TM-9-6115-644-24 Generator Set Tactical Quiet 15 Kw 50/60-400 Hz MEP-804A (60 Hz) MEP-814A (400 Hz) Manual

CHAPTER   1 INTRODUCTION - TM-9-6115-644-24_17
FIGURE 1-1. Generator Set, 30 kW, Tactical Quiet
EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRS).
GENERAL - TM-9-6115-644-24_20
TABLE 1-1. Tabulated Data - Continued - TM-9-6115-644-24_21
TABLE 1-1. Tabulated Data - Continued - TM-9-6115-644-24_22
TABLE 1-1. Tabulated Data
TABLE 1-1. Tabulated Data - Continued - TM-9-6115-644-24_24
DIFFERENCES BETWEEN MODELS - TM-9-6115-644-24_25
TABLE 1-2. Performance Characteristics - Continued - TM-9-6115-644-24_26
Fuel Float Switch Module
FIGURE 1-2. Fault System
Generator Set Cooling System - TM-9-6115-644-24_29
FIGURE 1-3. Generator Set Fuel System - TM-9-6115-644-24_30
FIGURE 1-4. Generator Set Cooling System
FIGURE 1-5. Engine Cooling System - TM-9-6115-644-24_32
Engine Air Intake and Exhaust System
FIGURE 1-6. Engine Lubrication System
FIGURE 1-7. Engine Air Intake and Exhaust System
FIGURE 1-8. Output Supply System - TM-9-6115-644-24_36
Generator Set Controls.
FIGURE 1-9. Engine Starting System
Shutdown. - TM-9-6115-644-24_39
FIGURE 1-10. Governor Control System
FIGURE 1-11. Voltage Regulation System - TM-9-6115-644-24_41
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - TM-9-6115-644-24_42
FIGURE 1-12. Generator Set Components - TM-9-6115-644-24_43
CONVENIENCE   RECEPTACLE - TM-9-6115-644-24_44
CHAPTER   2 UNIT   MAINTENANCE   INSTRUCTIONS - TM-9-6115-644-24_45
Fuel Tank.
TABLE 2-2. Fuel
GENERATOR SET INSTALLATION - TM-9-6115-644-24_48
FIGURE 2-1. Base Mounting Measurements
Outdoor Installation
FIGURE 2-2. Minimum Enclosure Clearance Measurements
FABRICATION/ASSMBLY OF PARTS
Table 2-4. Fabricated/Assembled Parts
Section IV.  PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
TABLE 2-5. Unit Preventive Maintenance Checks and Services
TABLE 2-5. Unit Preventive Maintenance Checks and Services - Continued - TM-9-6115-644-24_56
Section V. TROUBLESHOOTING
SYMPTOM  INDEX
TABLE 2-6. Unit Troubleshooting
TABLE 2-6. Unit Troubleshooting - Continued - TM-9-6115-644-24_60
TABLE 2-6. Unit Troubleshooting - Continued - TM-9-6115-644-24_61
TABLE 2-6. Unit Troubleshooting - Continued - TM-9-6115-644-24_62
TABLE 2-6. Unit Troubleshooting - Continued - TM-9-6115-644-24_63
TABLE 2-6. Unit Troubleshooting - Continued - TM-9-6115-644-24_64
TABLE 2-6. Unit Troubleshooting - Continued - TM-9-6115-644-24_65
TABLE 2-6. Unit Troubleshooting - Continued - TM-9-6115-644-24_66
TABLE 2-6. Unit Troubleshooting - Continued - TM-9-6115-644-24_67
TABLE 2-6. Unit Troubleshooting - Continued - TM-9-6115-644-24_68
