TM-9-6115-641-24 3KW Tactical Quiet Generator Sets MEP 831A (60 Hz) MEP 832A (400 Hz) Manual

CHAPTER   1 INTRODUCTION - TM-9-6115-641-24_18
Figure 1-1. Generator Set, 5 kW, Tactical Quiet
EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRs)
Table   1-1.   Tabulated   Data
Table   1-1.   Tabulated   Data   -   Continued - TM-9-6115-641-24_22
Table   1-1.   Tabulated   Data   -   Continued - TM-9-6115-641-24_23
Table 1-2. Performance Characteristics - Continued - TM-9-6115-641-24_24
Section   Ill.   PRINCIPLES   OF   OPERATION - TM-9-6115-641-24_25
Figure   1-2.   Fault   System
Fuel   System - TM-9-6115-641-24_27
Figure   1-3.   Generator   Set   Fuel   System - TM-9-6115-641-24_28
Generator Set Cooling System - TM-9-6115-641-24_29
Figure   1-4.   Generator   Set   Cooling   System
Figure   1-5.   Engine   Cooling   System
Figure   1-6.   Engine   Lubrication   System - TM-9-6115-641-24_32
Engine Air Intake and Exhaust System
Figure 1-7. Engine Air Intake and Exhaust System - TM-9-6115-641-24_34
Figure   1-8.   Output   Supply   System - TM-9-6115-641-24_35
Generator Set Control - TM-9-6115-641-24_36
Figure   1-9.   Engine   Starting   System - TM-9-6115-641-24_37
Shutdown. - TM-9-6115-641-24_38
Voltage Regulation System
Figure   1-10.   Governor   Control   System - TM-9-6115-641-24_40
Figure   1-11.   Voltage   Regulation   System - TM-9-6115-641-24_41
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - TM-9-6115-641-24_42
Figure   1-12.   Generator   Set   Components - TM-9-6115-641-24_43
CHAPTER 2 UNIT MAINTENANCE INSTRUCTIONS - TM-9-6115-641-24_44
Table   2-1.   Coolant - TM-9-6115-641-24_45
Table 2-3. Lubricating Oil - TM-9-6115-641-24_46
Outdoor   Installation - TM-9-6115-641-24_47
Figure 2-1. Minimum Enclosure Clearance Measurements
Figure 2-2. Base Mounting Measurements - TM-9-6115-641-24_49
Table 2-4. Fabricated/Assembled Parts
Table   2-5.   Unit   Preventive   Maintenance   Checks   and   Services
Table   2-5.   Unit   Preventive   Maintenance   Checks   and   Services   -   Continued - TM-9-6115-641-24_52
Table   2-5.   Unit   Preventive   Maintenance   Checks   and   Services   -   Continued - TM-9-6115-641-24_53
SYMPTOM INDEX GENERATOR SET - TM-9-6115-641-24_54
Table   2-6.   UNIT   TROUBLESHOOTING - TM-9-6115-641-24_55
Table   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-641-24_56
Table   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-641-24_57
Table   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-641-24_58
Table   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-641-24_59
Table   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-641-24_60
Table   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-641-24_61
Table   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-641-24_62
Table   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-641-24_63
Table   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-641-24_64
Table   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-641-24_65
Table   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-641-24_66
Table   2-6.   UNIT   TROUBLESHOOTING   -   Continued - TM-9-6115-641-24_67
Section VI. RADIO INTERFERENCE SUPPRESSION - TM-9-6115-641-24_68
Section   Vlll.   MAINTENANCE   OF   DC   ELECTRICAL   SYSTEM
Figure   2-3.   Batteries   and   Cables - TM-9-6115-641-24_70
Table 2-7. STATE OF CHARGE WITH SPECIFIC GRAVITY CORRECTED TO 80F (27C) - TM-9-6115-641-24_71
Table 2-8. SPECIFIC GRAVITY TEMPERATURE CORRECTIONS
Removal. - TM-9-6115-641-24_73
NATO SLAVE RECEPTACLE - TM-9-6115-641-24_74
Figure   2-4.   NATO   Slave   receptacle   and   Cables
Testing - TM-9-6115-641-24_76
Figure 2-5. Battery Charging Alternation
Section   IX.   MAINTENANCE   OF   HOUSING - TM-9-6115-641-24_78
Figure   2-6.   Generator   Set   Access   Doors
CONTROL BOX TOP PANEL - TM-9-6115-641-24_80
Figure 2-7. Control Box Top Panel
TOP HOUSING PANEL
FRONT HOUSING PANEL
Figure   2-8.   Generator   Set   front   Housing   Section
FRONT HOUSING SECTION - TM-9-6115-641-24_85
Installation - TM-9-6115-641-24_86
REAR HOUSING SECTION - TM-9-6115-641-24_87
Figure   2-9.   Generator   set   rear   Housing   Section
Removal - TM-9-6115-641-24_89
Section   X.   MAINTENANCE   OF   CONTROL   BOX   ASSEMBLY
CONVENIENCE   RECEPTACLE.
