CHAPTER 1 INTRODUCTION - TM-9-6115-464-34_17EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRs)TABULATED DATA - TM-9-6115-464-34_19Fuel injector Pump Classification and Rating.Static Exciter and Voltage Regulator Assembly Classification and Ratingovervoltage relay classification and RatingReverse Power Relay Classification and Rating.thermal watt converter classification and rating400 Hz Generator classification and rating50/60 Hz Generator Repair and Replacement Standards400 HZ Generation Repair and Replacement StandardsNut and Bolt Torque DataFuel injection pump - TM-9-6115-464-34_29Table 1-1. FITS AND TOLERANCESTable 1-1. FITS AND TOLERANCES (CONTINUED) - TM-9-6115-464-34_31Table 1-1. FITS AND TOLERANCES (CONTINUED) - TM-9-6115-464-34_32Table 1-1. FITS AND TOLERANCES (CONTINUED) - TM-9-6115-464-34_33CHAPTER 2 GENERAL MAINTENANCE INSTRUCTIONS Section I. REPAIR PARTS, SPECIAL TOOLS, AND EQUIPMENTTable 2-1. TOOLS AND SUPPORT EQUIPMENT (CONTINUED) - TM-9-6115-464-34_36Table 2-1. TOOLS AND SUPPORT EQUIPMENT (CONTINUED) - TM-9-6115-464-34_37Section II. TROUBLESHOOTING - TM-9-6115-464-34_38Table 2-2. TROUBLESHOOTING (CONTINUED) - TM-9-6115-464-34_39Table 2-2. TROUBLESHOOTING (CONTINUED) - TM-9-6115-464-34_40Table 2-2. TROUBLESHOOTING (CONTINUED) - TM-9-6115-464-34_41ENGINE KNOCKSENGINE OIL CONSUMPTION EXCESSIVEBATTERY CHARGING AMMETER SHOWS NO CHARGE WHEN BATTERIES ARE LOWTable 2-2. TROUBLESHOOTING (CONTINUED) - TM-9-6115-464-34_45GENERATORS DO NOT PARALLEL PROPERLY.FREQUENCY DRlFTSFigure 2-1. Engine Assembly, Removal and lnstallationSection Ill. REMOVAL AND INSTALLATION OF MAJOR COMPONENTSInstallation - TM-9-6115-464-34_50GENERATOR ASSEMBLY - TM-9-6115-464-34_51Installation. - TM-9-6115-464-34_52Installation. - TM-9-6115-464-34_53Figure 2-2. Generator Assembly, Removal and Installation - TM-9-6115-464-34_54CHAPTER 3 ENGINE AND GENERATOR REPAIR INSTRUCTIONSCleaning, Inspection, and Repair. - TM-9-6115-464-34_56Figure 31. Starter Assembly, Exploded View (Sheet 1 of 2)Figure 31. Starter Assembly, Exploded View (Sheet 2 of 2)CAUTION - TM-9-6115-464-34_59Testing - TM-9-6115-464-34_60STARTER ASSEMBLY - TM-9-6115-464-34_61Figure 3-2. Starter Assembly Motoring Test Circuit - TM-9-6115-464-34_62Figure 33. Starter Assembly Stalled Torque SetupFigure 3-4. Starter Assembly, Exploded View (Effective with Serial No. RZ60001) (Sheet 1 of 2)Figure 3-4. Starter Assembly, Exploded View (Effective with Serial No. RZ60001) WARNING - TM-9-6115-464-34_66WARNING - TM-9-6115-464-34_67Testing - TM-9-6115-464-34_68BATTERY CHARGING ALTERNATOR - TM-9-6115-464-34_69Cleaning lnspection. and RepairFigure 3-5. Alternator Assembly, Exploded View (Sheet 1 of 2)Figure 3-5. Alternator Assembly, Exploded View (Sheet 2 of 2)Figure 3-6. Rotor Assembly Current Draw Test CircuitAssembly. - TM-9-6115-464-34_74Testing. - TM-9-6115-464-34_75Figure 3-7. Alternator Test Leads InstallationTest alternator output circuit as followsFigure 3-8. Total Circuit Voltage TestFigure 3-9. Alternator Positive Output Circuit TestFigure 3-10. Alternator Negative