TM-9-6115-730-24 Generator Set Skid Mounted Tactical Quiet 200 kw 50/60 Hz MEP-809A Manual

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UNIT (FIELD) LEVEL MAINTENANCE WORK PACKAGES - TM-9-6115-730-240027
DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE WORK PACKAGES - TM-9-6115-730-240028
Chapter 1. GENERAL INFORMATION, EQUIPMENT DESCRIPTION AND THEORY OF OPERATION - TM-9-6115-730-240029
WORK PACKAGE INDEX - TM-9-6115-730-240030
GENERAL INFORMATION - TM-9-6115-730-240031
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) - TM-9-6115-730-240032
WARRANTY INFORMATION - TM-9-6115-730-240033
Table 1. Manufacturer's Warranties for 200 kW Generator Set. - TM-9-6115-730-240034
Table 1. Manufacturer's Warranties for 200 kW Generator Set - Continued.
NOMENCLATURE CROSS REFERENCE LIST - TM-9-6115-730-240036
LIST OF ABBREVIATIONS AND ACRONYMS - TM-9-6115-730-240037
LIST OF ABBREVIATIONS AND ACRONYMS - Continued - TM-9-6115-730-240038
SAFETY, CARE, AND HANDLING INFORMATION - TM-9-6115-730-240039
EQUIPMENT DESCRIPTION AND DATA - TM-9-6115-730-240041
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - TM-9-6115-730-240042
Figure 1. 200 kW Tactical Quiet Generator Location of Components (Sheet 2 of 6).
Figure 1. 200 kW Tactical Quiet Generator Location of Components (Sheet 3 of 6).
Figure 1. 200 kW Tactical Quiet Generator Location of Components (Sheet 4 of 6).
Figure 1. 200 kW Tactical Quiet Generator Location of Components (Sheet 5 of 6).
ALTERNATOR - TM-9-6115-730-240047
LOAD BOARD
DEAD CRANK SWITCH - TM-9-6115-730-240049
GENERATOR HOUSING
EQUIPMENT DATA - TM-9-6115-730-240051
Table 1. 200 kW TQG Equipment Data - TM-9-6115-730-240052
THEORY OF OPERATION - TM-9-6115-730-240053
ENGINE SENSORS - TM-9-6115-730-240054
Speed Input
FUEL SYSTEM - TM-9-6115-730-240056
Figure 2. Fuel System.
AUXILIARY FUEL SYSTEM
ELECTRONIC UNIT INJECTOR FUEL SYSTEM
ENGINE COOLING SYSTEM - TM-9-6115-730-240060
LUBRICATION SYSTEM - TM-9-6115-730-240061
Figure 5. Engine Lubrication System.
Engine Lubrication
AIR INLET AND EXHAUST SYSTEM - TM-9-6115-730-240064
AC POWER OUTPUT - TM-9-6115-730-240065
DC POWER DISTRIBUTION - TM-9-6115-730-240066
Batteries - TM-9-6115-730-240067
Engine Control Switch (ECS)
BATTLE SHORT Switch (BSS) Input to ECM - TM-9-6115-730-240069
SYNC MODE Switch (SMS)
AC POWER DISTRIBUTION - TM-9-6115-730-240071
Digital Voltage Regulator (DVR) A3 - TM-9-6115-730-240072
ELECTRONIC MODULAR CONTROL PANEL (EMCP)
GENERATOR SET CONTROL (GSC) - TM-9-6115-730-240074
GSC Outputs - TM-9-6115-730-240075
Table 1. GSC Display Relay Identification. - TM-9-6115-730-240076
DIGITAL VOLTAGE REGULATOR (DVR A3) MODULE
Startup Profile
Loading and Stopping Profile - TM-9-6115-730-240079
LOAD SHARING MODULE (LSM A4) INTERNAL OPERATION - TM-9-6115-730-240080
Speed Trim Summer - TM-9-6115-730-240081
GENERATOR - TM-9-6115-730-240082
WINTERIZATION KIT - TM-9-6115-730-240083
COMMON TOOLS AND TEST EQUIPMENT - TM-9-6115-730-240084
Chapter 2. FIELD LEVEL TROUBLESHOOTING PROCEDURES - TM-9-6115-730-240085
WORK PACKAGE INDEX - TM-9-6115-730-240086
INTRODUCTION - TM-9-6115-730-240087
TQG TROUBLESHOOTING - TM-9-6115-730-240088
GSC ALARM INDICATORS AND FAULT CODE TROUBLESHOOTING - TM-9-6115-730-240089
DIAGNOSTIC EVENTS AND EVENT CODES - TM-9-6115-730-240090
GSC FAULT CODES - TM-9-6115-730-240091
VIEWING FAULT LOG OP1 - TM-9-6115-730-240092
FAULT LOG CLEARING OP4 - TM-9-6115-730-240093
TRANSIENT CODES DURING TROUBLESHOOTING - TM-9-6115-730-240094
DVR FAULT CODE TROUBLESHOOTING - TM-9-6115-730-240095
TROUBLESHOOTING USING MAINTENANCE SUPPORT DEVICE (MSD) AND ELECTRONIC TECHNICIAN (ET) TOOL - TM-9-6115-730-240096
TROUBLESHOOTING INDEX - TM-9-6115-730-240097
GSC FAULT CODE - TM-9-6115-730-240098
GSC FAULT CODE - Continued - TM-9-6115-730-240099
GSC FAULT CODE - Continued - TM-9-6115-730-240100
DVR FAULT CODE - TM-9-6115-730-240101
FAILURES WITHOUT A FAULT CODE
GSC ALARM INDICATORS AND FAULT CODE TROUBLESHOOTING PROCEDURES - TM-9-6115-730-240103
TROUBLESHOOTING USING DEDICATED SHUTDOWN INDICATORS - TM-9-6115-730-240104
OVERCRANK light - TM-9-6115-730-240105
FAULT ALARM light flashing yellow. - TM-9-6115-730-240106
Undiagnosed shutdown. - TM-9-6115-730-240107
SP FAULT CODE TROUBLESHOOTING PROCEDURES - TM-9-6115-730-240109
Low Fuel Level.
Bus Frequency Fault (Paralleling Only)
CORRECTIVE ACTION - TM-9-6115-730-240112
AL FAULT CODE TROUBLESHOOTING PROCEDURES - TM-9-6115-730-240113
High Coolant Temperature
Low Coolant Temperature - TM-9-6115-730-240115
Fault Detected by Engine ECM - TM-9-6115-730-240116
Generator Over Voltage - TM-9-6115-730-240117
Generator Over Frequency - TM-9-6115-730-240118
Generator Reverse Power - TM-9-6115-730-240119
Phase Over Current
Phase A No Voltage Input at GSC input (P7-10) - TM-9-6115-730-240121
Incorrect Phase Sequence - Paralleling fault code - TM-9-6115-730-240122
Improper Generator or Bus Voltage - Paralleling fault code - TM-9-6115-730-240123
Synchronizer Time-out - Paralleling fault code - TM-9-6115-730-240124
GSC FAULT CODE TROUBLESHOOTING PROCEDURES - TM-9-6115-730-240125
TROUBLESHOOTING USING GSC FAULT CODES - TM-9-6115-730-240126
TROUBLESHOOTING USING GSC FAULT CODES - Continued - TM-9-6115-730-240127
TROUBLESHOOTING USING GSC FAULT CODES - Continued - TM-9-6115-730-240128
8 Volt Power Supply not Normal.
Throttle Position Signal. - TM-9-6115-730-240130
Fuel Pressure Sensor. - TM-9-6115-730-240131
Fuel Pressure Sensor. - TM-9-6115-730-240132
High Fuel Pressure Warning. - TM-9-6115-730-240133
Derate Overridden.
