of 3). - TM-9-6115-729-240593
REMOVAL - TM-9-6115-729-240594
INSTALLATION - TM-9-6115-729-240595
INSTALLATION - Continued - TM-9-6115-729-240596
COOLANT HOSE ASSEMBLIES MAINTENANCE - TM-9-6115-729-240597
REMOVAL - TM-9-6115-729-240598
Figure 1. Coolant Hose Assemblies (Sheet 1 of 2).
Figure 1. Coolant Hose Assemblies (Sheet 2 of 2).
INSTALLATION - TM-9-6115-729-240601
INSTALLATION - Continued - TM-9-6115-729-240602
RADIATOR ASSEMBLY MAINTENANCE - TM-9-6115-729-240603
REMOVAL - TM-9-6115-729-240604
Figure 1. Radiator Assembly (Sheet 1 of 2). - TM-9-6115-729-240605
Figure 1. Radiator Assembly (Sheet 2 of 2). - TM-9-6115-729-240606
INSTALLATION - TM-9-6115-729-240607
FLUSHING
EXHAUST SYSTEM MAINTENANCE - TM-9-6115-729-240609
REMOVAL - TM-9-6115-729-240610
Figure 1. Exhaust System. - TM-9-6115-729-240611
INSTALLATION - TM-9-6115-729-240612
CRANKCASE VENTILATION FILTER MAINTENANCE - TM-9-6115-729-240613
REMOVAL - TM-9-6115-729-240614
Figure 1. Crankcase Ventilation Filter. - TM-9-6115-729-240615
AIR CLEANER FILTER MAINTENANCE - TM-9-6115-729-240617
REMOVAL - TM-9-6115-729-240618
Figure 1. Air Cleaner Filter. - TM-9-6115-729-240619
INSTALLATION - TM-9-6115-729-240620
AIR CLEANER SYSTEM MAINTENANCE - TM-9-6115-729-240621
REMOVAL - TM-9-6115-729-240622
Figure 1. Air Cleaner System (Sheet 1 of 2). - TM-9-6115-729-240623
Figure 1. Air Cleaner System (Sheet 2 of 2). - TM-9-6115-729-240624
INSTALLATION - TM-9-6115-729-240625
INSTALLATION - Continued - TM-9-6115-729-240626
ALTERNATOR MAINTENANCE - TM-9-6115-729-240627
REMOVAL - TM-9-6115-729-240628
Figure 1. Alternator. - TM-9-6115-729-240629
BELT MAINTENANCE
REMOVAL - TM-9-6115-729-240632
Figure 1. Belt.
INSTALLATION - TM-9-6115-729-240634
STARTER MAINTENANCE - TM-9-6115-729-240635
REMOVAL - TM-9-6115-729-240636
Figure 1. Starter. - TM-9-6115-729-240637
TENSIONER MAINTENANCE - TM-9-6115-729-240639
REMOVAL - TM-9-6115-729-240640
Figure 1. Tensioner. - TM-9-6115-729-240641
FAN PULLEY MAINTENANCE - TM-9-6115-729-240643
Figure 1. Fan Pulley. - TM-9-6115-729-240644
INSTALLATION - TM-9-6115-729-240645
WATER PUMP MAINTENANCE - TM-9-6115-729-240647
REMOVAL - TM-9-6115-729-240648
Figure 1. Water Pump. - TM-9-6115-729-240649
INSTALLATION - TM-9-6115-729-240650
FUEL PRIMING PUMP MAINTENANCE - TM-9-6115-729-240651
REMOVAL - TM-9-6115-729-240652
Figure 1. Fuel Priming Pump. - TM-9-6115-729-240653
FUEL FILTER MAINTENANCE - TM-9-6115-729-240655
REMOVAL - TM-9-6115-729-240656
Figure 1. Fuel Filter. - TM-9-6115-729-240657
FUEL FILTER BASE MAINTENANCE
Figure 1. Fuel Filter Base.
INSTALLATION - TM-9-6115-729-240661
OIL FILTER MAINTENANCE AND OIL CHANGE - TM-9-6115-729-240663
FILTER REMOVAL AND OIL DRAIN - TM-9-6115-729-240664
Figure 1. Oil Filter Maintenance and Oil Change. - TM-9-6115-729-240665
OIL SAMPLING - TM-9-6115-729-240666
THERMOSTAT MAINTENANCE - TM-9-6115-729-240667
REMOVAL - TM-9-6115-729-240668
Figure 1. Thermostat. - TM-9-6115-729-240669
THERMOSTAT HOUSING MAINTENANCE
Figure 1. Thermostat Housing.