Output Circuit TestFigure 311. Excitation Voltage TestNOTE - TM-9-6115-464-34_82Figure 3-12. Faulty Voltage Regulator Circuit TestFigure 3-13. Field Current TestSPEED SWITCH.Disassemblv (Mechanical Type)Testing (Electronic Type).Testing (Mechanical Type).Figure 3-15. Speed Switch, Exploded View (Electronic Switch) (Sheet 1 of 2)Installation - TM-9-6115-464-34_90Figure 3-16. Speed Switch Test Points (Electronic Switch) (Sheet 1 of 2)Figure 3-16. Speed Switch Test Points (Mechanical Switch) (Sheet 2 of 2)Section Il. MAINTENANCE OF ENGINE FUEL SYSTEMFigure 3-17. Engine Wiring Harness Assembly, Drawing No. 72-2267 (Sheet 1 of 2)Figure 3-17. Engine Wiring Harness Assembly, Drawing No. 72-2267 (Sheet 2 of 2)MAIN FUEL TANK (METAL)MAIN FUEL TANK (PLASTIC).Figure 3-18. Main Fuel Tank (Metal), Removal and InstallationFigure 3-19. Main Fuel Tank (Plastic), Removal and InstallationFUEL INJECTION PUMP ASSEMBLYFigure 3-20. Fuel Injection Pump Assembly, Removal and InstallationCAUTION - TM-9-6115-464-34_103Figure 3-21. Fuel Injection Pump, Exploded ViewFigure 3-21. Fuel Injection Pump, Exploded View Figure 321. Fuel Injection Pump, Exploded View - TM-9-6115-464-34_106Figure 321. Fuel Injection Pump, Exploded View - TM-9-6115-464-34_107NOTE - TM-9-6115-464-34_108CAUTION - TM-9-6115-464-34_109CAUTION - TM-9-6115-464-34_110CAUTION - TM-9-6115-464-34_111Figure 3-22. Adjusting Fuel Injection Pump Roller-to-Roller DimensionCAUTION - TM-9-6115-464-34_113NOTE - TM-9-6115-464-34_114Fuel Inject Pump Bench Test.WARNING - TM-9-6115-464-34_116Figure 324. Solenoid Armature AdjustmentsTable 3-1. FUEL DELlVERYInstallation. - TM-9-6115-464-34_119FUEL INJECTION NOZZLE HOLDERS AND LINES.FUEL LINESSection Ill. MAINTENANCE OF ENGINE COOLING SYSTEMFigure 3-26. Shutter Control Assembly, Exploded ViewRADIATOR - TM-9-6115-464-34_124SHUTTER ASSEMBLY - TM-9-6115-464-34_125WATER PUMPCleaning, Inspection and Repair - TM-9-6115-464-34_127AsssemblySection IV. MAINTENANCE OF ENGINE LUBRICATION SYSTEMInstallation - TM-9-6115-464-34_130OIL PUMP ASSEMBLYFigure 331. Oil Pump Assembly, Exploded ViewAssembly - TM-9-6115-464-34_133Figure 3-32. Oil Pump Assembly DimensionsSection V. MAINTENANCE OF HYDRAULIC SYSTEMFigure 3-33. Hydraulic Sump, Removal and InstallationHYDRAULIC PUMP ASSEMBLY.Cleaning, Inspection, and Repair - TM-9-6115-464-34_138Installation. - TM-9-6115-464-34_139Figure 3-34. Hydraulic Pump Assembly, Exploded ViewHYDRAULIC SYSTEM FILTER ASSEMBLY. - TM-9-6115-464-34_141Figure 3-35. Hydraulic System Filter Assembly, Exploded ViewHYDRAULIC ACTUATOR UNITFigure 3-36. Hydraulic Actuator Unit, Removal and InstallationFigure 3-37. Hydraulic Actuator Unit, Exploded View (Sheet 1 of 2)Figure 338. Transducer and Armature Coil Schematic DiagramCleaning, Inspection, and Repair. - TM-9-6115-464-34_147Assembly. - TM-9-6115-464-34_148Test without test stand.Figure 3-39. Hydraulic Actuator Unit TestInstallation and Final Adjustment. - TM-9-6115-464-34_151Figure 3-40. Hydraulic Actuator Tests, Schematic DiagramTable 3-2. HYDRAULIC ACTUATOR TEST VALUESSection