Oil Pressure Sensor. - TM-9-6115-730-240135
Coolant Temperature Sensor.
Low Coolant Sensor.
CORRECTIVE ACTION - Continued - TM-9-6115-730-240138
Electrical System Voltage. - TM-9-6115-730-240139
Engine Oil Maintenance Required.
Intake manifold air temperature sensor.
CORRECTIVE ACTION Continued
Fuel Temperature Sensor.
Loss of Engine Speed Signal. - TM-9-6115-730-240144
Crankshaft (bottom) engine timing sensor.
CAT Data Link. - TM-9-6115-730-240146
ECM Self Test. - TM-9-6115-730-240147
5 V Sensor Power Supply.
CORRECTIVE ACTION - Continued - TM-9-6115-730-240149
E-Stop Shutdown. - TM-9-6115-730-240150
GSC Electronic Control. - TM-9-6115-730-240151
GSC 8V Sensor Power Supply. - TM-9-6115-730-240152
Turbo Outlet Pressure Sensor.
Atmospheric Pressure Sensor. - TM-9-6115-730-240154
Cool Down circuit (P7-36). - TM-9-6115-730-240155
ENGINE CONTROL switch. - TM-9-6115-730-240156
Camshaft (Top) Engine Timing Sensor.
Low Engine Oil Pressure Warning (Active & Logged). - TM-9-6115-730-240158
High engine coolant temperature warning (Active & Logged). - TM-9-6115-730-240159
Overspeed Warning (Active and Logged). - TM-9-6115-730-240160
Fuel Filter Restriction Warning (Active and Logged). - TM-9-6115-730-240161
GSC Engine Governor Relay (EGR) Output. - TM-9-6115-730-240162
GSC Generator Fault Relay (GFR) Output. - TM-9-6115-730-240163
GSC Crank Termination Relay (CTR) Output. - TM-9-6115-730-240164
CORRECTIVE ACTION - Continued - TM-9-6115-730-240165
GSC Run Relay (RR) Output. - TM-9-6115-730-240166
GSC Fuel Control Relay (FCR) Output. - TM-9-6115-730-240167
CORRECTIVE ACTION - Continued - TM-9-6115-730-240168
FMI 12 - Failed Component. - TM-9-6115-730-240169
Ether Control Relay.
Engine Electronic Control Module. - TM-9-6115-730-240171
Customer Communication Module (CCM) Data Link. - TM-9-6115-730-240172
Close Breaker Output.
Speed Adjust 1 Output (P7-27 (+) and P7-28 (-).
CORRECTIVE ACTION - Continued - TM-9-6115-730-240175
K1 Sense Input (P7-25). - TM-9-6115-730-240176
Dead Bus Sense Input (P7-29). - TM-9-6115-730-240177
AC Transformer Box (ATB) Sensor. - TM-9-6115-730-240178
Bus Transformer Box (BTB) Sensor. - TM-9-6115-730-240179
Turbo Air Inlet Pressure Sensor. - TM-9-6115-730-240180
Turbo air inlet pressure sensor. - TM-9-6115-730-240181
DVR FAULT CODE TROUBLESHOOTING PROCEDURES - TM-9-6115-730-240183
Internal Memory Failure
Internal Watchdog Failure
Rotating Diode Defective.
Reverse VAR (Alarm Fault) - TM-9-6115-730-240187
Undervoltage.
CORRECTIVE ACTION - Continued - TM-9-6115-730-240189
Overvoltage.
Overexcitation - TM-9-6115-730-240191
Reverse VAR (Shutdown Fault) - TM-9-6115-730-240192
Instantaneous Trip - TM-9-6115-730-240193
Loss of Frequency
DVR Memory Failure (Severe Fault)
FAILURES WITHOUT A FAULT CODE TROUBLESHOOTING PROCEDURES - TM-9-6115-730-240197
Figure 1. SMMS Relay Location
CORRECTIVE ACTION - Continued - TM-9-6115-730-240199
Setpoint Programming Error. - TM-9-6115-730-240200
GSC Operation Is Erratic.
Display Of Voltage on GSC is Zero For One or More Phases.
Display of Current on GSC is Zero For One or More Phases.
Display of Voltage on GSC is Inaccurate.
Display of Current on GSC is Inaccurate.
Display of Power on GSC is Inaccurate.
Generator Produces Low Voltage Under No Load Condition.
CORRECTIVE ACTION - Continued - TM-9-6115-730-240208
Generator Produces Low Voltage When Load is Applied. - TM-9-6115-730-240209
Generator Produces Fluctuating Voltage. - TM-9-6115-730-240210
Generator Produces High Voltage. - TM-9-6115-730-240211
Generator is Overheating.
Improper Load. - TM-9-6115-730-240213
Improper Engine Operation.
Load Sharing Module (LSM) A4 Erratic Operation. - TM-9-6115-730-240215
Load Sharing Module Malfunction.
Starter Motor Defective.
Engine Cranks But Will Not Start. - TM-9-6115-730-240218
Engine Timing Incorrect.
Ether Injection System Malfunction.
Engine Misfires, Runs Rough, or is Unstable. - TM-9-6115-730-240221
ECM may not be leaving cold mode operation. - TM-9-6115-730-240222
Low Power/Poor or No Response to Throttle. - TM-9-6115-730-240223
ECM may not be leaving cold mode operation. - TM-9-6115-730-240224
Intermittent Engine Shut Downs. - TM-9-6115-730-240225
Engine Timing.
Excessive White Smoke. - TM-9-6115-730-240227
Can Not Reach Operating Engine RPM. - TM-9-6115-730-240228
Fuel Supply Problem. - TM-9-6115-730-240229
Engine Temperature
Poor Acceleration or Response. - TM-9-6115-730-240231
Electrical Connections Faulty
Poor Fuel Consumption. - TM-9-6115-730-240233
Engine Stalls at Low RPM. - TM-9-6115-730-240234
Fuel Supply Problem. - TM-9-6115-730-240235
Auxiliary Fuel Pump Does Not Operate. - TM-9-6115-730-240236
Auxiliary Fuel Pump Relay.
Engine Runs Out of Fuel With No LOW FUEL LEVEL Alarm. - TM-9-6115-730-240238
Alternator Does Not Charge Batteries. - TM-9-6115-730-240239
Coolant in Engine Oil. - TM-9-6115-730-240240
Coolant Temperature Too High. - TM-9-6115-730-240241
Air in Coolant. - TM-9-6115-730-240242
Thermostat Malfunction. - TM-9-6115-730-240243
ECM Will Not Communicate With Other Systems or Display Modules. - TM-9-6115-730-240244
Engine Oil in Coolant. - TM-9-6115-730-240245
Engine Oil in Exhaust System. - TM-9-6115-730-240246
Engine Oil Temperature Too High. - TM-9-6115-730-240247
Incorrect Oil Level.