DISASSEMBLY - TM-9-6115-729-240673
INSTALLATION - TM-9-6115-729-240674
ENGINE CONTROL MODULE MAINTENANCE - TM-9-6115-729-240675
REMOVAL - TM-9-6115-729-240676
Figure 1. Engine Control Module. - TM-9-6115-729-240677
REPROGRAMMING - TM-9-6115-729-240679
REPROGRAMMING DVR PARAMETERS FOR VOLTAGE AND FREQUENCY CHANGE - TM-9-6115-729-240680
REPROGRAMMING OR VERIFYING DVR PARAMETERS - TM-9-6115-729-240681
Table 2. 100 kW TQG DVR Programming Parameters.
Table 2. 100 kW TQG DVR Programming Parameters - Continued. - TM-9-6115-729-240683
Table 2. 100 kW TQG DVR Programming Parameters - Continued. - TM-9-6115-729-240684
REPROGRAMMING OR VERIFYING DVR PARAMETERS - Continued
Table 3. 100 kW TQG GSC Programming Setpoints.
REPROGRAMMING GSC SETPOINTS FOR VOLTAGE AND FREQUENCY CHANGE - TM-9-6115-729-240687
REPROGRAMMING GSC SETPOINTS FOR VOLTAGE AND FREQUENCY CHANGE - Continued - TM-9-6115-729-240688
REPROGRAMMING OR VERIFYING GSC SETPOINTS - TM-9-6115-729-240689
REPROGRAMMING OR VERIFYING GSC SETPOINTS - Continued - TM-9-6115-729-240690
Table 4. 100 kW OP5-0 Engine/Generator Setpoint Programming.
Table 4. 100 kW OP5-0 Engine/Generator Setpoint Programming - Continued. - TM-9-6115-729-240692
Table 4. 100 kW OP5-0 Engine/Generator Setpoint Programming - Continued. - TM-9-6115-729-240693
Table 4. 100 kW OP5-0 Engine/Generator Setpoint Programming - Continued. - TM-9-6115-729-240694
Table 4. 100 kW OP5-0 Engine/Generator Setpoint Programming - Continued. - TM-9-6115-729-240695
Table 5. OP5-1 Protective Relaying Setpoint Programming. - TM-9-6115-729-240696
Table 5. OP5-1 Protective Relaying Setpoint Programming - Continued. - TM-9-6115-729-240697
Table 5. OP5-1 Protective Relaying Setpoint Programming - Continued. - TM-9-6115-729-240698
Table 5. OP5-1 Protective Relaying Setpoint Programming - Continued. - TM-9-6115-729-240699
Table 5. OP5-1 Protective Relaying Setpoint Programming - Continued. - TM-9-6115-729-240700
Table 5. OP5-1 Protective Relaying Setpoint Programming - Continued. - TM-9-6115-729-240701
Table 6. OP5-3 Synchronization Setpoint Programming. - TM-9-6115-729-240702
Table 6. OP5-3 Synchronization Setpoint Programming - Continued. - TM-9-6115-729-240703
Table 7. OP6 Spare Input/Output Setpoint Programming. - TM-9-6115-729-240704
Table 7. OP6 Spare Input/Output Setpoint Programming - Continued. - TM-9-6115-729-240705
Table 7. OP6 Spare Input/Output Setpoint Programming - Continued. - TM-9-6115-729-240706
Table 8. OP8 Voltmeter Ammeter Programming. - TM-9-6115-729-240707
INSTALLATION OF GENERATOR SET ON TRAILER - TM-9-6115-729-240709
INSTALLATION - TM-9-6115-729-240710
Figure 1. Installation of Generator Set on Trailer. - TM-9-6115-729-240711
PREPARATION FOR STORAGE OR SHIPMENT - TM-9-6115-729-240713
SHORT TERM STORAGE
LONG TERM STORAGE - TM-9-6115-729-240715
LONG TERM STORAGE - Continued - TM-9-6115-729-240716
LONG TERM STORAGE - Continued - TM-9-6115-729-240717
ILLUSTRATED LIST OF MANUFACTURED ITEMS - TM-9-6115-729-240719
TORQUE LIMITS - TM-9-6115-729-240721
Table 1. Standard Dry Torque Limits. - TM-9-6115-729-240722
Table 2. Metric Dry Torque Limits. - TM-9-6115-729-240723
Table 2. Metric Dry Torque Limits - Continued. - TM-9-6115-729-240724
WIRE LISTS - TM-9-6115-729-240725
GENERAL WIRING REPAIR PROCEDURES
HARNESS INSPECTION PROCEDURES - TM-9-6115-729-240727
Moisture and Corrosion Inspection
Terminal Retention into Socket Inspection - TM-9-6115-729-240729
Figure 1. Engine Sensors (Sheet 1 of 2). - TM-9-6115-729-240730
Figure 1. Engine Sensors (Sheet 2 of 2). - TM-9-6115-729-240731
Figure 2. Wire Harness Connectors (Sheet 1 of 3). - TM-9-6115-729-240732
Figure 2. Wire Harness Connectors (Sheet 2 of 3). - TM-9-6115-729-240733
Figure 2. Wire Harness Connectors (Sheet 3 of 3). - TM-9-6115-729-240734
Table 1. Control Panel Wire List. - TM-9-6115-729-240735
Table 1. Control Panel Wire List - Continued. - TM-9-6115-729-240736
Table 1. Control Panel Wire List - Continued. - TM-9-6115-729-240737
Table 1. Control Panel Wire List - Continued. - TM-9-6115-729-240738
Table 1. Control Panel Wire List - Continued. - TM-9-6115-729-240739
Table 1. Control Panel Wire List - Continued. - TM-9-6115-729-240740