Figure   2-10.   Control   Box   Assembly - TM-9-6115-641-24_92
GROUND FAULT CIRCUIT INTERRUPTER
MALFUNCTION INDICATOR PANEL - TM-9-6115-641-24_94
DC CONTROL POWER CIRCUIT BREAKER - TM-9-6115-641-24_95
AC VOLTAGE REGULATOR. - TM-9-6115-641-24_96
FREQUENCY TRANSDUCER. - TM-9-6115-641-24_97
FREQUENCY TRANSDUCER. (cont)
SHUNT
OVERVOLTAGE   RELAY
SHORT CIRCUIT/OVERLOAD RELAY - TM-9-6115-641-24_101
Testing - TM-9-6115-641-24_102
Figure   2-11.   Control   Box   Components
Removal.
RELAYS - TM-9-6115-641-24_105
Figure 2-12. Diode Identification
CONTROL BOX HARNESS - TM-9-6115-641-24_107
Figure 2-13. Diagnostic Connector Pin Positions (Front View)
Table   2-10.   Diagnostic   Connector   Connection   Points
PRESS TO TEST INDICATOR LIGHTS
Figure   2-14.   Control   Panel   Indicators   and   Switches
FUEL LEVEL INDICATOR - TM-9-6115-641-24_112
COOLANT TEMP. INDICATOR
OIL PRESSURE INDICATOR - TM-9-6115-641-24_114
OIL PRESSURE INDICATOR (cont)
TIME METER (TOTAL HOURS) - TM-9-6115-641-24_116
FREQUENCY METER (HERTZ)
FREQUENCY METER (HERTZ) (cnot)
FREQUENCY METER (HERTZ) (cont)
AC VOLTMETER (VOLTS AC)
MASTER SWITCH
VOLTAGE ADJUST POTENTIOMETER - TM-9-6115-641-24_122
EMERGENCY STOP SWICTH
BATTLE SHORT SWICTH
CIRCUIT   INTERRUPTER   SWITCH.
AM - VM TRANSFER SWITCH
PANEL LIGHTS SWITCH - TM-9-6115-641-24_127
CONTROL PANEL FRAME - TM-9-6115-641-24_128
CONTROL PANEL FRAME (cont)
Figure   2-15.   Control   Box   Housing   and   Control   Panel
CONTROL BOX SIDE PANELS. - TM-9-6115-641-24_131
CONTROL BOX TRAY
Section XI. MAINTENANCE   OF OUTPUT BOX ASSEMBLY
AC CIRCUIT INTERRUPTER RELAY - TM-9-6115-641-24_134
CRANKING RELAY - TM-9-6115-641-24_135
Figure   2-16.   Output   Box   Assembly
PRE-HEAT RELAY
VOLTAGE RECONNECTION SWITCH
Section   XII.   MAINTENANCE   OF   AIR   INTAKE   AND   EXHAUST   SYSTEM - TM-9-6115-641-24_139
Cleaning and Inspection - TM-9-6115-641-24_140
Figure   2-18.   Muffler - TM-9-6115-641-24_141
AIR RESTRICTION INDICATOR
AIR CLEANER ELEMENT
Figure   2-19.   Air   Cleaner   Assembly - TM-9-6115-641-24_144
Section   XIII.   MAINTENANCE   OF   COOLING   SYSTEM
RADIATOR - TM-9-6115-641-24_146
UPPER COOLANT HOSE.
Figure 2-20. Radiator Assembly and Cooling System
LOWER COOLANT HOSE - TM-9-6115-641-24_149
COOLANT RECOVERY SYSTEM
FAN BELT - TM-9-6115-641-24_151
FUEL LEVEL SENDER - TM-9-6115-641-24_152
LOW FUEL LEVEL/AUXILIARY FUEL PU MP FLOAT SWITCH
LOW FUEL LEVEL/AUXILIARY FUEL PU MP FLOAT SWITCH (cont)
FUEL FLOAT MODULE
FUEL TANK FILLER NECK.