Engine Vibration. - TM-9-6115-730-240249
Excessive Engine Oil Consumption. - TM-9-6115-730-240250
Excessive Valve Lash. - TM-9-6115-730-240251
Fuel in Engine Oil. - TM-9-6115-730-240252
Intermittent Low Power or Power Cutout. - TM-9-6115-730-240253
Low Engine Oil Pressure. - TM-9-6115-730-240254
Oil Filter Defective.
Mechanical Noise (Knock) in Engine. - TM-9-6115-730-240256
Noise Coming From Cylinder. - TM-9-6115-730-240257
ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING SOFTWARE INSTALLATION - TM-9-6115-730-240259
Figure 1. Connecting Caterpillar Communication Adapter.
LOADING ELECTRONIC TECHNICIAN (ET) SOFTWARE - TM-9-6115-730-240261
USING ELECTRONIC TECHNICIAN (ET) SOFTWARE - TM-9-6115-730-240262
Figure 2. Caterpillar ET Opening Screen. - TM-9-6115-730-240263
Table 1. Caterpillar ET Tool Navigation Icons. - TM-9-6115-730-240264
Diagnostics Tests
Figure 3. Cat ET Diagnostic Tests. - TM-9-6115-730-240266
ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - TM-9-6115-730-240267
ELECTRONIC TECHNICIAN (FIELD) LEVEL TROUBLESHOOTING - TM-9-6115-730-240268
ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - TM-9-6115-730-240269
Figure 1. 24 Vdc Electrical Circuits.
ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued - TM-9-6115-730-240271
Table 1. ECM Supply Voltage Test Points. - TM-9-6115-730-240272
Table 2. + Battery Voltage Input to ECM Test Points.
System Operation Description - TM-9-6115-730-240274
CORRECTIVE ACTION - Continued - TM-9-6115-730-240275
Figure 3. Timing Sensors.
CORRECTIVE ACTION - Continued - TM-9-6115-730-240277
Figure 4. Ether Injection System Circuit.
ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued - TM-9-6115-730-240279
ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued - TM-9-6115-730-240280
Injector Solenoid Circuit Test. - TM-9-6115-730-240281
Figure 5. Injector Solenoid Circuit.
Cylinder 1 - 6 Injector Solenoids
CORRECTIVE ACTION - Continued - TM-9-6115-730-240284
CORRECTIVE ACTION - Continued - TM-9-6115-730-240285
Table 3. Injector Solenoid Harness Terminals.
CORRECTIVE ACTION - Continued - TM-9-6115-730-240287
Speed Control Test. - TM-9-6115-730-240288
Figure 6. Speed Control Circuits.
Table 4. Speed Control Circuit Test Points.
CORRECTIVE ACTION - Continued - TM-9-6115-730-240291
Electronic Service Tool (Cat ET) will not communicate with ECM. - TM-9-6115-730-240292
CORRECTIVE ACTION - Continued - TM-9-6115-730-240293
Engine Timing Sensor Calibrate. - TM-9-6115-730-240294
Figure 7. Timing Calibration Plug.
CORRECTIVE ACTION - Continued - TM-9-6115-730-240296
Flash Programming - TM-9-6115-730-240297
Engine Fuel Pressure Reading. - TM-9-6115-730-240298
Engine Status
Load Injector Code.
CORRECTIVE ACTION - TM-9-6115-730-240301
Chapter 3. UNIT (FIELD) LEVEL MAINTENANCE INSTRUCTIONS - TM-9-6115-730-240303
WORK PACKAGE INDEX - TM-9-6115-730-240304
WORK PACKAGE INDEX (cont) - TM-9-6115-730-240305
SERVICE UPON RECEIPT - TM-9-6115-730-240307
PRELIMINARY CHECKS AND ADJUSTMENT OF EQUIPMENT - TM-9-6115-730-240308
OUTPUT VOLTAGE SETTING - TM-9-6115-730-240309
PMCS INTRODUCTION - TM-9-6115-730-240311
INTRODUCTION - TM-9-6115-730-240312
INSPECTION - TM-9-6115-730-240313
PMCS COLUMN DESCRIPTIONS (TABLE 1)
PMCS, INCLUDING LUBRICATION INSTRUCTIONS - TM-9-6115-730-240315
Table 1. Preventive Maintenance Checks and Services - TM-9-6115-730-240316
Table 1. Preventive Maintenance Checks and Services - Continued. - TM-9-6115-730-240317
Table 1. Preventive Maintenance Checks and Services - Continued. - TM-9-6115-730-240318
Table 1. Preventive Maintenance Checks and Services - Continued. - TM-9-6115-730-240319
Table 2. PMCS Mandatory Replacement Parts List. - TM-9-6115-730-240320
LUBRICATION INSTRUCTIONS - TM-9-6115-730-240321
Table 3. Engine Oil. - TM-9-6115-730-240322
Table 6. Lubrication Requirements. - TM-9-6115-730-240323
GENERAL MAINTENANCE INSTRUCTIONS - TM-9-6115-730-240325
CLEANING INSTRUCTIONS - TM-9-6115-730-240326
INSPECTION INSTRUCTIONS
RIGHT BATTERY ACCESS DOOR ASSEMBLY MAINTENANCE - TM-9-6115-730-240329
Figure 1. Right Battery Access Door Assembly. - TM-9-6115-730-240330
DISASSEMBLY - TM-9-6115-730-240331
LEFT BATTERY ACCESS DOOR ASSEMBLY MAINTENANCE - TM-9-6115-730-240333
Figure 1. Left Battery Access Door Assembly. - TM-9-6115-730-240334
ASSEMBLY - TM-9-6115-730-240335
CONTROL BOX DOOR ASSEMBLY MAINTENANCE - TM-9-6115-730-240337
ASSEMBLY - TM-9-6115-730-240338
Figure 1. Control Box Door Assembly. - TM-9-6115-730-240339
LEFT FRONT DOOR ASSEMBLY (LATCH) MAINTENANCE - TM-9-6115-730-240341
Figure 1. Left Front Door Assembly (Latch). - TM-9-6115-730-240342
ASSEMBLY - TM-9-6115-730-240343
INSTALLATION - TM-9-6115-730-240344
LEFT REAR DOOR ASSEMBLY MAINTENANCE - TM-9-6115-730-240345
Figure 1. Left Rear Door Assembly (Sheet 1 of 2).
Figure 1. Left Rear Door Assembly (Sheet 2 of 2).
DISASSEMBLY - TM-9-6115-730-240348
INSTALLATION - TM-9-6115-730-240349
LEFT REAR DOOR ASSEMBLY (LATCH) MAINTENANCE - TM-9-6115-730-240351
Figure 1. Left Rear Door Assembly (Latch) (Sheet 1 of 2).
Figure 1. Left Rear Door Assembly (Latch) (Sheet 2 of 2).
DISASSEMBLY - TM-9-6115-730-240354
INSTALLATION - TM-9-6115-730-240355
LOAD BOARD DOOR ASSEMBLY MAINTENANCE - TM-9-6115-730-240357
Figure 1. Load Board Door Assembly. - TM-9-6115-730-240358
ASSEMBLY - TM-9-6115-730-240359
RIGHT FRONT DOOR ASSEMBLY (LATCH) MAINTENANCE - TM-9-6115-730-240361
Figure 1. Right Front Door Assembly (Latch). - TM-9-6115-730-240362
ASSEMBLY - TM-9-6115-730-240363
RIGHT FRONT DOOR ASSEMBLY AND STORAGE BOX ASSEMBLY MAINTENANCE
Figure 1. Right Front Door Assembly.
