CHAPTER 1 INTRODUCTION - TM-9-6115-464-34_17
EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRs)
TABULATED DATA - TM-9-6115-464-34_19
Fuel injector Pump Classification and Rating.
Static Exciter and Voltage Regulator Assembly Classification and Rating
overvoltage relay classification and Rating
Reverse Power Relay Classification and Rating.
thermal watt converter classification and rating
400 Hz Generator classification and rating
50/60 Hz Generator Repair and Replacement Standards
400 HZ Generation Repair and Replacement Standards
Nut and Bolt Torque Data
Fuel injection pump - TM-9-6115-464-34_29
Table 1-1. FITS AND TOLERANCES
Table 1-1. FITS AND TOLERANCES (CONTINUED) - TM-9-6115-464-34_31
Table 1-1. FITS AND TOLERANCES (CONTINUED) - TM-9-6115-464-34_32
Table 1-1. FITS AND TOLERANCES (CONTINUED) - TM-9-6115-464-34_33
CHAPTER 2 GENERAL MAINTENANCE INSTRUCTIONS Section I. REPAIR PARTS, SPECIAL TOOLS, AND EQUIPMENT
Table 2-1. TOOLS AND SUPPORT EQUIPMENT (CONTINUED) - TM-9-6115-464-34_36
Table 2-1. TOOLS AND SUPPORT EQUIPMENT (CONTINUED) - TM-9-6115-464-34_37
Section II. TROUBLESHOOTING - TM-9-6115-464-34_38
Table 2-2. TROUBLESHOOTING (CONTINUED) - TM-9-6115-464-34_39
Table 2-2. TROUBLESHOOTING (CONTINUED) - TM-9-6115-464-34_40
Table 2-2. TROUBLESHOOTING (CONTINUED) - TM-9-6115-464-34_41
ENGINE KNOCKS
ENGINE OIL CONSUMPTION EXCESSIVE
BATTERY CHARGING AMMETER SHOWS NO CHARGE WHEN BATTERIES ARE LOW
Table 2-2. TROUBLESHOOTING (CONTINUED) - TM-9-6115-464-34_45
GENERATORS DO NOT PARALLEL PROPERLY.
FREQUENCY DRlFTS
Figure 2-1. Engine Assembly, Removal and lnstallation
Section Ill. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
Installation - TM-9-6115-464-34_50
GENERATOR ASSEMBLY - TM-9-6115-464-34_51
Installation. - TM-9-6115-464-34_52
Installation. - TM-9-6115-464-34_53
Figure 2-2. Generator Assembly, Removal and Installation - TM-9-6115-464-34_54
CHAPTER 3 ENGINE AND GENERATOR REPAIR INSTRUCTIONS
Cleaning, Inspection, and Repair. - TM-9-6115-464-34_56
Figure 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_59
Testing - TM-9-6115-464-34_60
STARTER ASSEMBLY - TM-9-6115-464-34_61
Figure 3-2. Starter Assembly Motoring Test Circuit - TM-9-6115-464-34_62
Figure 33. Starter Assembly Stalled Torque Setup
Figure 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_66
WARNING - TM-9-6115-464-34_67
Testing - TM-9-6115-464-34_68
BATTERY CHARGING ALTERNATOR - TM-9-6115-464-34_69
Cleaning lnspection. and Repair
Figure 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 Circuit
Assembly. - TM-9-6115-464-34_74
Testing. - TM-9-6115-464-34_75
Figure 3-7. Alternator Test Leads Installation
Test alternator output circuit as follows
Figure 3-8. Total Circuit Voltage Test
Figure 3-9. Alternator Positive Output Circuit Test
Figure 3-10. Alternator Negative Output Circuit Test
Figure 311. Excitation Voltage Test
NOTE - TM-9-6115-464-34_82
Figure 3-12. Faulty Voltage Regulator Circuit Test
Figure 3-13. Field Current Test
SPEED 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_90
Figure 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 SYSTEM
Figure 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 Installation
Figure 3-19. Main Fuel Tank (Plastic), Removal and Installation
FUEL INJECTION PUMP ASSEMBLY
Figure 3-20. Fuel Injection Pump Assembly, Removal and Installation
CAUTION - TM-9-6115-464-34_103
Figure 3-21. Fuel Injection Pump, Exploded View
Figure 3-21. Fuel Injection Pump, Exploded View
Figure 321. Fuel Injection Pump, Exploded View - TM-9-6115-464-34_106
Figure 321. Fuel Injection Pump, Exploded View - TM-9-6115-464-34_107
NOTE - TM-9-6115-464-34_108
CAUTION - TM-9-6115-464-34_109
CAUTION - TM-9-6115-464-34_110
CAUTION - TM-9-6115-464-34_111
Figure 3-22. Adjusting Fuel Injection Pump Roller-to-Roller Dimension
CAUTION - TM-9-6115-464-34_113
NOTE - TM-9-6115-464-34_114
Fuel Inject Pump Bench Test.
WARNING - TM-9-6115-464-34_116
Figure 324. Solenoid Armature Adjustments
Table 3-1. FUEL DELlVERY
Installation. - TM-9-6115-464-34_119
FUEL INJECTION NOZZLE HOLDERS AND LINES.