Figure   2-21.   Fuel   Tank,   Switches,   and   Auxiliary   Fuel   Pump
FUEL TANK DRAIN VALVE.
AUXILIARY FUEL PUMP.
FUEL TRANSFER PUMP.
FUEL FILTER/WATER SEPARATOR ASSEMBLY. - TM-9-6115-641-24_161
Figure   2-22.   Fuel   Filter/Water   Separator   and   Transfer   Pump
FUEL FILTER/WATER SEPARATOR ELEMENT - TM-9-6115-641-24_163
Section   XV.   MAINTENANCE   OF   LUBRICATION   SYSTEM
Figure   2-23.   Engine   Oil   Drain   Line - TM-9-6115-641-24_165
Section   XVI.   MAINTENANCE   OF   ENGINE   ACCESSORIES
LOW OIL PRESSURE SWITCH
Figure 2-25. Engine Related Switches and Senders
Testing. - TM-9-6115-641-24_169
OIL PRESSURE SENDER.
COOLANT TEMPERATURE SENDER - TM-9-6115-641-24_171
COOLANT HIGH TEMPERATURE SWITCH - TM-9-6115-641-24_172
MAGNETIC   PICKUP - TM-9-6115-641-24_173
FUEL SOLENOID
DEAD CRANK SWITCH - TM-9-6115-641-24_175
Section   XVII.   MAINTENANCE   OF   LOAD   OUTPUT   TERMINAL   BOARD   ASSEMBLY - TM-9-6115-641-24_176
Figure   2-26.   Load   Output   Terminal   Board   Assembly
LOAD OUTPUT TERMINALS - TM-9-6115-641-24_178
VARISTORS - TM-9-6115-641-24_179
MARKING
CHAPTER 3 GENERAL MAINTENANCE INSTRUCTIONS
SYMPTOM INDEX GENERATOR SET - TM-9-6115-641-24_183
Table   3-1.   DIRECT   SUPPORT   TROUBLESHOOTING - TM-9-6115-641-24_184
Table   3-1.   DIRECT   SUPPORT   TROUBLESHOOTING   -   Continued - TM-9-6115-641-24_185
Table   3-1.   DIRECT   SUPPORT   TROUBLESHOOTING   -   Continued - TM-9-6115-641-24_186
Table   3-1.   DIRECT   SUPPORT   TROUBLESHOOTING   -   Continued - TM-9-6115-641-24_187
Table   3-1.   DIRECT   SUPPORT   TROUBLESHOOTING   -   Continued - TM-9-6115-641-24_188
Section   Ill.   REMOVAL   AND   INSTALLATION   OF   MAJOR   COMPONENTS - TM-9-6115-641-24_189
ENGINE AND GENERATOR ASSEMBLY - TM-9-6115-641-24_190
Removal - TM-9-6115-641-24_191
Installation - TM-9-6115-641-24_192
Figure   3-1.   Engine   and   Generator   Assembly   Removal - TM-9-6115-641-24_193
Installation
Installation - Continued
ENGINE REPLACEMENT - TM-9-6115-641-24_196
CHAPTER 4 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS - TM-9-6115-641-24_198
Figure   4-2.   Brush   Test
Figure   4-5.   Stator   Winding   Test
Figure   4-6.   Rotor   Test
Figure   4-7.   Alternator   Assembly
Figure   4-8.   Assembling   Front   Housing   to   Rotor
Figure   4-9.   Performance   Test   Circuit
Section   Il.   MAINTENANCE   OF   CONTROL   BOX   ASSEMBLY
Figure   4-10.   Control   Box   Harness - TM-9-6115-641-24_206
Section   Ill.   MAINTENANCE   OF   OUTPUT   BOX   ASSEMBLY - TM-9-6115-641-24_207
OUTPUT BOX ASSEMBLY
OUTPUT   BOX/ENGINE   HARNESS - TM-9-6115-641-24_209
Figure   4-11.   Output   Box   Assembly - TM-9-6115-641-24_210
Installation - TM-9-6115-641-24_211
Figure   4-12.   Testing   Current   Transformer - TM-9-6115-641-24_212
Section   V.   MAINTENANCE   OF   ENGINE   ACCESSORIES
Figure 4-13. Frequency Droop Adjustment
lnspection
Figure 4-14. Skid Base
Figure   4-16.   Excitation   Block   Diagram
ADJUSTMENTS AND TESTS - TM-9-6115-641-24_218
Figure 4-17. Testing Rotating Rectifiers
Figure 4-19. Testing Exciter Armature
Figure   4-21.   Testing   Rotor   for   Grounds - TM-9-6115-641-24_221
Figure   4-22.   Testing   Stator   Windings - TM-9-6115-641-24_223