DISASSEMBLY - TM-9-6115-730-240367
REMOVAL - TM-9-6115-730-240368
Figure 2. Storage Box Assembly.
RIGHT REAR DOOR ASSEMBLY MAINTENANCE - TM-9-6115-730-240371
Figure 1. Right Rear Door Assembly. - TM-9-6115-730-240372
DISASSEMBLY - TM-9-6115-730-240373
RIGHT REAR DOOR ASSEMBLY (LATCH) MAINTENANCE - TM-9-6115-730-240375
Figure 1. Right Rear Door Assembly (Latch). - TM-9-6115-730-240376
DISASSEMBLY - TM-9-6115-730-240377
ACCESS COVERS MAINTENANCE - TM-9-6115-730-240379
INSTALLATION - TM-9-6115-730-240380
Figure 1. Access Covers. - TM-9-6115-730-240381
FRONT ROOF SECTION HOUSING ASSEMBLY MAINTENANCE - TM-9-6115-730-240383
REMOVAL - TM-9-6115-730-240384
Figure 1. Front Roof Section Housing Assembly (Sheet 1 of 2). - TM-9-6115-730-240385
Figure 1. Front Roof Section Housing Assembly (Sheet 2 of 2). - TM-9-6115-730-240386
ASSEMBLY - TM-9-6115-730-240387
REAR ROOF SECTION HOUSING ASSEMBLY MAINTENANCE - TM-9-6115-730-240389
Figure 1. Rear Roof Section Housing Assembly.
DISASSEMBLY - TM-9-6115-730-240391
ENGINE GENERATOR COMPARTMENT CEILING ASSEMBLY MAINTENANCE - TM-9-6115-730-240393
REMOVAL - TM-9-6115-730-240394
Figure 1. Engine Generator Compartment Ceiling Assembly. - TM-9-6115-730-240395
INSTALLATION - TM-9-6115-730-240396
GENERATOR ACCESS COVER ASSEMBLY MAINTENANCE - TM-9-6115-730-240397
ASSEMBLY - TM-9-6115-730-240398
Figure 1. Generator Access Cover Assembly. - TM-9-6115-730-240399
FRONT SECTION HOUSING ASSEMBLY MAINTENANCE - TM-9-6115-730-240401
Figure 1. Front Section Housing Assembly (Sheet 1 of 2). - TM-9-6115-730-240402
Figure 1. Front Section Housing Assembly (Sheet 2 of 2). - TM-9-6115-730-240403
DISASSEMBLY - TM-9-6115-730-240404
INSTALLATION - TM-9-6115-730-240405
REAR SECTION HOUSING ASSEMBLY MAINTENANCE - TM-9-6115-730-240407
Figure 1. Rear Section Housing Assembly. - TM-9-6115-730-240408
DISASSEMBLY - TM-9-6115-730-240409
LEFT CENTER PANEL ASSEMBLY MAINTENANCE - TM-9-6115-730-240411
Figure 1. Left Center Panel Assembly. - TM-9-6115-730-240412
INSTALLATION - TM-9-6115-730-240413
RIGHT CENTER PANEL ASSEMBLY MAINTENANCE - TM-9-6115-730-240415
Figure 1. Right Center Panel Assembly. - TM-9-6115-730-240416
INSTALLATION - TM-9-6115-730-240417
RIGHT REAR PANEL ASSEMBLY MAINTENANCE - TM-9-6115-730-240419
INSTALLATION - TM-9-6115-730-240420
Figure 1. Right Rear Panel Assembly. - TM-9-6115-730-240421
LEFT REAR PANEL ASSEMBLY MAINTENANCE - TM-9-6115-730-240423
Figure 1. Left Rear Panel Assembly. - TM-9-6115-730-240424
DOOR SUPPORT ASSEMBLY MAINTENANCE - TM-9-6115-730-240425
Figure 1. Door Support Assembly. - TM-9-6115-730-240426
INSTALLATION - TM-9-6115-730-240427
CONTROL BOX PANEL ASSEMBLY MAINTENANCE - TM-9-6115-730-240429
Table 1. WP 0041 Guide. - TM-9-6115-730-240430
Figure 1. Control Box Panel Assembly (Sheet 1 of 4). - TM-9-6115-730-240431
Figure 1. Control Box Panel Assembly (Sheet 2 of 4). - TM-9-6115-730-240432
Figure 1. Control Box Panel Assembly (Sheet 3 of 4). - TM-9-6115-730-240433
Figure 1. Control Box Panel Assembly (Sheet 4 of 4). - TM-9-6115-730-240434
DISASSEMBLY - TM-9-6115-730-240435
VOLTAGE Adjust Potentiometer Test - TM-9-6115-730-240436
FREQUENCY Adjust Potentiometer Test - TM-9-6115-730-240437
ASSEMBLY - TM-9-6115-730-240438
INSTALLATION - TM-9-6115-730-240439
CONTROL BOX ASSEMBLY MAINTENANCE - TM-9-6115-730-240441
Figure 1. Control Box. - TM-9-6115-730-240442
Table 1. WP 0042 Guide.
Table 1. WP 0042 Guide - Continued.
Figure 2. Control Box Assembly (Sheet 1 of 5). - TM-9-6115-730-240445
Figure 2. Control Box Assembly (Sheet 2 of 5).
Figure 2. Control Box Assembly (Sheet 3 of 5).
Figure 2. Control Box Assembly (Sheet 4 of 5).
Figure 2. Control Box Assembly (Sheet 5 of 5).
DISASSEMBLY - TM-9-6115-730-240450
ASSEMBLY - TM-9-6115-730-240451
ASSEMBLY - Continued - TM-9-6115-730-240452
INSTALLATION - TM-9-6115-730-240453
LSM A4 LOAD GAIN ADJUSTMENT
RESISTOR ASSEMBLY A7 MAINTENANCE - TM-9-6115-730-240455
Figure 1. Resistor Assembly A7. - TM-9-6115-730-240456
TEST - TM-9-6115-730-240457
CONTROL BOX HARNESS ASSEMBLY MAINTENANCE - TM-9-6115-730-240459
REPAIR OR REPLACEMENT - TM-9-6115-730-240460
RECONNECTION TERMINAL BOARD ASSEMBLY MAINTENANCE - TM-9-6115-730-240461
Figure 1. Reconnection Terminal Board Assembly. - TM-9-6115-730-240462
ASSEMBLY - TM-9-6115-730-240463
LOAD TERMINAL BOARD ASSEMBLY MAINTENANCE - TM-9-6115-730-240465
Figure 1. Load Terminal Board Assembly (Sheet 1 of 2).
Figure 1. Load Terminal Board Assembly (Sheet 2 of 2).