VI MAINTENANCE OF INTAKE AND EXHAUST SYSTEMS AND BREATHERRemoval. - TM-9-6115-464-34_155FLYWHEEL AND FLYWHEEL HOUSINGFigure 3-42. Flywheel and Flywheel Housing, Exploded ViewTesting - TM-9-6115-464-34_158Figure 3-43. Checking Flywheel Concentricity and AlignmentCleaning, Inspection, and Repair. - TM-9-6115-464-34_160Figure 3-44. Timing Gears and Cover, Exploded ViewInstall gasketFigure 3-45. liming Gear RelationshipsCYLINDER HEAD AND ROCKER ARM ASSEMBLY.Figure 3-46. Cylinder Head and Rocker Assembly, Exploded ViewCleaning, Inspection, and Repair - TM-9-6115-464-34_166NOTE - TM-9-6115-464-34_167Assembly. - TM-9-6115-464-34_168Figure 3-47. Rocker Arm Mounting Blocks InstallationCAMSHAFT - TM-9-6115-464-34_170Disassembly. - TM-9-6115-464-34_171Figure 3-50. Camshaft, Exploded ViewFigure 3-51 .Dimensional Inspection of CamshaftCRANKSHAFT, CONNECTING RODS, AND PISTONS.Disassembly. - TM-9-6115-464-34_175Figure 3-52. Crankshaft, Connecting Rods and Pistons, Exploded ViewCleaning, Inspection, and Repair. - TM-9-6115-464-34_177CAUTION - TM-9-6115-464-34_178Installation. - TM-9-6115-464-34_179CYLINDER BLOCK ASSEMBLYCleaning, Inspection, and Repair. - TM-9-6115-464-34_181Cleaning, Inspection, and Repair. - TM-9-6115-464-34_182Figure 3-53. Cylinder Block Assembly, Exploded ViewSection Vlll. MAINTENANCE OF GENERATOR SET CONTROLSFigure 3-55. Thermal Watt Converter Circuit SchematicControl Cubicle Relay AssemblyCleaning, Inspection, and Repair. - TM-9-6115-464-34_187Figure 3-56. Control Cubicle Housing Assembly, Exploded ViewFigure 357. Control Cubicle Relay Assembly, Exploded ViewInstallation - TM-9-6115-464-34_190Control Cubicle Terrminal Board.FAULT LOCATING INDICATORCleaning, Inspection, and Repair - TM-9-6115-464-34_193Assembly - TM-9-6115-464-34_194Figure 3-59. Control Cubicle Wiring Harness (Sheet 1 of 6) Drawing No. 69-677Figure 3-59. Control Cubicle Wiring Harness (Sheet 2 of 6) Drawing No. 69-677Figure 3-59. Control Cubicle Wiring Harness (Sheet 3 of 6) Drawing No. 69-677Figure 3-59. Control Cubicle Wiring Harness (Sheet 4 of 6) Drawing No. 69-677Figure 3-59. Control Cubicle Wiring Harness (Sheet 5 of 6) Drawing No. 69-677Figure 359. Control Cubicle Wiring Harness (Sheet 6 of 6) Drawing No. 69-677Figure 3-60. Fault Locating Indicator, Exploded View (Sheet 1 of 2)Figure 3-60. Fault Locating Indicator, Exploded View (Sheet 2 of 2)Figure 3-61. Fault Locating Indicator, Schematic DiagramFigure 3-62. Fault Locating Indicator Component Board AssemblyFigure 3-63. Fault Locating Indicator Wiring Harness Drawing No. 722247LOAD MEASURING UNIT.Figure 3-64. Load Measuring Unit, Exploded ViewFigure 3-65. Load Measuring Unit Wiring Harness, Drawing No. 69-511Testing and Repair.Figure 3-66. Load Measuring Unit Component Test and Replacement DiagramELECTRO-HYDRAULIC GOVERNOR CONTROL UNIT.Removal. - TM-9-6115-464-34_212Figure 3-67. Load Measuring Unit Test Circuit and Test Data RelationshipDisassembly. - TM-9-6115-464-34_214Figure 3-68. Electro-Hydraulic Governor Control Unit. Exploded View (Sheet 1 of 2)Figure 3-68. Electro-Hydraulic Governor Control Unit, Exploded View (Sheet 2 of 2)Assembly. - TM-9-6115-464-34_217PottingTable 3-6. 