Table 1. Control Panel Wire List - Continued. - TM-9-6115-729-240741
Table 1. Control Panel Wire List - Continued. - TM-9-6115-729-240742
Table 1. Control Panel Wire List - Continued. - TM-9-6115-729-240743
Table 1. Control Panel Wire List - Continued. - TM-9-6115-729-240744
Table 1. Control Panel Wire List - Continued. - TM-9-6115-729-240745
Table 1. Control Panel Wire List - Continued. - TM-9-6115-729-240746
Table 1. Control Panel Wire List - Continued. - TM-9-6115-729-240747
Table 1. Control Panel Wire List - Continued. - TM-9-6115-729-240748
Table 1. Control Panel Wire List - Continued. - TM-9-6115-729-240749
Table 1. Control Panel Wire List - Continued. - TM-9-6115-729-240750
Table 1. Control Panel Wire List - Continued. - TM-9-6115-729-240751
Table 1. Control Panel Wire List - Continued. - TM-9-6115-729-240752
Table 1. Control Panel Wire List - Continued. - TM-9-6115-729-240753
Table 1. Control Panel Wire List - Continued. - TM-9-6115-729-240754
Table 1. Control Panel Wire List - Continued. - TM-9-6115-729-240755
Table 1. Control Panel Wire List - Continued. - TM-9-6115-729-240756
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List. - TM-9-6115-729-240757
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued. - TM-9-6115-729-240758
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued. - TM-9-6115-729-240759
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued. - TM-9-6115-729-240760
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued. - TM-9-6115-729-240761
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued. - TM-9-6115-729-240762
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued. - TM-9-6115-729-240763
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued. - TM-9-6115-729-240764
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued. - TM-9-6115-729-240765
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued. - TM-9-6115-729-240766
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued. - TM-9-6115-729-240767
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued. - TM-9-6115-729-240768
Table 3. ECM to EMCP Harness Wire List. - TM-9-6115-729-240769
Table 3. ECM to EMCP Harness Wire List - Continued. - TM-9-6115-729-240770
Table 3. ECM to EMCP Harness Wire List - Continued. - TM-9-6115-729-240771
Table 3. ECM to EMCP Harness Wire List - Continued. - TM-9-6115-729-240772
Table 4. Engine Harness Wire List. - TM-9-6115-729-240773
Table 4. Engine Harness Wire List - Continued. - TM-9-6115-729-240774
Table 4. Engine Harness Wire List - Continued. - TM-9-6115-729-240775
Table 4. Engine Harness Wire List - Continued. - TM-9-6115-729-240776
Table 4. Engine Harness Wire List - Continued. - TM-9-6115-729-240777
Table 4. Engine Harness Wire List - Continued. - TM-9-6115-729-240778
Table 4. Engine Harness Wire List - Continued. - TM-9-6115-729-240779
Table 5. Engine Harness to Unit Injectors Wire List. - TM-9-6115-729-240780
Table 5. Engine Harness to Unit Injectors Wire List - Continued. - TM-9-6115-729-240781
Table 6. Winterization Control Panel Wire List. - TM-9-6115-729-240782
Table 6. Winterization Control Panel Wire List - Continued. - TM-9-6115-729-240783
Table 6. Winterization Control Panel Wire List - Continued. - TM-9-6115-729-240784
Table 7. Winterization Kit Heater Cable Wire List. - TM-9-6115-729-240785
Table 7. Winterization Kit Heater Cable Wire List - Continued. - TM-9-6115-729-240786
Table 8. Winterization Kit Power Cable Wire List. - TM-9-6115-729-240787
Chapter 4. UNIT (FIELD) LEVEL MAINTENANCE INSTRUCTIONS WINTERIZATION KIT - TM-9-6115-729-240789
WORK PACKAGE INDEX - TM-9-6115-729-240791
WINTERIZATION HEATER CONTROL BOX ASSEMBLY MAINTENANCE - TM-9-6115-729-240793
Figure 1. Winterization Heater Control Box Assembly. - TM-9-6115-729-240794
DISASSEMBLY - TM-9-6115-729-240795
ASSEMBLY - TM-9-6115-729-240796
WINTERIZATION HEATER ASSEMBLY MAINTENANCE - TM-9-6115-729-240797
REMOVAL - TM-9-6115-729-240798
Figure 1. Winterization Heater Assembly. - TM-9-6115-729-240799
INSTALLATION - TM-9-6115-729-240800
WINTERIZATION HEATER HOSES MAINTENANCE - TM-9-6115-729-240801
REMOVAL - TM-9-6115-729-240802
Figure 1. Winterization Heater Hoses (Sheet 1 of 2).