TABLE 2-6. Unit Troubleshooting - Continued - TM-9-6115-644-24_69
TABLE 2-6. Unit Troubleshooting - Continued - TM-9-6115-644-24_70
Section   VI.   RADIO   INTERFERENCE   SUPPRESSION - TM-9-6115-644-24_71
Section  VIII. M AINTENANCE OF  DC ELECTRICAL SYSTEM
Removal. - TM-9-6115-644-24_74
FIGURE 2-3. Batteries and Cables
TABLE 2-7. State of Charge with Specific Gravity Corrected to 80OF (27C)
TABLE 2-8. Specific   Gravity   Temperature   Corrections
Inspection - TM-9-6115-644-24_78
FIGURE 2-4. NATO Slave Receptacle and Cables - TM-9-6115-644-24_79
Section   IX. MAINTENANCE  OF HOUSING
Repair - TM-9-6115-644-24_81
FIGURE 2-5. Generator Set Access Doors - TM-9-6115-644-24_82
Inspection - TM-9-6115-644-24_83
FIGURE 2-6. Control Box Top Panel
TOP HOUSINGS SECTION
FIGURE 2-7. Generator Set Top Housing Section (Sheet 1 of 2)
FIGURE 2-7. Generator Set Top Housing Section (Sheet 2 of 2)
Repair. - TM-9-6115-644-24_88
FRONT HOUSING SECTION - TM-9-6115-644-24_89
FIGURE 2-8. Generator Set Front Housing Section
Repair. - TM-9-6115-644-24_91
REAR HOUSING SECTION - TM-9-6115-644-24_92
Repair. - TM-9-6115-644-24_93
FIGURE 2-9. Generator Set Rear Housing Section
Section X. MAINTENANCE OF CONTROL BOX ASSEMBLY
PANEL LIGHTS
FIGURE 2-10. Control Box Assembly
PRESS TO TEST LIGHTS
FIGURE 2-11. Control Panel Lights - TM-9-6115-644-24_99
FUEL LEVEL INDICATOR.
COOLANT   TEMP.   INDICATOR
Removal - TM-9-6115-644-24_102
OIL PRESSURE INDICATOR - TM-9-6115-644-24_103
TIME METER (TOTAL HOURS).
BATTERY CHARGE AMMETER.
FIGURE 2-12. Control Panel Indicators
FREQUENCY   METER   (HERTZ).
AMMETER (PERCENT RATED CURRENT). - TM-9-6115-644-24_108
KILOWATTMETER   (PERCENT   POWER).
Testing. - TM-9-6115-644-24_110
AC VOLTMETER (VOLTS AC)
MASTER   SWITCH - TM-9-6115-644-24_112
ETHER SWITCH
Inspection. - TM-9-6115-644-24_114
FREQUENCY ADJUST POTENTIOMETER
lnspection - TM-9-6115-644-24_116
AC CIRCUIT INTERRUPTER SWITCH
FIGURE 2-13. Control Panel Switches
Removal - TM-9-6115-644-24_119
Testing - TM-9-6115-644-24_120
Testing - TM-9-6115-644-24_121
Testing - TM-9-6115-644-24_122
Installation - TM-9-6115-644-24_123
Removal. - TM-9-6115-644-24_124
Removal - TM-9-6115-644-24_125
Removal - TM-9-6115-644-24_126
Removal. - TM-9-6115-644-24_127
GROUND FAULT CIRCUIT INTERRUPTER
In-Line Fuse Installation
Installation - TM-9-6115-644-24_131
Inspection - TM-9-6115-644-24_132
Removal. - TM-9-6115-644-24_133
FIGURE 2-14. Control Box Components
AC VOLTAGE REGULATOR. - TM-9-6115-644-24_135
Removal. - TM-9-6115-644-24_136
Removal. - TM-9-6115-644-24_137
Removal. - TM-9-6115-644-24_138
Removal. - TM-9-6115-644-24_139
PERMISSIVE PARALLELING RELAY
FIGURE 2-15. Permissive Paralleling Relay Test Set-up
REVERSE POWER RELAY.