400 Hz Electro-Hydraulic Governor Control Unit Resistance Test ValuesFigure 3-69. 50/60 Hz Governor Control Unit Wiring Harness, Drawing No. 69731 (Sheet 2 of 2)Figure 3-70. 400 Hz Electro-Hydraulic Governor Control Unit Wiring Harness, Drawing No. 69-814 (Sheet 2 of 2)Figure 3-71. Electro-Hydraulic Governor Control Unit Printed Circuit BoardFigure 3-72. 50/60 Hz Governor Control Unit Wiring Diagram, DWG No. 69-730Figure 3-73. 400 Hz EIectro-Hydraulic Governor Control Unit Wiring Diagram, DWG No. 69-633Figure 3-74. 50/60 Hz Governor Control Unit Schematic Diagram, Drawing No. 69-729 (Sheet 1 of 2)Figure 3-74, 50/60 Hz Governor Control Unit Schematic Diagram, Drawing No. 69-729 (Sheet 2 of 2)Figure 375. 400 Hz Electro-Hydraulic Governor Control Unit Schematic Diagram, Drawing No. 69-612 (Sheet 1 of 2)Figure 3-75. 400 Hz Electro-Hydraulic Governor Control Unit Schematic Diagram, Drawing No. 69-812 (Sheet 2 of 2)Figure 3-77. Electro-Hydraulic Governor Control Unit Magnetic Amplifier Bias Test CircuitFigure 3-78. Electro-Hydraulic Governor Control Unit Frequency Sensing Test CircuitFigure 3-79. Electro-Hydraulic Governor Control Unit Rectifier Bridge and Feedback Winding Test CircuitAlignment Procedure.NOTE - TM-9-6115-464-34_235Figure 3-81. Approximate Position of Controls for Connecting Hydraulic ActuatorFigure 3-82. Approximate Position of Controls for Connecting Hydraulic ActuatorFigure 3-83. Electro-Hydraulic Governor Control Unit Control PanelFigure 3-84. Tactical Relay Assembly to Special Relay Assembly Wiring Harness, Drawing No. 72-2224ELECTRIC GOVERNOR CONTROL UNIT (MEP-113A)Adjustment ProcedureFigure 3-85. Functional Theory of OperationFigure 3-86. Governor Control Unit Removal and InstallationTable 3-7. Electric Governor Malfunction TestingACTUATOR UNIT.Section IX. MAINTENANCE OF INTERCONNECTING WIRING HARNESSESFigure 3-87. Actuator Removal and InstallationFigure 3-88. Magnetic Pickup Removal and InstallationAC POWER CONTROL WIRING HARNESS.SPECIAL RELAY ASSEMBLY TO CONTROL CUBICLE ASSEMBLY WIRING HARNESS.Figure 3-89. Special Relay Assembly to Static Exciter Assembly Wiring Harness, Drawing No. 72-2220Figure 3-90. Load Measuring Unit to Tactical Relay Assembly Wiring Harness, Drawing No. 72-2234Figure 3-91. Governor Control Unit to Hydraulic Actuator Unit Wiring Harness, Drawing No. 72-2223 (Electro-Hydraulic Governor Equipped Precise Sets Only)Figure 3-92. 400 Hz Electric Governor System Wiring Harness AssemblyFigure 3-92.400 Hz Electric Governor System Wiring Harness Assembly Figure 3-93. AC Power Control Wiring Harness, Drawing No. 72-2259 (Sheet 1 of 2)Figure 3-93. AC Power Control Wiring Harness, Drawing No. 72-2259 (Sheet 2 of 2)Figure 3-94. Exciter Control Wiring Harness, Drawing No. 73-2288Figure 3-95. Special Relay Assembly to Fault Locating Indicator Wiring Harness, Drawing No. 76-2247Figure 3-96. Special Relay Assembly to Control Cubicle Wiring Harness, Drawing No. 