FUEL LINES
Section Ill. MAINTENANCE OF ENGINE COOLING SYSTEM
Figure 3-26. Shutter Control Assembly, Exploded View
RADIATOR - TM-9-6115-464-34_124
SHUTTER ASSEMBLY - TM-9-6115-464-34_125
WATER PUMP
Cleaning, Inspection and Repair - TM-9-6115-464-34_127
Asssembly
Section IV. MAINTENANCE OF ENGINE LUBRICATION SYSTEM
Installation - TM-9-6115-464-34_130
OIL PUMP ASSEMBLY
Figure 331. Oil Pump Assembly, Exploded View
Assembly - TM-9-6115-464-34_133
Figure 3-32. Oil Pump Assembly Dimensions
Section V. MAINTENANCE OF HYDRAULIC SYSTEM
Figure 3-33. Hydraulic Sump, Removal and Installation
HYDRAULIC PUMP ASSEMBLY.
Cleaning, Inspection, and Repair - TM-9-6115-464-34_138
Installation. - TM-9-6115-464-34_139
Figure 3-34. Hydraulic Pump Assembly, Exploded View
HYDRAULIC SYSTEM FILTER ASSEMBLY. - TM-9-6115-464-34_141
Figure 3-35. Hydraulic System Filter Assembly, Exploded View
HYDRAULIC ACTUATOR UNIT
Figure 3-36. Hydraulic Actuator Unit, Removal and Installation
Figure 3-37. Hydraulic Actuator Unit, Exploded View (Sheet 1 of 2)
Figure 338. Transducer and Armature Coil Schematic Diagram
Cleaning, Inspection, and Repair. - TM-9-6115-464-34_147
Assembly. - TM-9-6115-464-34_148
Test without test stand.
Figure 3-39. Hydraulic Actuator Unit Test
Installation and Final Adjustment. - TM-9-6115-464-34_151
Figure 3-40. Hydraulic Actuator Tests, Schematic Diagram
Table 3-2. HYDRAULIC ACTUATOR TEST VALUES
Section VI MAINTENANCE OF INTAKE AND EXHAUST SYSTEMS AND BREATHER
Removal. - TM-9-6115-464-34_155
FLYWHEEL AND FLYWHEEL HOUSING
Figure 3-42. Flywheel and Flywheel Housing, Exploded View
Testing - TM-9-6115-464-34_158
Figure 3-43. Checking Flywheel Concentricity and Alignment
Cleaning, Inspection, and Repair. - TM-9-6115-464-34_160
Figure 3-44. Timing Gears and Cover, Exploded View
Install gasket
Figure 3-45. liming Gear Relationships
CYLINDER HEAD AND ROCKER ARM ASSEMBLY.
Figure 3-46. Cylinder Head and Rocker Assembly, Exploded View
Cleaning, Inspection, and Repair - TM-9-6115-464-34_166
NOTE - TM-9-6115-464-34_167
Assembly. - TM-9-6115-464-34_168
Figure 3-47. Rocker Arm Mounting Blocks Installation
CAMSHAFT - TM-9-6115-464-34_170
Disassembly. - TM-9-6115-464-34_171
Figure 3-50. Camshaft, Exploded View
Figure 3-51 .Dimensional Inspection of Camshaft
CRANKSHAFT, CONNECTING RODS, AND PISTONS.
Disassembly. - TM-9-6115-464-34_175
Figure 3-52. Crankshaft, Connecting Rods and Pistons, Exploded View
Cleaning, Inspection, and Repair. - TM-9-6115-464-34_177
CAUTION - TM-9-6115-464-34_178
Installation. - TM-9-6115-464-34_179
CYLINDER BLOCK ASSEMBLY
Cleaning, Inspection, and Repair. - TM-9-6115-464-34_181
Cleaning, Inspection, and Repair. - TM-9-6115-464-34_182
Figure 3-53. Cylinder Block Assembly, Exploded View
Section Vlll. MAINTENANCE OF GENERATOR SET CONTROLS
Figure 3-55. Thermal Watt Converter Circuit Schematic
Control Cubicle Relay Assembly
Cleaning, Inspection, and Repair. - TM-9-6115-464-34_187
Figure 3-56. Control Cubicle Housing Assembly, Exploded View
Figure 357. Control Cubicle Relay Assembly, Exploded View
Installation - TM-9-6115-464-34_190
Control Cubicle Terrminal Board.
FAULT LOCATING INDICATOR
Cleaning, Inspection, and Repair - TM-9-6115-464-34_193
Assembly - TM-9-6115-464-34_194
Figure 3-59. Control Cubicle Wiring Harness (Sheet 1 of 6) Drawing No. 69-677
Figure 3-59. Control Cubicle Wiring Harness (Sheet 2 of 6) Drawing No. 69-677
Figure 3-59. Control Cubicle Wiring Harness (Sheet 3 of 6) Drawing No. 69-677
Figure 3-59. Control Cubicle Wiring Harness (Sheet 4 of 6) Drawing No. 69-677
Figure 3-59. Control Cubicle Wiring Harness (Sheet 5 of 6) Drawing No. 69-677
Figure 359. Control Cubicle Wiring Harness (Sheet 6 of 6) Drawing No. 69-677
Figure 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 Diagram
Figure 3-62. Fault Locating Indicator Component Board Assembly
Figure 3-63. Fault Locating Indicator Wiring Harness Drawing No. 722247
LOAD MEASURING UNIT.