DISASSEMBLY - TM-9-6115-730-240468
ASSEMBLY - TM-9-6115-730-240469
BATTERY CABLE ASSEMBLIES MAINTENANCE - TM-9-6115-730-240471
REMOVAL - TM-9-6115-730-240472
Figure 1. Battery Cable Assemblies (Sheet 1 of 2). - TM-9-6115-730-240473
Figure 1. Battery Cable Assemblies (Sheet 2 of 2). - TM-9-6115-730-240474
INSTALLATION - TM-9-6115-730-240475
INSTALLATION - Continued - TM-9-6115-730-240476
POWER CABLE ASSEMBLIES MAINTENANCE - TM-9-6115-730-240477
Figure 1. Power Cable Assemblies. - TM-9-6115-730-240478
REMOVAL - TM-9-6115-730-240479
INSTALLATION - TM-9-6115-730-240480
MAIN LOAD CONTACTOR MAINTENANCE
Figure 1. Main Load Contactor.
INSTALLATION - TM-9-6115-730-240483
BATTERIES MAINTENANCE - TM-9-6115-730-240485
REMOVAL - TM-9-6115-730-240486
Figure 1. Batteries.
TEST AND INSPECTION - TM-9-6115-730-240488
INSTALLATION - TM-9-6115-730-240489
BATTERY DISCONNECT SWITCH MAINTENANCE - TM-9-6115-730-240491
REMOVAL - TM-9-6115-730-240492
Figure 1. Battery Disconnect Switch. - TM-9-6115-730-240493
CURRENT TRANSFORMERS MAINTENANCE
REMOVAL - TM-9-6115-730-240496
Figure 1. Current Transformers (Sheet 1 of 2).
Figure 1. Current Transformers (Sheet 2 of 2).
INSTALLATION - TM-9-6115-730-240499
POTENTIAL TRANSFORMER MAINTENANCE - TM-9-6115-730-240501
Figure 1. Potential Transformer. - TM-9-6115-730-240502
INSTALLATION - TM-9-6115-730-240503
SLAVE RECEPTACLE MAINTENANCE - TM-9-6115-730-240505
REMOVAL - TM-9-6115-730-240506
Figure 1. Slave Receptacle. - TM-9-6115-730-240507
INSTALLATION - TM-9-6115-730-240508
ELECTRICAL INSTALLATION MAINTENANCE - TM-9-6115-730-240509
Table 1. WP 0055 Guide.
Figure 1. Electrical Installation (Sheet 1 of 2).
Figure 1. Electrical Installation (Sheet 2 of 2).
REMOVAL - TM-9-6115-730-240513
INSTALLATION - TM-9-6115-730-240514
INSTALLATION - Continued - TM-9-6115-730-240515
FUEL LEVEL SWITCH ASSEMBLY MAINTENANCE - TM-9-6115-730-240517
Figure 1. Fuel Level Switch Assembly. - TM-9-6115-730-240518
INSTALLATION - TM-9-6115-730-240519
FUEL HOSES MAINTENANCE - TM-9-6115-730-240521
REMOVAL - TM-9-6115-730-240522
Figure 1. Fuel Hoses (Sheet 1 of 4).
Figure 1. Fuel Hoses (Sheet 2 of 4).
Figure 1. Fuel Hoses (Sheet 3 of 4).
Figure 1. Fuel Hoses (Sheet 4 of 4).
INSTALLATION - TM-9-6115-730-240527
INSTALLATION - Continued - TM-9-6115-730-240528
FUEL PICKUP TUBE ASSEMBLY MAINTENANCE - TM-9-6115-730-240529
Figure 1. Fuel Pickup Tube Assembly. - TM-9-6115-730-240530
INSTALLATION - TM-9-6115-730-240531
AUXILIARY FUEL PUMP ASSEMBLY MAINTENANCE
SERVICING - TM-9-6115-730-240534
Figure 1. Auxiliary Fuel Pump Assembly.
INSTALLATION - TM-9-6115-730-240536
FUEL COOLER MAINTENANCE - TM-9-6115-730-240537
REMOVAL - TM-9-6115-730-240538
Figure 1. Fuel Cooler (Sheet 1 of 2). - TM-9-6115-730-240539
Figure 1. Fuel Cooler (Sheet 2 of 2). - TM-9-6115-730-240540
WATER SEPARATOR FILTER AND BRACKET MAINTENANCE - TM-9-6115-730-240541
DRAINING
Figure 1. Water Separator Filter and Bracket. - TM-9-6115-730-240543
WATER SEPARATOR FILTER REMOVAL - TM-9-6115-730-240544
FUEL LEVEL SENDER MAINTENANCE - TM-9-6115-730-240545
Figure 1. Fuel Level Sender (Sheet 1 of 2). - TM-9-6115-730-240546
Figure 1. Fuel Level Sender (Sheet 2 of 2). - TM-9-6115-730-240547
TEST AND INSPECTION - TM-9-6115-730-240548
INSTALLATION - TM-9-6115-730-240549
FUEL TANK MAINTENANCE - TM-9-6115-730-240551
REMOVAL - TM-9-6115-730-240552
Figure 1. Fuel Tank Maintenance. - TM-9-6115-730-240553
INSTALLATION - TM-9-6115-730-240554
COOLANT RECOVERY SYSTEM MAINTENANCE - TM-9-6115-730-240555
REMOVAL - TM-9-6115-730-240556
Figure 1. Coolant Recovery System. - TM-9-6115-730-240557
SURGE TANK MAINTENANCE - TM-9-6115-730-240559
REMOVAL - TM-9-6115-730-240560
Figure 1. Surge Tank. - TM-9-6115-730-240561
INSTALLATION - TM-9-6115-730-240562
FAN AND FAN GUARDS MAINTENANCE - TM-9-6115-730-240563
Table 1. WP 0066 Guide.
Figure 1. Fan and Fan Guards (Sheet 1 of 3). - TM-9-6115-730-240565
Figure 1. Fan and Fan Guards (Sheet 2 of 3). - TM-9-6115-730-240566
Figure 1. Fan and Fan Guards (Sheet 3 of 3). - TM-9-6115-730-240567
REMOVAL - TM-9-6115-730-240568
INSTALLATION - TM-9-6115-730-240569
INSTALLATION - Continued - TM-9-6115-730-240570
INSTALLATION - Continued - TM-9-6115-730-240571
COOLANT HOSE ASSEMBLIES MAINTENANCE - TM-9-6115-730-240573
REMOVAL - TM-9-6115-730-240574
Figure 1. Coolant Hose Assemblies (Sheet 1 of 4).
Figure 1. Coolant Hose Assemblies (Sheet 2 of 4).
Figure 1. Coolant Hose Assemblies (Sheet 3 of 4).
Figure 1. Coolant Hose Assemblies (Sheet 4 of 4).