72-2248Figure 3-97. Precise Relay Assebly to Governor Control Unit Wiring Harness, Drawing No. 72-2245 (Electro-Hydraulic Governor Equipped Precise Sets Only)Figure 3-98. Special Relay Assembly to Precise Relay Assembly, Drawing No. 72-2238Section X. MAINTENANCE OF CONVENIENCE AND PARALLELING RECEPTACLES AND WIRING HARNESSFigure 3-99. Convenience and Paralleling Receptacles Wiring Harness, Drawing No. 72-2286MAIN LOAD CONTACTORDisassembly Type BCleaning Inspection and Repair (Type A.)Assembly (Type A)Figure 3-100. Main Load Contactor (Type A), Exploded View (Sheet 1 of 3)Figure 3-100. Main Load Contactor (Type A), Exploded View (Sheet 2 of 3)Figure 3-100. Main Load Contactor (Type A), Exploded View (Sheet 3 of 3)Figure 3-101. Main Load Contactor Type B (Sheet 1 of 3)Figure 3-101. Main Load Contactor (Sheet 2 of 3)Figure 3-101. Main Load Contactor (Sheet 3 of 3)Figure 3-102. Actuator Assembly Adjustment Points (Type A)Figure 3-103. Main Contact Preload Check PointsAdjust auxiliary contacts as followsFigure 3-104. Main Load Contactor Adjustments (Type A)Figure 3-105. Main Load Contactor Schematic Diagram, Contactor to Load Terminals Wiring Harness, Dwg. No. 72-2290, and Contactor to Reconnection Board Wiring Harness, Dwg. No. 72-2225 (Sheet 1 of 3)Contractor to Load terminals Wiring Harness - TM-9-6115-464-34_280Contractor to Load terminals Wiring Harness - TM-9-6115-464-34_281Economizing SwitchInstallation. - TM-9-6115-464-34_283Figure 3-106. Load Terminal Board Assembly, Exploded ViewLOAD TERMINAL BOARD ASSEMBLY - TM-9-6115-464-34_285Figure 3-107. Routing of Generator Leads Through Current TransformersCleaning. Inspection. and TestingFigure 3-109. Current Transformer Test PointELECTROMAGNETIC INTERFERENCE CAPACITORSSection X11. MAINTENANCE OF RELAY TABLE COMPONENTSCleaning, lnspection, and Repair.Figure 3-111. Tactical Relay Assembly, Exploded ViewTest over voltage relay as followsFigure 3-112. Tactical Relay Assembly Wiring Harness, Drawing No. 72-2243 (Sheet 1 of 2)Figure 3-112. Tactical Relay Assembly Wiring Harness, Drawing No. 722243 (Sheet 2 of 2)Figure 3-113. Reverse Power Relay Test CircuitFigure 3-114. Overvoltage Relay Test CircuitFigure 3-115. Short Circuit Relay Test CircuitFigure 3-116. Overload Protective Device Test CircuitInstallation. - TM-9-6115-464-34_300SPECIAL RELAY ASSEMBLY.WARNING - TM-9-6115-464-34_302Figure 3-118. Tactical Relay Resistor Assembly, Exploded ViewFigure 3-119. Special Relay Assembly, Exploded View (Sheet 1 of 2)Figure 3-119. Special Relay Assembly, Exploded View (Sheet 2 of 2)PRECISE RELAY ASSEMBLY - TM-9-6115-464-34_306Figure 3-120. Special Relay Assembly Wiring Harness, Drawing No. 72-2239 (Sheet 1 of 4)Figure 3-120. Special Relay Assembly Wiring Harness, Drawing No. 72-2239 (Sheet 2 of 4)Figure 3-120. Special Relay Assembly Wiring Harness, Drawing No. 72-2239 (Sheet 3 of 4)Figure 3-120. Special Relay Assembly Wiring Harness, Drawing No. 72-2239 (Sheet 4 of 4)Figure 3-121. DC Relay Assembly Schematic DiagramTest under frequency relay as followsFigure 3122. DC Relay Assembly, Exploded ViewFigure 3-123. Precise Relay Assembly, Exploded ViewFigure 3-124. Under Voltage Relay Test CircuitTest permissive paralleling relay as followsFigure 31 26. Permissive Paralleling Relay Test CircuitSTATIC EXCITER AND VOLTAGE REGULATOR ASSEMBLY.Cleaning. lnspection, and Repair.Figure 3-127. Electronics Components AssemblyFigure 3-128. 