Figure 3-64. Load Measuring Unit, Exploded View
Figure 3-65. Load Measuring Unit Wiring Harness, Drawing No. 69-511
Testing and Repair.
Figure 3-66. Load Measuring Unit Component Test and Replacement Diagram
ELECTRO-HYDRAULIC GOVERNOR CONTROL UNIT.
Removal. - TM-9-6115-464-34_212
Figure 3-67. Load Measuring Unit Test Circuit and Test Data Relationship
Disassembly. - TM-9-6115-464-34_214
Figure 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_217
Potting
Table 3-6. 400 Hz Electro-Hydraulic Governor Control Unit Resistance Test Values
Figure 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 Board
Figure 3-72. 50/60 Hz Governor Control Unit Wiring Diagram, DWG No. 69-730
Figure 3-73. 400 Hz EIectro-Hydraulic Governor Control Unit Wiring Diagram, DWG No. 69-633
Figure 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 Circuit
Figure 3-78. Electro-Hydraulic Governor Control Unit Frequency Sensing Test Circuit
Figure 3-79. Electro-Hydraulic Governor Control Unit Rectifier Bridge and Feedback Winding Test Circuit
Alignment Procedure.
NOTE - TM-9-6115-464-34_235
Figure 3-81. Approximate Position of Controls for Connecting Hydraulic Actuator
Figure 3-82. Approximate Position of Controls for Connecting Hydraulic Actuator
Figure 3-83. Electro-Hydraulic Governor Control Unit Control Panel
Figure 3-84. Tactical Relay Assembly to Special Relay Assembly Wiring Harness, Drawing No. 72-2224
ELECTRIC GOVERNOR CONTROL UNIT (MEP-113A)
Adjustment Procedure
Figure 3-85. Functional Theory of Operation
Figure 3-86. Governor Control Unit Removal and Installation
Table 3-7. Electric Governor Malfunction Testing
ACTUATOR UNIT.
Section IX. MAINTENANCE OF INTERCONNECTING WIRING HARNESSES
Figure 3-87. Actuator Removal and Installation
Figure 3-88. Magnetic Pickup Removal and Installation
AC 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. 72-2220
Figure 3-90. Load Measuring Unit to Tactical Relay Assembly Wiring Harness, Drawing No. 72-2234
Figure 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 Assembly
Figure 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. 73-2288
Figure 3-95. Special Relay Assembly to Fault Locating Indicator Wiring Harness, Drawing No. 76-2247
Figure 3-96. Special Relay Assembly to Control Cubicle Wiring Harness, Drawing No. 72-2248
Figure 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. 72-2238
Section X. MAINTENANCE OF CONVENIENCE AND PARALLELING RECEPTACLES AND WIRING HARNESS
Figure 3-99. Convenience and Paralleling Receptacles Wiring Harness, Drawing No. 72-2286
MAIN LOAD CONTACTOR
Disassembly Type B
Cleaning 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 Points
Adjust auxiliary contacts as follows
Figure 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_280
Contractor to Load terminals Wiring Harness - TM-9-6115-464-34_281
Economizing Switch
Installation. - TM-9-6115-464-34_283
Figure 3-106. Load Terminal Board Assembly, Exploded View
LOAD TERMINAL BOARD ASSEMBLY - TM-9-6115-464-34_285
Figure 3-107. Routing of Generator Leads Through Current Transformers
Cleaning. Inspection. and Testing
Figure 3-109. Current Transformer Test Point
ELECTROMAGNETIC INTERFERENCE CAPACITORS
Section X11. MAINTENANCE OF RELAY TABLE COMPONENTS
Cleaning, lnspection, and Repair.
Figure 3-111. Tactical Relay Assembly, Exploded View
Test over voltage relay as follows
Figure 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 Circuit
Figure 3-114. Overvoltage Relay Test Circuit
Figure 3-115. Short Circuit Relay Test Circuit
Figure 3-116. Overload Protective Device Test Circuit
Installation. - TM-9-6115-464-34_300
SPECIAL RELAY ASSEMBLY.
WARNING - TM-9-6115-464-34_302
Figure 3-118. Tactical Relay Resistor Assembly, Exploded View
Figure 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_306
Figure 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 Diagram
Test under frequency relay as follows
Figure 3122. DC Relay Assembly, Exploded View
Figure 3-123. Precise Relay Assembly, Exploded View
Figure 3-124. Under Voltage Relay Test Circuit
Test permissive paralleling relay as follows
Figure 31 26. Permissive Paralleling Relay Test Circuit
STATIC EXCITER AND VOLTAGE REGULATOR ASSEMBLY.
Cleaning. lnspection, and Repair.
Figure 3-127. Electronics Components Assembly
Figure 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. 72-2629
Assembly - TM-9-6115-464-34_329
Testing. - TM-9-6115-464-34_330
RELAY TABLE COMPONENTS ADJUSTMENTS
Table 3-8. STATIC EXCITER AND VOLTAGE REGULATOR RESISTOR AND CAPACITOR VALUES
Figure 3132. 400 Hz Static Exciter and Voltage Schematic Diagram, Drawing No. 72-2630
A. 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 Harness
Figure 3134. Static Exciter and Voltage Regulator Assembly Sensing Circuit Bench Test
Section XIII. MAINTENANCE OF GENERATOR ASSEMBLIES
Figure 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_342
Figure 3-137. Securing Generator Rotor to Stator
Figure 3-138. End Bell Assembly, Exploded View
Figure 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 View
Figure 3-141. Generator Stator Assembly, Exploded View
WARNING - TM-9-6115-464-34_349
NOTE - TM-9-6115-464-34_350
Assembly - TM-9-6115-464-34_351
Figure 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 Procedures
Figure 3-145. 400 Hz Generator Rotor Winding Procedures
Assemble end bell assembly as follows
Figure 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_364
Equipment Test of Field Flash Circuit
REPLACEMENT OF INTERFERENCE SUPPRESSION COMPONENTS.