FIGURE 2-16. Reverse Power Relay Test Set-up
VOLTAGE SENSING RELAY
GOVERNOR CONTROL UNIT
CONTROL BOX HARNESS - TM-9-6115-644-24_146
Installation - TM-9-6115-644-24_147
TABLE 2-9. Diagnostic Connector Connection Points - TM-9-6115-644-24_148
FIGURE 2-17. Diagnostic Connector Pin Positions
LOAD MEASURING UNIT
FIGURE 2-18. Diode Identification - TM-9-6115-644-24_151
CONTROL PANEL
CONTROL PANEL FRAME
CONTROL BOX SIDE PANELS - TM-9-6115-644-24_154
Inspection - TM-9-6115-644-24_155
FIGURE 2-19. Control Box Panels
Section   Xl.   MAINTENANCE   OF   AIR   INTAKE   AND   EXHAUST   SYSTEM
AIR RESTRICTION INDICATOR - TM-9-6115-644-24_158
FIGURE 2-20. Muffler and Exhaust Pipe
Service - TM-9-6115-644-24_160
AIR   CLEANER   TUBING   AND   BREATHER
FIGURE 2-21. Air Cleaner Assembly
Removal - TM-9-6115-644-24_163
Service. - TM-9-6115-644-24_164
lnspection and Cleaning
FIGURE 2-22. Radiator Cap
FIGURE 2-23. Coolant System
Installation - TM-9-6115-644-24_168
FIGURE 2-24. Fan Guards and Coolant Recovery System
Inspection   and   Cleaning
Inspection   and   Cleaning.
RADIATOR - TM-9-6115-644-24_172
Repair.\
Inspection - TM-9-6115-644-24_174
FIGURE 2-25. Fan Belt
COOLANT RECOVERY SYSTEM
LOW PRESSURE FUEL LINES AND FITTINGS
FIGURE 2-26. Fuel Tank FIller Neck and Low Pressure Fuel System - TM-9-6115-644-24_178
Removal. - TM-9-6115-644-24_179
FUEL   TANK   FILLER   NECK
FUEL   DRAIN   VALVE
LOW   FUEL   LEVEL/AUXILIARY   FUEL   PUMP   FLOAT   SWITCH
Testing - TM-9-6115-644-24_183
FUEL   PICKUP - TM-9-6115-644-24_184
Testing - TM-9-6115-644-24_185
FUEL   FILTER/DRAIN   VALVE   ASSEMBLY
FIGURE 2-27. Ether Start System
ETHER    SOLENOID    VALVE
VOLTAGE   RECONNECTION   TERMINAL   BOARD
FIGURE 2-28. Output Box Assembly
CURRENT   TRANSFORMER - TM-9-6115-644-24_191
POWER POTENTIAL TRANSFORMER - TM-9-6115-644-24_192
CRANKING   RELAY - TM-9-6115-644-24_193
LOAD   OUTPUT   TERMINAL   BOARD.
Inspection - TM-9-6115-644-24_195
LOAD OUTPUT TERMINALS - TM-9-6115-644-24_196
FIGURE 2-29. Load Terminal Board Assembly - TM-9-6115-644-24_197
VARISTORS - TM-9-6115-644-24_198
Removal. - TM-9-6115-644-24_199
OIL   PRESSURE   SENDER
Installation - TM-9-6115-644-24_201
FIGURE 2-30. Engine Switches and Senders
Removal. - TM-9-6115-644-24_203
COOLANT HIGH TEMPERATURE SWITCH - TM-9-6115-644-24_204
MAGNETIC   PICKUP - TM-9-6115-644-24_205
Installation - TM-9-6115-644-24_206
Removal. - TM-9-6115-644-24_207
Section   XVI.   MAINTENANCE   OF   LUBRICATION   SYSTEM - TM-9-6115-644-24_208
FIGURE 2-31. Oil Drain Valve
Section   XVII.   PREPARATION   FOR   SHIPMENT   AND   STORAGE - TM-9-6115-644-24_210
CHAPTER   3 GENERAL    MAINTENANCE    INSTRUCTIONS - TM-9-6115-644-24_211
SYMPTOM   INDEX GENERATOR   SET - TM-9-6115-644-24_212
TABLE 3-1. Direct Support Troubleshooting - TM-9-6115-644-24_213
TABLE 3-1. Direct Support Troubleshooting - Continued - TM-9-6115-644-24_214
TABLE 3-1. Direct Support Troubleshooting - Continued - TM-9-6115-644-24_215