50/60 Hz Precise Relay Assembly Wiring Harness, Drawing No. 72-2242 (Sheet 1 of 2)Figure 3-128. 50/60 Hz Precise Relay Assembly Wiring Harness, Drawing No. 72-2242 (Sheet 2 of 2)Figure 3-129. 400Hz Precise Relay Assembly Wiring Harness, Drawing No. 722260 (Sheet 1 of 2)Figure 3-129. 400Hz Precise Relay Assembly Wiring Harness, Drawing No. 72-2260 (Sheet 2 of 2)Figure 3130. Static Exciter and Voltage Regulator Assembly, Exploded View (Sheet 1-3)Figure 3-130. Static Exciter and Voltage Regulator Assembly, Exploded View (Sheet 2 of 3)Figure 3-130. Static Exciter and Voltage Regulator Assembly, Exploded View (Sheet 3 of 3)Figure 3-131. 50/60 Hz Static Exciter and Voltage Regulator Schematic Diagram, Drawing No. 72-2629Assembly - TM-9-6115-464-34_329Testing. - TM-9-6115-464-34_330RELAY TABLE COMPONENTS ADJUSTMENTSTable 3-8. STATIC EXCITER AND VOLTAGE REGULATOR RESISTOR AND CAPACITOR VALUESFigure 3132. 400 Hz Static Exciter and Voltage Schematic Diagram, Drawing No. 72-2630A. Static Exciter Wiring Harness (Sheet 1 of 2)B. Static Exciter Wiring (Sheet 2 of 2)Figure 3-133. Static Exciter Wiring Harness,Figure 3133. Static Exciter Wiring HarnessFigure 3134. Static Exciter and Voltage Regulator Assembly Sensing Circuit Bench TestSection XIII. MAINTENANCE OF GENERATOR ASSEMBLIESFigure 3-136. Generator Assembly, Exploded View (Sheet 1 of 2)Figure 3-136. Generator Assembly, Exploded View (Sheet 2 of 2)NOTE - TM-9-6115-464-34_342Figure 3-137. Securing Generator Rotor to StatorFigure 3-138. End Bell Assembly, Exploded ViewFigure 3-139. Generator Rotor and Balance Assembly, Exploded View (Sheet 1 of 2)Figure 3-139. Generator Rotor and Balance Assembly, Exploded View (Sheet 2 of 2)Figure 3140. Lead Block Assembly, Exploded ViewFigure 3-141. Generator Stator Assembly, Exploded ViewWARNING - TM-9-6115-464-34_349NOTE - TM-9-6115-464-34_350Assembly - TM-9-6115-464-34_351Figure 3142. 50/60 Hz Generator Stator Winding Procedures (Sheet 1 of 2)Figure 3-142. 50/60 Hz Generator Stator Winding Procedures (Sheet 2 of 2)Figure 3-143. 400 Hz Generator Stator Winding Procedures (Sheet 1 of 3)Figure 3-143. 400 Hz Generator Stator Winding Procedures (Sheet 2 of 3)Figure 3-143. 400 Hz Generator Stator Winding Procedures (Sheet 3 of 3)Figure 3-144. 50/60 Hz Generator, Rewinding ProceduresFigure 3-145. 