REMOVAL - TM-9-6115-730-240579
INSTALLATION - TM-9-6115-730-240580
RADIATOR ASSEMBLY MAINTENANCE - TM-9-6115-730-240581
REMOVAL - TM-9-6115-730-240582
Figure 1. Radiator Assembly (Sheet 1 of 2). - TM-9-6115-730-240583
Figure 1. Radiator Assembly (Sheet 2 of 2). - TM-9-6115-730-240584
REPAIR OR REPLACEMENT - TM-9-6115-730-240585
INSTALLATION - TM-9-6115-730-240586
INSTALLATION - Continued - TM-9-6115-730-240587
EXHAUST SYSTEM MAINTENANCE - TM-9-6115-730-240589
REMOVAL - TM-9-6115-730-240590
Figure 1. Exhaust System. - TM-9-6115-730-240591
INSTALLATION - TM-9-6115-730-240592
CRANKCASE VENTILATION FILTER MAINTENANCE - TM-9-6115-730-240593
REMOVAL - TM-9-6115-730-240594
Figure 1. Crankcase Ventilation Filter. - TM-9-6115-730-240595
AIR CLEANER FILTER MAINTENANCE - TM-9-6115-730-240597
REMOVAL - TM-9-6115-730-240598
Figure 1. Air Cleaner Filter. - TM-9-6115-730-240599
AIR CLEANER SYSTEM MAINTENANCE - TM-9-6115-730-240601
REMOVAL - TM-9-6115-730-240602
Figure 1. Air Cleaner System (Sheet 1 of 2). - TM-9-6115-730-240603
Figure 1. Air Cleaner System (Sheet 2 of 2). - TM-9-6115-730-240604
INSTALLATION - TM-9-6115-730-240605
ETHER INJECTION ASSEMBLY MAINTENANCE
REMOVAL - TM-9-6115-730-240608
Figure 1. Ether Injection Assembly.
ALTERNATOR MAINTENANCE - TM-9-6115-730-240611
REMOVAL - TM-9-6115-730-240612
Figure 1. Alternator. - TM-9-6115-730-240613
ALTERNATOR BELT MAINTENANCE
REMOVAL - TM-9-6115-730-240616
Figure 1. Alternator Belt.
BELT TENSION ADJUSTMENT
STARTER MAINTENANCE - TM-9-6115-730-240619
REMOVAL - TM-9-6115-730-240620
Figure 1. Starter. - TM-9-6115-730-240621
TENSIONER MAINTENANCE - TM-9-6115-730-240623
REMOVAL - TM-9-6115-730-240624
Figure 1. Tensioner. - TM-9-6115-730-240625
FUEL PRIMING PUMP MAINTENANCE - TM-9-6115-730-240627
REMOVAL - TM-9-6115-730-240628
Figure 1. Fuel Priming Pump. - TM-9-6115-730-240629
OIL FILTER MAINTENANCE AND OIL CHANGE - TM-9-6115-730-240631
FILTER REMOVAL AND OIL DRAIN - TM-9-6115-730-240632
Figure 1. Oil Filter Maintenance and Oil Change. - TM-9-6115-730-240633
OIL SAMPLING - TM-9-6115-730-240634
FUEL FILTER MAINTENANCE - TM-9-6115-730-240635
Figure 1. Fuel Filter. - TM-9-6115-730-240636
INSTALLATION - TM-9-6115-730-240637
THERMOSTAT MAINTENANCE - TM-9-6115-730-240639
REMOVAL - TM-9-6115-730-240640
Figure 1. Thermostat. - TM-9-6115-730-240641
ENGINE CONTROL MODULE MAINTENANCE - TM-9-6115-730-240643
REMOVAL - TM-9-6115-730-240644
Figure 1. Engine Control Module. - TM-9-6115-730-240645
REPROGRAMMING - TM-9-6115-730-240647
REPROGRAMMING DVR PARAMETERS FOR VOLTAGE AND FREQUENCY CHANGE - TM-9-6115-730-240648
REPROGRAMMING OR VERIFYING DVR PARAMETERS - TM-9-6115-730-240649
Table 2. 200 kW TQG DVR Programming Parameters.
Table 2. 200 kW TQG DVR Programming Parameters - Continued. - TM-9-6115-730-240651
Table 2. 200 kW TQG DVR Programming Parameters - Continued. - TM-9-6115-730-240652
REPROGRAMMING GSC SETPOINTS FOR VOLTAGE AND FREQUENCY CHANGE - TM-9-6115-730-240653
REPROGRAMMING GSC SETPOINTS FOR VOLTAGE AND FREQUENCY CHANGE - Continued - TM-9-6115-730-240654
REPROGRAMMING OR VERIFYING GSC SETPOINTS - TM-9-6115-730-240655
REPROGRAMMING OR VERIFYING GSC SETPOINTS - Continued - TM-9-6115-730-240656
Table 4. 200 kW OP5-0 Engine/Generator Setpoint Programming.
Table 4. 200 kW OP5-0 Engine/Generator Setpoint Programming - Continued. - TM-9-6115-730-240658
Table 4. 200 kW OP5-0 Engine/Generator Setpoint Programming - Continued. - TM-9-6115-730-240659
Table 4. 200 kW OP5-0 Engine/Generator Setpoint Programming - Continued. - TM-9-6115-730-240660
Table 4. 200 kW OP5-0 Engine/Generator Setpoint Programming - Continued. - TM-9-6115-730-240661
Table 5. OP5-1 Protective Relaying Setpoint Programming. - TM-9-6115-730-240662
Table 5. OP5-1 Protective Relaying Setpoint Programming - Continued. - TM-9-6115-730-240663
Table 5. OP5-1 Protective Relaying Setpoint Programming - Continued. - TM-9-6115-730-240664
Table 5. OP5-1 Protective Relaying Setpoint Programming - Continued. - TM-9-6115-730-240665
Table 5. OP5-1 Protective Relaying Setpoint Programming - Continued. - TM-9-6115-730-240666
Table 5. OP5-1 Protective Relaying Setpoint Programming - Continued. - TM-9-6115-730-240667
Table 6. OP5-3 Synchronization Setpoint Programming. - TM-9-6115-730-240668
Table 6. OP5-3 Synchronization Setpoint Programming - Continued. - TM-9-6115-730-240669
Table 7. OP6 Spare Input/Output Setpoint Programming. - TM-9-6115-730-240670
Table 7. OP6 Spare Input/Output Setpoint Programming - Continued. - TM-9-6115-730-240671
Table 7. OP6 Spare Input/Output Setpoint Programming - Continued. - TM-9-6115-730-240672
Table 8. OP8 Voltmeter Ammeter Programming. - TM-9-6115-730-240673
INSTALLATION OF GENERATOR SET ON TRAILER - TM-9-6115-730-240675
Figure 1. Installation of Generator Set on Trailer. - TM-9-6115-730-240676
INSTALLATION - TM-9-6115-730-240677
PREPARATION FOR STORAGE OR SHIPMENT - TM-9-6115-730-240679
PREPARATION FOR STORAGE OR SHIPMENT - TM-9-6115-730-240680
Figure 1. Preparation for Storage or Shipment.