Figure   4-23.   Support   of   Rotor   Assembly
Assembly/lnstallation
GENERATOR ASSEMBLY (MEP-812A)
Figure   4-24.   Generator   Assembly   (MEP-802A)
Disassembly - TM-9-6115-641-24_228
Assembly. - TM-9-6115-641-24_229
Figure   4-25.   Generator   Assembly   (MEP-812A)
Appendix   A. REFERENCE
Appendix   B. MAINTENANCE   ALLOCATION   CHART   (MAC)
EXPLANATION OF COLU MNS IN THE MAC, SECTION Il
Section Il. MAINTENANCE ALLOCATION CHART - TM-9-6115-641-24_236
Section Il. MAINTENANCE ALLOCATION CHART - Continued
Section Il. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-641-24_238
Section Il. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-641-24_239
Section Il. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-641-24_240
Section Il. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-641-24_241
Section Il. MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-641-24_242
Section Ill. TOOL AND TEST EQUIPMENT REQUIREMENTS
Appendix   C. EXPENDABLE/DURABLE   SUPPLIES   AND   MATERIALS   LIST
Section   II.   TABULAR   LIST - TM-9-6115-641-24_245
Appendix D. FABRICATION/ASSEMBLY OF PARTS
Figure D-1. Cable Assembly, Battery (P/N: 88-20312)
Figure   D-2.   Cable   Assembly,   Battery   (P/N:   88-20313) - TM-9-6115-641-24_248
Figure   D-3.   Cable   Assembly,   (P/N:   88-20314)
Figure   D-4.   Cable   Assembly,   Battery   (P/N:   88-20315)
Figure   D-5.   Cable   Assembly,   Battery   (P/N:   88-20316)
Figure D-7. Diode Assembly (P/N: 88-22418-1)
Figure   D-8.   Holder,   Control   Panel   (P/N:   88-20134)
Figure D-9. Insulation,Skid   (P/N:   88-20296)
Figure   D-10.   Pump   Assembly,   Fuel   (P/N:   88-20479)
Figure   D-11.   Pump   Assembly,   Fuel   (P/N:   88-22546)
Figure   D-12.   Solenoid   Assembly,   Fuel   (P/N:   88-20482)
Figure   D-13.   Transducer   Assembly   (P/N:   88-20480)
Figure   D-14.   Wire,   Varistor   (P/Ns:   88-20305-1   through   88-203054)
Table D-1. INCHES TO METRIC CONVERSION
PART Il. Inches to Centimeters - TM-9-6115-641-24_261
ALPHABETICAL   INDEX
ALPHABETICAL   INDEX   -   Continued - TM-9-6115-641-24_263
ALPHABETICAL   INDEX   -   Continued - TM-9-6115-641-24_264
ALPHABETICAL   INDEX   -   Continued - TM-9-6115-641-24_265
ALPHABETICAL   INDEX   -   Continued - TM-9-6115-641-24_266
ALPHABETICAL   INDEX   -   Continued - TM-9-6115-641-24_267
ALPHABETICAL   INDEX   -   Continued - TM-9-6115-641-24_268
ALPHABETICAL   INDEX   -   Continued - TM-9-6115-641-24_269
ALPHABETICAL   INDEX   -   Continued - TM-9-6115-641-24_270
ALPHABETICAL   INDEX   -   Continued - TM-9-6115-641-24_271
ALPHABETICAL   INDEX   -   Continued - TM-9-6115-641-24_272
ALPHABETICAL   INDEX   -   Continued - TM-9-6115-641-24_273
ALPHABETICAL   INDEX   -   Continued - TM-9-6115-641-24_274
ALPHABETICAL   INDEX   -   Continued - TM-9-6115-641-24_275
ALPHABETICAL   INDEX   -   Continued - TM-9-6115-641-24_276
ALPHABETICAL   INDEX   -   Continued - TM-9-6115-641-24_277
ALPHABETICAL   INDEX   -   Continued - TM-9-6115-641-24_278
fo-1. electrical schematic
fo-2. wiring diagram (sheet 1 of 5)
fo-2. wiring diagram (sheet 2 of 5)
fo-2. wiring diagram (sheet 3 of 5)
fo-2. wiring diagram (sheet 4 of 5)
fo-2. wiring diagram (sheet 5 of 5)

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