400 Hz Generator Rotor Winding ProceduresAssemble end bell assembly as followsFigure 3-146. Generator Exciter Stator Winding Procedures (Sheet 1 of 2)Figure 3-146. Generator Exciter Stator Winding Procedures (Sheet 2 of 2)Figure 3-147. Generator Exciter Rotor Winding Procedures (Sheet 1 of 2)Figure 3-147. Generator Exciter Rotor Winding Procedures (Sheet 2 of 2)Installation - TM-9-6115-464-34_364Equipment Test of Field Flash CircuitREPLACEMENT OF INTERFERENCE SUPPRESSION COMPONENTS.Cleaning. Inspection. and RepairInstallation. - TM-9-6115-464-34_368Section XVI. MAINTENANCE OF LIFTING FRAMEInstallation. - TM-9-6115-464-34_370Figure 3-149. Relay Table Assembly, Exploded ViewFigure 3-150. Relay Table Assembly, Exploded View effective on generator sets serial numbers KZ00001 and upFigure 3-151. Lifting Frame, Exploded ViewSection XVII. MAINTENANCE OF SKID BASE ASSEMBLYInstallation - TM-9-6115-464-34_375Figure 3-152. Skid Base Assembly, Exploded ViewCHAPTER 4 GENERATOR SET TESTS AFTER OVERHAUL REPAIR INSTRUCTIONS Section I. INSPECTIONSection Il. OPERATING TESTSPARALLEL OPERATION PROVISIONSTable 4-1. OPERATING TESTSTable 4-2. ENGINE GENERATOR SET CLASSIFICATIONTable 4-3. ELECTRICAL PERFORMANCE CHARACTERISTIC PARAMETERS AC PRECISE (CLASS 1)Table 4-3. ELECTRICAL PERFORMANCE CHARACTERISTIC PARAMETERS AC PRECISE (CLASS 1) (CONTINUED)REGULATOR RANGE TESTNOTE - TM-9-6115-464-34_386FREQUENCY AND VOLTAGE REGULATION, STABILITY, AND TRANSIENT RESPONSE TEST (SHORT-TERM)Procedure - TM-9-6115-464-34_388Results. - TM-9-6115-464-34_389CAUTION - TM-9-6115-464-34_390Figure 4-1. Overshoot and Undershoot Chart RecordingFREQUENCY ADJUST RANGE TESTOVERSPEED PROTECTIVE DEVICE TESTCIRCUIT INTERRUPTER TEST (SHORT CIRCUIT).CIRCUIT INTERRUPTER TEST (OVERLOAD CURRENT) - TM-9-6115-464-34_395CIRCUIT INTERRUPTER TEST (OVER VOLTAGE AND UNDER VOLTAGE).Procedure II (Undervoltage).LOW OIL PRESSURE PROTECTIVE DEVICE TEST - TM-9-6115-464-34_398PHASE SEQUENCE TEST (ROTATION)MAXIMUM POWER TESTFor Class II SetsUNDER FREQUENCY PROTECTIVE DEVICE TESTCHAPTER 5 FOR MATERIAL USED IN CONJUNCTION WITH THE GENERATOR SETTable 5-1. FUEL BURNING WINTERIZATION KIT TROUBLESHOOTING CHART (Continued)COOLANT PUMP FAILS TO RECIRCULATE LIQUIDLEAKAGEHEATER CONTROL ASSEMBLY. - TM-9-6115-464-34_408Assembly. Figure 5-1. Fuel Burning Heater, Control AssemblyFigure 5-2. Fuel Burning Heater Control Assembly Wiring Diagram, Drawing 72-2863HEATER ASSEMBLYCleaning, lnspection, and RepairFigure 5-3. Fuel Burning Heater Assembly, Exploded View (Sheet 1 of 2)Figure 5-3. Fuel Burning Heater Assembly, Exploded View (Sheet 2 of 2)Assembly. - TM-9-6115-464-34_416Testing and AdjustmentFigure 5-4 Coolant Pump Test DiagramFigure 5-5. Fuel Burning Winterization Kit Wiring Harness, Drawing No. 72-2856Figure 5-6. Fuel Burning Winterization Heater Control Assembly to Special Relay Assembly Wiring Harness Drawing No. 72-2875Section Il. ELECTRIC WINTERIZATION KITTable 5-2. ELECTRIC WINTERIZATION KIT TROUBLESHOOTING CHART (Continued)HEATER CONTROL ASSEMBLY. - TM-9-6115-464-34_423Disassembly - TM-9-6115-464-34_424Figure 5-7. Electric Winterization Kit Heater Control Assembly, Exploded View (Sheet 1 of 2)Figure 5-7. Electric Winterization Kit Heater Control Assembly, Exploded View (Sheet 2 of 2)Assembly - TM-9-6115-464-34_427Figure 5-9. Electric Winterization Kit Heater Control Assembly, Wiring Harness - TM-9-6115-464-34_428Figure 5-9. Electric Winterization Kit Heater Control