Cleaning. Inspection. and Repair
Installation. - TM-9-6115-464-34_368
Section XVI. MAINTENANCE OF LIFTING FRAME
Installation. - TM-9-6115-464-34_370
Figure 3-149. Relay Table Assembly, Exploded View
Figure 3-150. Relay Table Assembly, Exploded View effective on generator sets serial numbers KZ00001 and up
Figure 3-151. Lifting Frame, Exploded View
Section XVII. MAINTENANCE OF SKID BASE ASSEMBLY
Installation - TM-9-6115-464-34_375
Figure 3-152. Skid Base Assembly, Exploded View
CHAPTER 4 GENERATOR SET TESTS AFTER OVERHAUL REPAIR INSTRUCTIONS Section I. INSPECTION
Section Il. OPERATING TESTS
PARALLEL OPERATION PROVISIONS
Table 4-1. OPERATING TESTS
Table 4-2. ENGINE GENERATOR SET CLASSIFICATION
Table 4-3. ELECTRICAL PERFORMANCE CHARACTERISTIC PARAMETERS AC PRECISE (CLASS 1)
Table 4-3. ELECTRICAL PERFORMANCE CHARACTERISTIC PARAMETERS AC PRECISE (CLASS 1) (CONTINUED)
REGULATOR RANGE TEST
NOTE - TM-9-6115-464-34_386
FREQUENCY AND VOLTAGE REGULATION, STABILITY, AND TRANSIENT RESPONSE TEST (SHORT-TERM)
Procedure - TM-9-6115-464-34_388
Results. - TM-9-6115-464-34_389
CAUTION - TM-9-6115-464-34_390
Figure 4-1. Overshoot and Undershoot Chart Recording
FREQUENCY ADJUST RANGE TEST
OVERSPEED PROTECTIVE DEVICE TEST
CIRCUIT INTERRUPTER TEST (SHORT CIRCUIT).
CIRCUIT INTERRUPTER TEST (OVERLOAD CURRENT) - TM-9-6115-464-34_395
CIRCUIT INTERRUPTER TEST (OVER VOLTAGE AND UNDER VOLTAGE).
Procedure II (Undervoltage).
LOW OIL PRESSURE PROTECTIVE DEVICE TEST - TM-9-6115-464-34_398
PHASE SEQUENCE TEST (ROTATION)
MAXIMUM POWER TEST
For Class II Sets
UNDER FREQUENCY PROTECTIVE DEVICE TEST
CHAPTER 5 FOR MATERIAL USED IN CONJUNCTION WITH THE GENERATOR SET
Table 5-1. FUEL BURNING WINTERIZATION KIT TROUBLESHOOTING CHART (Continued)
COOLANT PUMP FAILS TO RECIRCULATE LIQUID
LEAKAGE
HEATER CONTROL ASSEMBLY. - TM-9-6115-464-34_408
Assembly.
Figure 5-1. Fuel Burning Heater, Control Assembly
Figure 5-2. Fuel Burning Heater Control Assembly Wiring Diagram, Drawing 72-2863
HEATER ASSEMBLY
Cleaning, lnspection, and Repair
Figure 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_416
Testing and Adjustment
Figure 5-4 Coolant Pump Test Diagram
Figure 5-5. Fuel Burning Winterization Kit Wiring Harness, Drawing No. 72-2856
Figure 5-6. Fuel Burning Winterization Heater Control Assembly to Special Relay Assembly Wiring Harness Drawing No. 72-2875
Section Il. ELECTRIC WINTERIZATION KIT
Table 5-2. ELECTRIC WINTERIZATION KIT TROUBLESHOOTING CHART (Continued)
HEATER CONTROL ASSEMBLY. - TM-9-6115-464-34_423
Disassembly - TM-9-6115-464-34_424
Figure 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_427
Figure 5-9. Electric Winterization Kit Heater Control Assembly, Wiring Harness - TM-9-6115-464-34_428
Figure 5-9. Electric Winterization Kit Heater Control Assembly, Wiring Harness - TM-9-6115-464-34_429
HEATER ASSEMBLY. - TM-9-6115-464-34_430
COOLANT LINES AND FlTTINGS.
Figure 5-11. Electric Winterization Kit Wiring Harness, Drawing No. 72-2855
Section Ill. WHEEL MOUNTING KIT
AXLE ASSEMBLIES.