Figure 1. Winterization Heater Hoses (Sheet 2 of 2).
REMOVAL - TM-9-6115-729-240805
INSTALLATION - TM-9-6115-729-240806
WINTERIZATION THERMOSTAT, RESISTORS, AND DIODE MAINTENANCE - TM-9-6115-729-240807
REMOVAL - TM-9-6115-729-240808
Figure 1. Winterization Thermostat, Resistors, and Diode. - TM-9-6115-729-240809
INSTALLATION - TM-9-6115-729-240810
WINTERIZATION WIRING HARNESSES MAINTENANCE - TM-9-6115-729-240811
REMOVAL - TM-9-6115-729-240812
Figure 1. Winterization Wiring Harnesses. - TM-9-6115-729-240813
Chapter 5. DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE INSTRUCTIONS - TM-9-6115-729-240815
WORK PACKAGE INDEX - TM-9-6115-729-240817
GENERATOR MAINTENANCE
DISASSEMBLY - TM-9-6115-729-240820
Figure 1. Generator Repair. - TM-9-6115-729-240821
DISASSEMBLY - TM-9-6115-729-240822
CLEANING - TM-9-6115-729-240823
ASSEMBLY - TM-9-6115-729-240824
ASSEMBLY - Continued - TM-9-6115-729-240825
GENERATOR REPLACEMENT - TM-9-6115-729-240827
REMOVAL - TM-9-6115-729-240828
Figure 1. Generator Replacement (Sheet 1 of 2).
Figure 1. Generator Replacement (Sheet 2 of 2).
INSTALLATION - TM-9-6115-729-240831
INSTALLATION - Continued - TM-9-6115-729-240832
ENGINE REPLACEMENT - TM-9-6115-729-240833
REMOVAL - TM-9-6115-729-240834
Figure 1. Engine Replacement.
INSTALLATION - TM-9-6115-729-240836
INSTALLATION - Continued - TM-9-6115-729-240837
ENGINE/GENERATOR BASE ASSEMBLY REPAIR - TM-9-6115-729-240839
REPAIR OR REPLACEMENT - TM-9-6115-729-240840
ENGINE ELECTRICAL SYSTEM REPAIR - TM-9-6115-729-240841
Table 1. WP 0100 Guide.
Figure 1. Electrical System (Sheet 1 of 2).
Figure 1. Electrical System (Sheet 2 of 2).
REMOVAL - Continued - TM-9-6115-729-240845
INSTALLATION - TM-9-6115-729-240846
INSTALLATION - Continued - TM-9-6115-729-240847
VALVE COVER, GASKET, AND MANIFOLD MAINTENANCE
Figure 1. Valve Cover, Gasket, and Manifold.
CLEANING - TM-9-6115-729-240851
FUEL TRANSFER PUMP/INJECTION ACTUATION PUMP, AND INJECTION ACTUATION PRESSURE CONTROL VALVE MAINTENANCE
Figure 1. Fuel Transfer Pump. - TM-9-6115-729-240854
DISASSEMBLY - TM-9-6115-729-240855
Figure 2. Injection Actuation Pump Control Valve.
INSTALLATION - TM-9-6115-729-240857
AIR INLET ELBOW, HEATER, AND MANIFOLD COVER MAINTENANCE
REMOVAL - TM-9-6115-729-240860
Figure 1. Air Inlet Elbow, Heater, and Manifold Cover.
INSTALLATION - TM-9-6115-729-240862
CRANKSHAFT PULLEY AND DAMPER MAINTENANCE
Figure 1. Crankshaft Pulley and Damper.