LONG TERM STORAGE - TM-9-6115-730-240682
ILLUSTRATED LIST OF MANUFACTURED ITEMS - TM-9-6115-730-240683
TORQUE LIMITS - TM-9-6115-730-240685
Table 1. Standard Dry Torque Limits. - TM-9-6115-730-240686
Table 2. Metric Dry Torque Limits. - TM-9-6115-730-240687
Table 2. Metric Dry Torque Limits - Continued. - TM-9-6115-730-240688
WIRE LISTS - TM-9-6115-730-240689
INTRODUCTION - TM-9-6115-730-240690
HARNESS INSPECTION PROCEDURES - TM-9-6115-730-240691
Wire Insulation Damage Inspection
Terminal Retention into Socket Inspection - TM-9-6115-730-240693
Figure 1. Engine Sensors (Sheet 1 of 2). - TM-9-6115-730-240694
Figure 1. Engine Sensors (Sheet 2 of 2). - TM-9-6115-730-240695
Figure 2. Wire Harness Connectors (Sheet 1 of 3). - TM-9-6115-730-240696
Figure 2. Wire Harness Connectors (Sheet 2 of 3). - TM-9-6115-730-240697
Figure 2. Wire Harness Connectors (Sheet 3 of 3). - TM-9-6115-730-240698
Table 1. Control Panel Wire List. - TM-9-6115-730-240699
Table 1. Control Panel Wire List - Continued. - TM-9-6115-730-240700
Table 1. Control Panel Wire List - Continued. - TM-9-6115-730-240701
Table 1. Control Panel Wire List - Continued. - TM-9-6115-730-240702
Table 1. Control Panel Wire List - Continued. - TM-9-6115-730-240703
Table 1. Control Panel Wire List - Continued. - TM-9-6115-730-240704
Table 1. Control Panel Wire List - Continued. - TM-9-6115-730-240705
Table 1. Control Panel Wire List - Continued. - TM-9-6115-730-240706
Table 1. Control Panel Wire List - Continued. - TM-9-6115-730-240707
Table 1. Control Panel Wire List - Continued. - TM-9-6115-730-240708
Table 1. Control Panel Wire List - Continued. - TM-9-6115-730-240709
Table 1. Control Panel Wire List - Continued. - TM-9-6115-730-240710
Table 1. Control Panel Wire List - Continued. - TM-9-6115-730-240711
Table 1. Control Panel Wire List - Continued. - TM-9-6115-730-240712
Table 1. Control Panel Wire List - Continued. - TM-9-6115-730-240713
Table 1. Control Panel Wire List - Continued. - TM-9-6115-730-240714
Table 1. Control Panel Wire List - Continued. - TM-9-6115-730-240715
Table 1. Control Panel Wire List - Continued. - TM-9-6115-730-240716
Table 1. Control Panel Wire List - Continued. - TM-9-6115-730-240717
Table 1. Control Panel Wire List - Continued. - TM-9-6115-730-240718
Table 1. Control Panel Wire List - Continued. - TM-9-6115-730-240719
Table 1. Control Panel Wire List - Continued. - TM-9-6115-730-240720
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List. - TM-9-6115-730-240721
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued. - TM-9-6115-730-240722
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued. - TM-9-6115-730-240723
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued. - TM-9-6115-730-240724
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued. - TM-9-6115-730-240725
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued. - TM-9-6115-730-240726
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued. - TM-9-6115-730-240727
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued. - TM-9-6115-730-240728
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued. - TM-9-6115-730-240729
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued. - TM-9-6115-730-240730
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued. - TM-9-6115-730-240731
Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued. - TM-9-6115-730-240732
Table 3. ECM to EMCP Harness Wire List. - TM-9-6115-730-240733
Table 3. ECM to EMCP Harness Wire List - Continued. - TM-9-6115-730-240734
Table 3. ECM to EMCP Harness Wire List - Continued. - TM-9-6115-730-240735
Table 3. ECM to EMCP Harness Wire List - Continued. - TM-9-6115-730-240736
Table 3. ECM to EMCP Harness Wire List - Continued. - TM-9-6115-730-240737
Table 3. ECM to EMCP Harness Wire List - Continued. - TM-9-6115-730-240738
Table 4. Engine Harness Wire List. - TM-9-6115-730-240739
Table 4. Engine Harness Wire List - Continued. - TM-9-6115-730-240740
Table 4. Engine Harness Wire List - Continued. - TM-9-6115-730-240741
Table 4. Engine Harness Wire List - Continued. - TM-9-6115-730-240742
Table 4. Engine Harness Wire List - Continued. - TM-9-6115-730-240743
Table 4. Engine Harness Wire List - Continued. - TM-9-6115-730-240744
Table 5. Engine Harness to Unit Injectors Wire List. - TM-9-6115-730-240745
Table 5. Engine Harness to Unit Injectors Wire List - Continued. - TM-9-6115-730-240746
Table 6. Winterization Control Panel Wire List. - TM-9-6115-730-240747
Table 6. Winterization Control Panel Wire List - Continued. - TM-9-6115-730-240748
Table 6. Winterization Control Panel Wire List - Continued. - TM-9-6115-730-240749
Table 7. Winterization Kit Heater Cable Wire List. - TM-9-6115-730-240750
Table 7. Winterization Kit Heater Cable Wire List - Continued. - TM-9-6115-730-240751
Table 8. Winterization Kit Power Cable Wire List. - TM-9-6115-730-240752
Chapter 4. UNIT (FIELD) LEVEL MAINTENANCE INSTRUCTIONS WINTERIZATION KIT - TM-9-6115-730-240753
WORK PACKAGE INDEX - TM-9-6115-730-240754
WINTERIZATION HEATER CONTROL BOX ASSEMBLY MAINTENANCE - TM-9-6115-730-240755
Figure 1. Winterization Heater Control Box Assembly. - TM-9-6115-730-240756
DISASSEMBLY - TM-9-6115-730-240757
ASSEMBLY - TM-9-6115-730-240758
WINTERIZATION HEATER ASSEMBLY MAINTENANCE - TM-9-6115-730-240759
REMOVAL - TM-9-6115-730-240760
Figure 1. Winterization Heater Assembly. - TM-9-6115-730-240761
INSTALLATION - TM-9-6115-730-240762
WINTERIZATION HEATER HOSES MAINTENANCE - TM-9-6115-730-240763
REMOVAL - TM-9-6115-730-240764
Figure 1. Winterization Heater Hoses.
INSTALLATION - TM-9-6115-730-240766
WINTERIZATION THERMOSTAT, RESISTORS, AND DIODE MAINTENANCE - TM-9-6115-730-240767
REMOVAL - TM-9-6115-730-240768
Figure 1. Winterization Thermostat, Resistors, and Diode. - TM-9-6115-730-240769
INSTALLATION - TM-9-6115-730-240770
WINTERIZATION WIRING HARNESSES MAINTENANCE - TM-9-6115-730-240771
REMOVAL - TM-9-6115-730-240772
Figure 1. Winterization Wiring Harnesses. - TM-9-6115-730-240773
Chapter 5. DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE INSTRUCTIONS - TM-9-6115-730-240775
WORK PACKAGE INDEX - TM-9-6115-730-240776
GENERATOR REPAIR
DISASSEMBLY - TM-9-6115-730-240778
Figure 1. Generator Repair. - TM-9-6115-730-240779
CLEANING - TM-9-6115-730-240780
ASSEMBLY - TM-9-6115-730-240781
ASSEMBLY - Continued - TM-9-6115-730-240782
ASSEMBLY - Continued - TM-9-6115-730-240783
GENERATOR REPLACEMENT - TM-9-6115-730-240785
REMOVAL - TM-9-6115-730-240786
Figure 1. Generator.
INSTALLATION - TM-9-6115-730-240788
ENGINE REPLACEMENT - TM-9-6115-730-240789
REMOVAL - TM-9-6115-730-240790
Figure 1. Engine.