Cleaning, Inspection, and Repair - TM-9-6115-464-34_435
Assembly - TM-9-6115-464-34_436
Figure 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_439
Assembly - TM-9-6115-464-34_440
Figure 5-14. Load Bank Control Box Assembly, Exploded View
LOAD BANK HOUSING
Figure 5-15. Control Box Assembly Wiring Harness, Drawing No. 72-2868
Figure 5-16. Control Box Assembly Branched Wiring Harness (Sheet 1 of 2), Drawing No. 72-2828
Figure 5-16. Control Box Assembly Branched Wiring Harness (Sheet 2 of 2), Drawing 72-2828
Figure 5-17. Load Bank Housing, Exploded View
Figure 5-18. Load Bank Wiring Harness (Sheet 1 of 2), Drawing No. 72-2823
Figure 5-18. Load Bank Wiring Harness (Sheet 2 of 2), Drawing No. 72-2823
Figure 5-19. Top Load Bank Wiring Harness (Sheet 1 of 2), Drawing No. 72-2822
Figure 5-19. Top Load Bank Wiring Harness (Sheet 2 of 2) Drawing No. 72-2822
Figure 5-20. Bottom Load Bank Wiring Harness (Sheet 1 of 2), Drawing No. 72-2825
Figure 5-20. Bottom Load Bank Wiring Harness (Sheet 2 of 2), Drawing No. 72-2825
Figure 5-21. Load Bank Power Wiring Harness, Drawing No. 72-2829
Figure 5-22. Load Bank Signal Wiring Harness, Drawing No. 72-2830
Section V. APPLICATIONS KIT
Table 5-3. APPLICATIONS KIT TROUBLESHOOTING CHART
Figure 5-23. Plate and Sleeve Assembly Removal - TM-9-6115-464-34_457
Figure 5-23. Plate and Sleeve Assembly Removal - TM-9-6115-464-34_458
Remove tags from load terminal cables.
Figure 5-25. Application Kit Cable Harness Assembly Installation (Right Side)
Test. - TM-9-6115-464-34_461
Figure 5-27. Applications Kit Cable Harness Assembly Installation (Left Side)
Figure 5-28. Application Kit Components
NOTE - TM-9-6115-464-34_464
Figure 5-29. Remote Functions Assembly
Figure 5-30. Wiring Harness Assembly Diagram
REMOVAL/INSTALLATION REMOTE FUNCTIONS ASSEMBLY.
Figure 5-31. Relay Socket Replacement
Table 5-4. CABLE HARNESS ASSEMBLY WIRING LIST- Continued
Figure 5-32. Application Kit Cable Harness Diagram
Figure 5-33. Application Kit Electrical Schematic Diagram
Section VI. ACOUSTIC SUPPRESSION KIT
CAUTION
NOTE - TM-9-6115-464-34_474
CAUTION - TM-9-6115-464-34_475
NOTE - TM-9-6115-464-34_476
Figure 5-34. Roof Stiffeners, Sealing Angle, Oil Drain, Isolators, Bottom Panel Tray Assembly, and Trailer Brackets
Figure 5-35. Hole Locations on Skid Base Assembly
Figure 5-36. Mounting Hardware and Hole Location for Side Panel Assembly
Figure 5-37. Acoustic Suppression Kit Major Components
APPENDIX A REFERENCES - TM-9-6115-464-34_481
APPENDIX A REFERENCES - TM-9-6115-464-34_482
APPENDIX B FABRICATION/ASSEMBLY OF PARTS
Figure 2-1. Breakout Cable (Sheet 1 of 2)
Figure 2-1 Breakout Cable (Sheet 2 of 2)
ALPHABETICAL INDEX - TM-9-6115-464-34_487
ALPHABETICAL INDEX - TM-9-6115-464-34_488
ALPHABETICAL INDEX - TM-9-6115-464-34_489
EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRs)
TABULATED DATA - TM-9-6115-464-34_19
Fuel injector Pump Classification and Rating.
Static Exciter and Voltage Regulator Assembly Classification and Rating
overvoltage relay classification and Rating
Reverse Power Relay Classification and Rating.
thermal watt converter classification and rating
400 Hz Generator classification and rating
50/60 Hz Generator Repair and Replacement Standards
400 HZ Generation Repair and Replacement Standards
Nut and Bolt Torque Data
Fuel injection pump - TM-9-6115-464-34_29
Table 1-1. FITS AND TOLERANCES
Table 1-1. FITS AND TOLERANCES (CONTINUED) - TM-9-6115-464-34_31
Table 1-1. FITS AND TOLERANCES (CONTINUED) - TM-9-6115-464-34_32
Table 1-1. FITS AND TOLERANCES (CONTINUED) - TM-9-6115-464-34_33
CHAPTER 2 GENERAL MAINTENANCE INSTRUCTIONS Section I. REPAIR PARTS, SPECIAL TOOLS, AND EQUIPMENT
Table 2-1. TOOLS AND SUPPORT EQUIPMENT (CONTINUED) - TM-9-6115-464-34_36
Table 2-1. TOOLS AND SUPPORT EQUIPMENT (CONTINUED) - TM-9-6115-464-34_37
Section II. TROUBLESHOOTING - TM-9-6115-464-34_38
Table 2-2. TROUBLESHOOTING (CONTINUED) - TM-9-6115-464-34_39
Table 2-2. TROUBLESHOOTING (CONTINUED) - TM-9-6115-464-34_40
Table 2-2. TROUBLESHOOTING (CONTINUED) - TM-9-6115-464-34_41
ENGINE KNOCKS
ENGINE OIL CONSUMPTION EXCESSIVE
BATTERY CHARGING AMMETER SHOWS NO CHARGE WHEN BATTERIES ARE LOW
Table 2-2. TROUBLESHOOTING (CONTINUED) - TM-9-6115-464-34_45
GENERATORS DO NOT PARALLEL PROPERLY.