REMOVAL - TM-9-6115-729-240865
CRANKSHAFT FRONT SEAL MAINTENANCE - TM-9-6115-729-240867
INSTALLATION - TM-9-6115-729-240868
Figure 1. Crankshaft Front Seal. - TM-9-6115-729-240869
TURBOCHARGER MAINTENANCE - TM-9-6115-729-240871
REMOVAL - TM-9-6115-729-240872
Figure 1. Turbocharger. - TM-9-6115-729-240873
EXHAUST MANIFOLD MAINTENANCE - TM-9-6115-729-240875
REMOVAL - TM-9-6115-729-240876
Figure 1. Exhaust Manifold. - TM-9-6115-729-240877
FLYWHEEL MAINTENANCE - TM-9-6115-729-240879
Figure 1. Flywheel. - TM-9-6115-729-240880
FLYWHEEL HOUSING MAINTENANCE - TM-9-6115-729-240881
Figure 1. Flywheel Housing. - TM-9-6115-729-240882
FRONT COVER MAINTENANCE - TM-9-6115-729-240883
REMOVAL - TM-9-6115-729-240884
Figure 1. Front Cover. - TM-9-6115-729-240885
ENGINE OIL FILTER BASE AND OIL COOLER MAINTENANCE
REMOVAL - TM-9-6115-729-240888
Figure 1. Engine Oil Filter Base and Oil Cooler.
INSTALLATION - TM-9-6115-729-240890
ENGINE OIL PAN MAINTENANCE
REMOVAL - TM-9-6115-729-240892
Figure 1. Engine Oil Pan.
ENGINE OIL PUMP MAINTENANCE
Figure 1. Engine Oil Pump.
UNIT INJECTOR MAINTENANCE - TM-9-6115-729-240897
REMOVAL - TM-9-6115-729-240898
Figure 1. Unit Injector. - TM-9-6115-729-240899
INSTALLATION - TM-9-6115-729-240900
ROCKER SHAFT AND PUSHRODS MAINTENANCE
Figure 1. Rocker Shaft and Pushrods Removal and Installation.
DISASSEMBLY - TM-9-6115-729-240903
VALVE LASH CHECK - TM-9-6115-729-240904
Table 1. Crankshaft Positions for Valve Lash Setting. - TM-9-6115-729-240905
VALVE LASH ADJUSTMENT - TM-9-6115-729-240906
VALVE LASH ADJUSTMENT - Continued - TM-9-6115-729-240907
CYLINDER HEAD AND GASKET MAINTENANCE
Figure 1. Cylinder Head and Gasket.
REMOVAL - TM-9-6115-729-240911
INSTALLATION - TM-9-6115-729-240912
INSTALLATION - Continued - TM-9-6115-729-240913
Chapter 6. GENERAL SUPPORT Moved to Sustainment (NMWR) - TM-9-6115-729-240915
Chapter 7. SUPPORTING INFORMATION - TM-9-6115-729-240917
WORK PACKAGE INDEX - TM-9-6115-729-240919
REFERENCES - TM-9-6115-729-240921
TECHNICAL MANUALS - TM-9-6115-729-240923
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION - TM-9-6115-729-240925
Maintenance Functions - TM-9-6115-729-240926
Explanation of Columns in the MAC - TM-9-6115-729-240927
Explanation of Columns in the Remarks - TM-9-6115-729-240928
MAINTENANCE ALLOCATION CHART (MAC)
Table 1. MAC
Table 1. MAC - Continued - TM-9-6115-729-240931
Table 1. MAC - Continued - TM-9-6115-729-240932
Table 2. Tools and Test Equipment Requirements. - TM-9-6115-729-240933
Table 3. Remarks. - TM-9-6115-729-240934
Table 3. Remarks - Continued. - TM-9-6115-729-240935
EXPENDABLE AND DURABLE ITEMS LIST - TM-9-6115-729-240937
Table 1. Expendable and Durable Items List - TM-9-6115-729-240938
Table 1. Expendable and Durable Items List - Continued. - TM-9-6115-729-240939
Table 1. Expendable and Durable Items List - Continued. - TM-9-6115-729-240940
Table 1. Expendable and Durable Items List - Continued. - TM-9-6115-729-240941
Table 1. Expendable and Durable Items List - Continued. - TM-9-6115-729-240942
GLOSSARY - TM-9-6115-729-240943
GLOSSARY - Continued - TM-9-6115-729-240944
TM-9-6115-729-24 Generator Set Skid Mounted Tactical Quiet 100 kw 50/60 Hz MEP-807A Manual

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