Assembly, Wiring Harness - TM-9-6115-464-34_429HEATER ASSEMBLY. - TM-9-6115-464-34_430COOLANT LINES AND FlTTINGS.Figure 5-11. Electric Winterization Kit Wiring Harness, Drawing No. 72-2855Section Ill. WHEEL MOUNTING KITAXLE ASSEMBLIES.Cleaning, Inspection, and Repair - TM-9-6115-464-34_435Assembly - TM-9-6115-464-34_436Figure 5-13. Wheel Mounting Kit, Exploded View (Sheet 1 of 2)Figure 5-13. Wheel Mounting Kit, Exploded View (Sheet 2 of 2)Section IV. LOAD BANK - TM-9-6115-464-34_439Assembly - TM-9-6115-464-34_440Figure 5-14. Load Bank Control Box Assembly, Exploded ViewLOAD BANK HOUSINGFigure 5-15. Control Box Assembly Wiring Harness, Drawing No. 72-2868Figure 5-16. Control Box Assembly Branched Wiring Harness (Sheet 1 of 2), Drawing No. 72-2828Figure 5-16. Control Box Assembly Branched Wiring Harness (Sheet 2 of 2), Drawing 72-2828Figure 5-17. Load Bank Housing, Exploded ViewFigure 5-18. Load Bank Wiring Harness (Sheet 1 of 2), Drawing No. 72-2823Figure 5-18. Load Bank Wiring Harness (Sheet 2 of 2), Drawing No. 72-2823Figure 5-19. Top Load Bank Wiring Harness (Sheet 1 of 2), Drawing No. 72-2822Figure 5-19. Top Load Bank Wiring Harness (Sheet 2 of 2) Drawing No. 72-2822Figure 5-20. Bottom Load Bank Wiring Harness (Sheet 1 of 2), Drawing No. 72-2825Figure 5-20. Bottom Load Bank Wiring Harness (Sheet 2 of 2), Drawing No. 72-2825Figure 5-21. Load Bank Power Wiring Harness, Drawing No. 72-2829Figure 5-22. Load Bank Signal Wiring Harness, Drawing No. 72-2830Section V. APPLICATIONS KITTable 5-3. APPLICATIONS KIT TROUBLESHOOTING CHARTFigure 5-23. Plate and Sleeve Assembly Removal - TM-9-6115-464-34_457Figure 5-23. Plate and Sleeve Assembly Removal - TM-9-6115-464-34_458Remove tags from load terminal cables.Figure 5-25. Application Kit Cable Harness Assembly Installation (Right Side)Test. - TM-9-6115-464-34_461Figure 5-27. Applications Kit Cable Harness Assembly Installation (Left Side)Figure 5-28. Application Kit ComponentsNOTE - TM-9-6115-464-34_464Figure 5-29. Remote Functions AssemblyFigure 5-30. Wiring Harness Assembly DiagramREMOVAL/INSTALLATION REMOTE FUNCTIONS ASSEMBLY.Figure 5-31. Relay Socket ReplacementTable 5-4. CABLE HARNESS ASSEMBLY WIRING LIST- ContinuedFigure 5-32. Application Kit Cable Harness DiagramFigure 5-33. Application Kit Electrical Schematic DiagramSection VI. ACOUSTIC SUPPRESSION KITCAUTION NOTE - TM-9-6115-464-34_474CAUTION - TM-9-6115-464-34_475NOTE - TM-9-6115-464-34_476Figure 5-34. Roof Stiffeners, Sealing Angle, Oil Drain, Isolators, Bottom Panel Tray Assembly, and Trailer BracketsFigure 5-35. Hole Locations on Skid Base AssemblyFigure 5-36. Mounting Hardware and Hole Location for Side Panel AssemblyFigure 5-37. Acoustic Suppression Kit Major ComponentsAPPENDIX A REFERENCES - TM-9-6115-464-34_481APPENDIX A REFERENCES - TM-9-6115-464-34_482APPENDIX B FABRICATION/ASSEMBLY OF PARTSFigure 2-1. Breakout Cable (Sheet 1 of 2)Figure 2-1 Breakout Cable (Sheet 2 of 2)ALPHABETICAL INDEX - TM-9-6115-464-34_487ALPHABETICAL INDEX - TM-9-6115-464-34_488ALPHABETICAL INDEX - TM-9-6115-464-34_489