FREQUENCY DRlFTS
Figure 2-1. Engine Assembly, Removal and lnstallation
Section Ill. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
Installation - TM-9-6115-464-34_50
GENERATOR ASSEMBLY - TM-9-6115-464-34_51
Installation. - TM-9-6115-464-34_52
Installation. - TM-9-6115-464-34_53
Figure 2-2. Generator Assembly, Removal and Installation - TM-9-6115-464-34_54
CHAPTER 3 ENGINE AND GENERATOR REPAIR INSTRUCTIONS
Cleaning, Inspection, and Repair. - TM-9-6115-464-34_56
Figure 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_59
Testing - TM-9-6115-464-34_60
STARTER ASSEMBLY - TM-9-6115-464-34_61
Figure 3-2. Starter Assembly Motoring Test Circuit - TM-9-6115-464-34_62
Figure 33. Starter Assembly Stalled Torque Setup
Figure 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_66
WARNING - TM-9-6115-464-34_67
Testing - TM-9-6115-464-34_68
BATTERY CHARGING ALTERNATOR - TM-9-6115-464-34_69
Cleaning lnspection. and Repair
Figure 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 Circuit
Assembly. - TM-9-6115-464-34_74
Testing. - TM-9-6115-464-34_75
Figure 3-7. Alternator Test Leads Installation
Test alternator output circuit as follows
Figure 3-8. Total Circuit Voltage Test
Figure 3-9. Alternator Positive Output Circuit Test
Figure 3-10. Alternator Negative Output Circuit Test
Figure 311. Excitation Voltage Test
NOTE - TM-9-6115-464-34_82
Figure 3-12. Faulty Voltage Regulator Circuit Test
Figure 3-13. Field Current Test
SPEED 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_90
Figure 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 SYSTEM
Figure 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 Installation
Figure 3-19. Main Fuel Tank (Plastic), Removal and Installation
FUEL INJECTION PUMP ASSEMBLY
Figure 3-20. Fuel Injection Pump Assembly, Removal and Installation
CAUTION - TM-9-6115-464-34_103
Figure 3-21. Fuel Injection Pump, Exploded View
Figure 3-21. Fuel Injection Pump, Exploded View
Figure 321. Fuel Injection Pump, Exploded View - TM-9-6115-464-34_106
Figure 321. Fuel Injection Pump, Exploded View - TM-9-6115-464-34_107
NOTE - TM-9-6115-464-34_108
CAUTION - TM-9-6115-464-34_109
CAUTION - TM-9-6115-464-34_110
CAUTION - TM-9-6115-464-34_111
Figure 3-22. Adjusting Fuel Injection Pump Roller-to-Roller Dimension
CAUTION - TM-9-6115-464-34_113
NOTE - TM-9-6115-464-34_114
Fuel Inject Pump Bench Test.
WARNING - TM-9-6115-464-34_116
Figure 324. Solenoid Armature Adjustments
Table 3-1. FUEL DELlVERY
Installation. - TM-9-6115-464-34_119
FUEL INJECTION NOZZLE HOLDERS AND LINES.
FUEL LINES
Section Ill. MAINTENANCE OF ENGINE COOLING SYSTEM
Figure 3-26. Shutter Control Assembly, Exploded View
RADIATOR - TM-9-6115-464-34_124
SHUTTER ASSEMBLY - TM-9-6115-464-34_125
WATER PUMP
Cleaning, Inspection and Repair - TM-9-6115-464-34_127
Asssembly
Section IV. MAINTENANCE OF ENGINE LUBRICATION SYSTEM
Installation - TM-9-6115-464-34_130
OIL PUMP ASSEMBLY
Figure 331. Oil Pump Assembly, Exploded View
Assembly - TM-9-6115-464-34_133
Figure 3-32. Oil Pump Assembly Dimensions
Section V. MAINTENANCE OF HYDRAULIC SYSTEM
Figure 3-33. Hydraulic Sump, Removal and Installation
HYDRAULIC PUMP ASSEMBLY.
Cleaning, Inspection, and Repair - TM-9-6115-464-34_138
Installation. - TM-9-6115-464-34_139
Figure 3-34. Hydraulic Pump Assembly, Exploded View
HYDRAULIC SYSTEM FILTER ASSEMBLY. - TM-9-6115-464-34_141
Figure 3-35. Hydraulic System Filter Assembly, Exploded View
HYDRAULIC ACTUATOR UNIT
Figure 3-36. Hydraulic Actuator Unit, Removal and Installation
Figure 3-37. Hydraulic Actuator Unit, Exploded View (Sheet 1 of 2)
Figure 338. Transducer and Armature Coil Schematic Diagram
Cleaning, Inspection, and Repair. - TM-9-6115-464-34_147
Assembly. - TM-9-6115-464-34_148
Test without test stand.