TABLE 3-1. Direct Support Troubleshooting - Continued - TM-9-6115-644-24_216
TABLE 3-1. Direct Support Troubleshooting - Continued - TM-9-6115-644-24_217
TABLE 3-1. Direct Support Troubleshooting - Continued - TM-9-6115-644-24_218
TABLE 3-1. Direct Support Troubleshooting - Continued - TM-9-6115-644-24_219
TABLE 3-1. Direct Support Troubleshooting - Continued - TM-9-6115-644-24_220
Installation - TM-9-6115-644-24_221
FIGURE 3-1. Engine and Generator Assembly - TM-9-6115-644-24_222
ENGINE   ASSEMBLY
FIGURE 3-2. Top Housing   Panel
FIGURE 3-4. Overflow Bottle Assembly
FIGURE 3-5. Top Housing Section Assembly
FIGURE 3-6. Radiator Assembly
FIGURE 3-7. Rear Housing Panel
FIGURE 3-9. Left Side Housing Panels
FIGURE 3-11. Oil Drain Hose
FIGURE 3-13. Right Side Engine
FIGURE 3-14. Load Output Terminal Board
FIGURE 3-15. Radiator Mounting Bracket
Installation - TM-9-6115-644-24_234
Installation - TM-9-6115-644-24_235
REPLACEMENT - TM-9-6115-644-24_236
FIGURE 3-16. Engine Components (Left Side)
FIGURE 3-17. Engine Components (Right Side)
REPLACEMENT (cont)
CHAPTER   4 DIRECT   SUPPORT   MAINTENANCE   INSTRUCTIONS - TM-9-6115-644-24_241
TABLE 4-1. Voltage Adjustment Range (MEP-805A)
Testing - TM-9-6115-644-24_243
Removal. - TM-9-6115-644-24_244
FIGURE 4-1. Test Circuit
Testing - TM-9-6115-644-24_246
Adjustment. - TM-9-6115-644-24_247
FIGURE 4-2. Fuel Injection Pump High Idle Speed Adjustment
Adjustment. (cont) - TM-9-6115-644-24_249
Replacement - TM-9-6115-644-24_250
Inspection - TM-9-6115-644-24_251
LOAD   MEASURING   UNIT
FIGURE 4-3. Control Box Components
Section   Il.   MAINTENANCE   OF   COOLANT   SYSTEM - TM-9-6115-644-24_254
Installation - TM-9-6115-644-24_255
FIGURE 4-4. Fuel Tank
Installation - TM-9-6115-644-24_257
FIGURE 4-5. Output Box Assembly
VOLTAGE RECONNECTION TERMINAL BOARD
Removal - TM-9-6115-644-24_260
CURRENT TRANSFORMER - TM-9-6115-644-24_261
FIGURE 4-6. Testing Current Transformer
Testing - TM-9-6115-644-24_263
POWER POTENTIAL TRANSFORMER - TM-9-6115-644-24_264
OUTPUT BOX PANELS - TM-9-6115-644-24_265
Repair - TM-9-6115-644-24_266
Section V. MAINTENANCE OF ENGINE ACCESSORIES
FIGURE   4-8.   Governor   Actuator   Assembly - TM-9-6115-644-24_268
Installation. - TM-9-6115-644-24_269
FIGURE 4-9. Governor Actuator Adjustment
FIGURE   4-10.   Brushless   Generator   Schematic
GENERATOR   ASSEMBLY
FIGURE 4-11. Generator Assembly Removal
ROTATING RECTIFIER DIODES
FIGURE 4-12. Rectifier Assembly
END BELL AND MAIN BEARING - TM-9-6115-644-24_276
FIGURE 4-13. End Bell Removal
FIGURE 4-14. Generator Assembly
ROTATING RECITIFIER
Removal - TM-9-6115-644-24_280
TABLE 4-3. Generator Resistance Values At 25C (77F)
GENERATOR ASSEMBLY
FIGURE 4-15. Rotor Assembly Lifting Device Typical)
GENERATOR MAIN STATOR AND HOUSING
Section VII.    MAINTENANCE OF SKID BASE
FIGURE 4-16. Skid Base
APPENDIX A REFERENCES
APPENDIX A REFERENCES - CONTINUED
APPENDIX   B MAINTENANCE   ALLOCATION   CHART
EXPLANATION OF CQLUMNS IN MAC, SECTIQN   II.