INSTALLATION - TM-9-6115-730-240792
INSTALLATION - Continued - TM-9-6115-730-240793
ENGINE/GENERATOR BASE ASSEMBLY REPAIR - TM-9-6115-730-240795
REPAIR OR REPLACEMENT - TM-9-6115-730-240796
ENGINE ELECTRICAL SYSTEM REPAIR - TM-9-6115-730-240797
Table 1. WP 0098 Guide.
Figure 1. Engine Electrical System Repair (Sheet 1 of 3).
Figure 1. Engine Electrical System Repair (Sheet 2 of 3).
Figure 1. Engine Electrical System Repair (Sheet 3 of 3).
REMOVAL - Continued - TM-9-6115-730-240802
INSTALLATION - TM-9-6115-730-240803
INSTALLATION - Continued - TM-9-6115-730-240804
FAN PULLEY MAINTENANCE - TM-9-6115-730-240805
Figure 1. Fan Pulley. - TM-9-6115-730-240806
INSTALLATION - TM-9-6115-730-240807
VALVE COVER AND BASE MAINTENANCE
REMOVAL - TM-9-6115-730-240810
Figure 1. Valve Cover and Base (Sheet 1 of 3).
Figure 1. Valve Cover and Base (Sheet 2 of 3).
Figure 1. Valve Cover and Base (Sheet 3 of 3).
FUEL FILTER BASE AND MANIFOLD MAINTENANCE
REMOVAL - TM-9-6115-730-240816
Figure 1. Fuel Filter Base and Manifold.
FUEL TRANSFER PUMP MAINTENANCE
Figure 1. Fuel Transfer Pump. - TM-9-6115-730-240820
INSTALLATION - TM-9-6115-730-240821
TURBOCHARGER MAINTENANCE - TM-9-6115-730-240823
REMOVAL - TM-9-6115-730-240824
Figure 1. Turbocharger. - TM-9-6115-730-240825
INSTALLATION - TM-9-6115-730-240826
CRANKSHAFT VIBRATION DAMPER AND PULLEY MAINTENANCE
REMOVAL - TM-9-6115-730-240828
Figure 1. Crankshaft Vibration Damper and Pulley.
CRANKSHAFT FRONT SEAL MAINTENANCE - TM-9-6115-730-240831
REMOVAL - TM-9-6115-730-240832
Figure 1. Crankshaft Front Seal. - TM-9-6115-730-240833
FRONT COVER MAINTENANCE - TM-9-6115-730-240835
REMOVAL - TM-9-6115-730-240836
Figure 1. Front Cover. - TM-9-6115-730-240837
OIL FILTER BASE MAINTENANCE
REMOVAL - TM-9-6115-730-240840
Figure 1. Oil Filter Base.
ASSEMBLY - TM-9-6115-730-240842
OIL COOLER MAINTENANCE - TM-9-6115-730-240843
REMOVAL - TM-9-6115-730-240844
Figure 1. Oil Cooler.
INSTALLATION - TM-9-6115-730-240846
OIL PUMP MAINTENANCE - TM-9-6115-730-240847
Figure 1. Oil Pump.
DISASSEMBLY - TM-9-6115-730-240849
ASSEMBLY - TM-9-6115-730-240850
WATER PUMP MAINTENANCE - TM-9-6115-730-240851
Figure 1. Water Pump. - TM-9-6115-730-240852
INSTALLATION - TM-9-6115-730-240853
FLYWHEEL MAINTENANCE - TM-9-6115-730-240855
REMOVAL - TM-9-6115-730-240856
Figure 1. Flywheel. - TM-9-6115-730-240857
CRANKSHAFT REAR SEAL MAINTENANCE
Figure 1. Crankshaft Rear Seal.
INSTALLATION - TM-9-6115-730-240861
FLYWHEEL HOUSING MAINTENANCE - TM-9-6115-730-240863
REMOVAL - TM-9-6115-730-240864
Figure 1. Flywheel Housing. - TM-9-6115-730-240865
CRANKSHAFT REAR SEAL CARRIER MAINTENANCE
REMOVAL - TM-9-6115-730-240868
Figure 1. Crankshaft Rear Seal Carrier.
EXHAUST MANIFOLD MAINTENANCE - TM-9-6115-730-240871
REMOVAL - TM-9-6115-730-240872
Figure 1. Exhaust Manifold. - TM-9-6115-730-240873
INLET MANIFOLD MAINTENANCE
REMOVAL - TM-9-6115-730-240876
Figure 1. Inlet Manifold.
OIL PAN MAINTENANCE
REMOVAL - TM-9-6115-730-240880
Figure 1. Oil Pan.
UNIT INJECTOR MAINTENANCE - TM-9-6115-730-240883
REMOVAL - TM-9-6115-730-240884
Figure 1. Unit Injector. - TM-9-6115-730-240885
ROCKER SHAFT AND PUSHROD MAINTENANCE
REMOVAL - TM-9-6115-730-240888
Figure 1. Rocker Shaft and Pushrod Removal and Installation.
INSPECTION OF INSTALLED ITEMS
ASSEMBLY - TM-9-6115-730-240891
VALVE LASH CHECK - TM-9-6115-730-240892
Table 1. Crankshaft Positions for Valve Lash Setting. - TM-9-6115-730-240893
VALVE LASH ADJUSTMENT - TM-9-6115-730-240894
VALVE LASH ADJUSTMENT - Continued - TM-9-6115-730-240895
CYLINDER HEAD MAINTENANCE - TM-9-6115-730-240897
REMOVAL - TM-9-6115-730-240898
Figure 1. Cylinder Head.
INSTALLATION - TM-9-6115-730-240900
INSTALLATION - Continued - TM-9-6115-730-240901
Chapter 6. GENERAL SUPPORT Moved to Sustainment (NMWR) - TM-9-6115-730-240903
Chapter 7. SUPPORTING INFORMATION - TM-9-6115-730-240905
WORK PACKAGE INDEX - TM-9-6115-730-240906
REFERENCES - TM-9-6115-730-240907
DETAIL SPECIFICATION
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION - TM-9-6115-730-240911
Maintenance Functions - TM-9-6115-730-240912
Explanation of Columns in the MAC - TM-9-6115-730-240913
Explanation of Columns in the Remarks - TM-9-6115-730-240914
Table 1. MAC.
Table 1. MAC - Continued. - TM-9-6115-730-240916
Table 1. MAC - Continued. - TM-9-6115-730-240917
Table 1. MAC - Continued. - TM-9-6115-730-240918
Table 2. Tools and Test Equipment Requirements. - TM-9-6115-730-240919
Table 3. Remarks. - TM-9-6115-730-240920
Table 3. Remarks - Continued. - TM-9-6115-730-240921
EXPENDABLE AND DURABLE ITEMS LIST - TM-9-6115-730-240923
Table 1. Expendable and Durable Items List - TM-9-6115-730-240924
Table 1. Expendable and Durable Items List - Continued. - TM-9-6115-730-240925
Table 1. Expendable and Durable Items List - Continued. - TM-9-6115-730-240926
Table 1. Expendable and Durable Items List - Continued. - TM-9-6115-730-240927
GLOSSARY - TM-9-6115-730-240929
GLOSSARY - Continued - TM-9-6115-730-240930
TM-9-6115-730-24 Generator Set Skid Mounted Tactical Quiet 200 kw 50/60 Hz MEP-809A Manual

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