Figure 3-39. Hydraulic Actuator Unit Test
Installation and Final Adjustment. - TM-9-6115-464-34_151
Figure 3-40. Hydraulic Actuator Tests, Schematic Diagram
Table 3-2. HYDRAULIC ACTUATOR TEST VALUES
Section VI MAINTENANCE OF INTAKE AND EXHAUST SYSTEMS AND BREATHER
Removal. - TM-9-6115-464-34_155
FLYWHEEL AND FLYWHEEL HOUSING
Figure 3-42. Flywheel and Flywheel Housing, Exploded View
Testing - TM-9-6115-464-34_158
Figure 3-43. Checking Flywheel Concentricity and Alignment
Cleaning, Inspection, and Repair. - TM-9-6115-464-34_160
Figure 3-44. Timing Gears and Cover, Exploded View
Install gasket
Figure 3-45. liming Gear Relationships
CYLINDER HEAD AND ROCKER ARM ASSEMBLY.
Figure 3-46. Cylinder Head and Rocker Assembly, Exploded View
Cleaning, Inspection, and Repair - TM-9-6115-464-34_166
NOTE - TM-9-6115-464-34_167
Assembly. - TM-9-6115-464-34_168
Figure 3-47. Rocker Arm Mounting Blocks Installation
CAMSHAFT - TM-9-6115-464-34_170
Disassembly. - TM-9-6115-464-34_171
Figure 3-50. Camshaft, Exploded View
Figure 3-51 .Dimensional Inspection of Camshaft
CRANKSHAFT, CONNECTING RODS, AND PISTONS.
Disassembly. - TM-9-6115-464-34_175
Figure 3-52. Crankshaft, Connecting Rods and Pistons, Exploded View
Cleaning, Inspection, and Repair. - TM-9-6115-464-34_177
CAUTION - TM-9-6115-464-34_178
Installation. - TM-9-6115-464-34_179
CYLINDER BLOCK ASSEMBLY
Cleaning, Inspection, and Repair. - TM-9-6115-464-34_181
Cleaning, Inspection, and Repair. - TM-9-6115-464-34_182
Figure 3-53. Cylinder Block Assembly, Exploded View
Section Vlll. MAINTENANCE OF GENERATOR SET CONTROLS
Figure 3-55. Thermal Watt Converter Circuit Schematic
Control Cubicle Relay Assembly
Cleaning, Inspection, and Repair. - TM-9-6115-464-34_187
Figure 3-56. Control Cubicle Housing Assembly, Exploded View
Figure 357. Control Cubicle Relay Assembly, Exploded View
Installation - TM-9-6115-464-34_190
Control Cubicle Terrminal Board.
FAULT LOCATING INDICATOR
Cleaning, Inspection, and Repair - TM-9-6115-464-34_193
Assembly - TM-9-6115-464-34_194
Figure 3-59. Control Cubicle Wiring Harness (Sheet 1 of 6) Drawing No. 69-677
Figure 3-59. Control Cubicle Wiring Harness (Sheet 2 of 6) Drawing No. 69-677
Figure 3-59. Control Cubicle Wiring Harness (Sheet 3 of 6) Drawing No. 69-677
Figure 3-59. Control Cubicle Wiring Harness (Sheet 4 of 6) Drawing No. 69-677
Figure 3-59. Control Cubicle Wiring Harness (Sheet 5 of 6) Drawing No. 69-677
Figure 359. Control Cubicle Wiring Harness (Sheet 6 of 6) Drawing No. 69-677
Figure 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 Diagram
Figure 3-62. Fault Locating Indicator Component Board Assembly
Figure 3-63. Fault Locating Indicator Wiring Harness Drawing No. 722247
LOAD MEASURING UNIT.
Figure 3-64. Load Measuring Unit, Exploded View
Figure 3-65. Load Measuring Unit Wiring Harness, Drawing No. 69-511
Testing and Repair.
Figure 3-66. Load Measuring Unit Component Test and Replacement Diagram
ELECTRO-HYDRAULIC GOVERNOR CONTROL UNIT.
Removal. - TM-9-6115-464-34_212
Figure 3-67. Load Measuring Unit Test Circuit and Test Data Relationship
Disassembly. - TM-9-6115-464-34_214
Figure 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_217
Potting
Table 3-6. 400 Hz Electro-Hydraulic Governor Control Unit Resistance Test Values
Figure 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 Board
Figure 3-72. 50/60 Hz Governor Control Unit Wiring Diagram, DWG No. 69-730
Figure 3-73. 400 Hz EIectro-Hydraulic Governor Control Unit Wiring Diagram, DWG No. 69-633
Figure 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 Circuit
Figure 3-78. Electro-Hydraulic Governor Control Unit Frequency Sensing Test Circuit
Figure 3-79. Electro-Hydraulic Governor Control Unit Rectifier Bridge and Feedback Winding Test Circuit
Alignment Procedure.
NOTE - TM-9-6115-464-34_235
Figure 3-81. Approximate Position of Controls for Connecting Hydraulic Actuator
Figure 3-82. Approximate Position of Controls for Connecting Hydraulic Actuator
Figure 3-83. Electro-Hydraulic Governor Control Unit Control Panel
Figure 3-84. Tactical Relay Assembly to Special Relay Assembly Wiring Harness, Drawing No. 72-2224
ELECTRIC GOVERNOR CONTROL UNIT (MEP-113A)
Adjustment Procedure
Figure 3-85. Functional Theory of Operation
Figure 3-86. Governor Control Unit Removal and Installation
Table 3-7. Electric Governor Malfunction Testing
ACTUATOR UNIT.