EXPLANATION OF COLUMNS IN REMARKS, SECTION IV - TM-9-6115-644-24_291
Section II   MAINTENANCE ALLOCATION CHART
Section II MAINTENANCE ALLOCATION CHART - Continued
Section II MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-644-24_294
Section II MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-644-24_295
Section II MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-644-24_296
Section II MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-644-24_297
Section II MAINTENANCE ALLOCATION CHART - Continued - TM-9-6115-644-24_298
Section  III. TOOL AND TEST EQUIPMENT REQUIREMENTS
APPENDIX   C EXPENDABLE/DURABLE   SUPPLIES   AND   MATERIALS   LIST - TM-9-6115-644-24_301
Section II . TABULAR LIST
FIGURE D-1. Cable Assembly, AC Power (P/Ns 88-22126-1 through 88-22126-7)
FIGURE D-2. Cable Assembly, Battery (P/N: 88-22178)
FIGURE D-3. Cable Assembly, Battery (P/N: 88-22127)
FIGURE D-4. Cable Assembly, Battery (P/N: 88-22181)
FlGURE D-5. Cable Assembly, Battery (P/N: 88-22179)
FIGURE D-6. Cable Assembly, Battery (P/N: 88-22207)
FIGURE D-7. Holder, Control Panel (P/N: 88-22120)
FlGURE D-8. Hose Assembly (P/N: 88-20191-6)
FIGURE D-9. Insulation, Panel, Top (P/N: 88-22582)
FIGURE D-10. Insulation, Baffle (P/N: 88-22592)
FIGURE D-11. Insulation, Baffle (P/N: 88-22593)
FIGURE D-12. Insulation, Top, Center (P/N: 88-22584)
FlGURE D-13. Insulation, Top, Rear (P/N: 88-22585)
FlGURE D-14. Insulation, Front Housing (P/N: 88-22591)
FlGURE D15. Insulation, Top, Front (P/N: 88-22586)
FIGURE D-16. Insulation, Top, Center (P/N: 88-22587)
FIGURE D-17. Insulation, Top, Center (P/N: 88-22588)
FIGURE D-18. Insulation, Top, Front (P/N: 88-22583)
FIGURE D-19. Pump Assembly, Fuel (P/N: 88-22546)
FIGURE D-20. Resistor Assembly (P/Ns: 122-3066-1 and 29879)
FIGURE D-21. Resistor Assembly, Volt (P/N: 88-22631)
FIGURE D-22. Resistor-Diode Assembly (P/N: 88-22632)
FIGURE D-23. Resistor-Diode Assembly (P/N: 88-22106)
FIGURE D-24. Solenold Assembly (P/N: 88-22553)
FIGURE D-25. Switch Assembly, Fuel Level (P/N: 88-22548)
FIGURE D-26. Wire, Varistor (P/Ns: 88-20305-1 through 88-20305-3, and 88-20305-5)
TABLE   D-1.   INCHES   TO   METRIC   CONVERSION
OF-1. Electrical Schematic
Fo-2. Wiring Diagram (sheet 1 of 4) - TM-9-6115-644-24_332
Fo-2. Wiring Diagram (sheet 2 of 4)
Fo-2. Wiring Diagram (sheet 3 of 4) - TM-9-6115-644-24_334
Fo-2. Wiring Diagram (sheet 4 of 4) - TM-9-6115-644-24_335

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