Section IX. MAINTENANCE OF INTERCONNECTING WIRING HARNESSES
Figure 3-87. Actuator Removal and Installation
Figure 3-88. Magnetic Pickup Removal and Installation
AC 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. 72-2220
Figure 3-90. Load Measuring Unit to Tactical Relay Assembly Wiring Harness, Drawing No. 72-2234
Figure 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 Assembly
Figure 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. 73-2288
Figure 3-95. Special Relay Assembly to Fault Locating Indicator Wiring Harness, Drawing No. 76-2247
Figure 3-96. Special Relay Assembly to Control Cubicle Wiring Harness, Drawing No. 72-2248
Figure 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. 72-2238
Section X. MAINTENANCE OF CONVENIENCE AND PARALLELING RECEPTACLES AND WIRING HARNESS
Figure 3-99. Convenience and Paralleling Receptacles Wiring Harness, Drawing No. 72-2286
MAIN LOAD CONTACTOR
Disassembly Type B
Cleaning 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 Points
Adjust auxiliary contacts as follows
Figure 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_280
Contractor to Load terminals Wiring Harness - TM-9-6115-464-34_281
Economizing Switch
Installation. - TM-9-6115-464-34_283
Figure 3-106. Load Terminal Board Assembly, Exploded View
LOAD TERMINAL BOARD ASSEMBLY - TM-9-6115-464-34_285
Figure 3-107. Routing of Generator Leads Through Current Transformers
Cleaning. Inspection. and Testing
Figure 3-109. Current Transformer Test Point
ELECTROMAGNETIC INTERFERENCE CAPACITORS
Section X11. MAINTENANCE OF RELAY TABLE COMPONENTS
Cleaning, lnspection, and Repair.
Figure 3-111. Tactical Relay Assembly, Exploded View
Test over voltage relay as follows
Figure 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 Circuit
Figure 3-114. Overvoltage Relay Test Circuit
Figure 3-115. Short Circuit Relay Test Circuit
Figure 3-116. Overload Protective Device Test Circuit
Installation. - TM-9-6115-464-34_300
SPECIAL RELAY ASSEMBLY.
WARNING - TM-9-6115-464-34_302
Figure 3-118. Tactical Relay Resistor Assembly, Exploded View
Figure 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_306
Figure 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 Diagram
Test under frequency relay as follows
Figure 3122. DC Relay Assembly, Exploded View
Figure 3-123. Precise Relay Assembly, Exploded View
Figure 3-124. Under Voltage Relay Test Circuit
Test permissive paralleling relay as follows
Figure 31 26. Permissive Paralleling Relay Test Circuit
STATIC EXCITER AND VOLTAGE REGULATOR ASSEMBLY.
Cleaning. lnspection, and Repair.
Figure 3-127. Electronics Components Assembly
Figure 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. 72-2629
Assembly - TM-9-6115-464-34_329
Testing. - TM-9-6115-464-34_330
RELAY TABLE COMPONENTS ADJUSTMENTS
Table 3-8. STATIC EXCITER AND VOLTAGE REGULATOR RESISTOR AND CAPACITOR VALUES
Figure 3132. 400 Hz Static Exciter and Voltage Schematic Diagram, Drawing No. 72-2630
A. 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 Harness
Figure 3134. Static Exciter and Voltage Regulator Assembly Sensing Circuit Bench Test
Section XIII. MAINTENANCE OF GENERATOR ASSEMBLIES
Figure 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_342
Figure 3-137. Securing Generator Rotor to Stator
Figure 3-138. End Bell Assembly, Exploded View
Figure 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 View
Figure 3-141. Generator Stator Assembly, Exploded View
WARNING - TM-9-6115-464-34_349
NOTE - TM-9-6115-464-34_350
Assembly - TM-9-6115-464-34_351
Figure 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 Procedures
Figure 3-145. 400 Hz Generator Rotor Winding Procedures
Assemble end bell assembly as follows
Figure 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_364
Equipment Test of Field Flash Circuit
REPLACEMENT OF INTERFERENCE SUPPRESSION COMPONENTS.
Cleaning. Inspection. and Repair
Installation. - TM-9-6115-464-34_368
Section XVI. MAINTENANCE OF LIFTING FRAME
Installation. - TM-9-6115-464-34_370
Figure 3-149. Relay Table Assembly, Exploded View
Figure 3-150. Relay Table Assembly, Exploded View effective on generator sets serial numbers KZ00001 and up
Figure 3-151. Lifting Frame, Exploded View
Section XVII. MAINTENANCE OF SKID BASE ASSEMBLY
Installation - TM-9-6115-464-34_375
Figure 3-152. Skid Base Assembly, Exploded View
CHAPTER 4 GENERATOR SET TESTS AFTER OVERHAUL REPAIR INSTRUCTIONS Section I. INSPECTION
Section Il. OPERATING TESTS
PARALLEL OPERATION PROVISIONS
Table 4-1. OPERATING TESTS
Table 4-2. ENGINE GENERATOR SET CLASSIFICATION
Table 4-3. ELECTRICAL PERFORMANCE CHARACTERISTIC PARAMETERS AC PRECISE (CLASS 1)
Table 4-3. ELECTRICAL PERFORMANCE CHARACTERISTIC PARAMETERS AC PRECISE (CLASS 1) (CONTINUED)
REGULATOR RANGE TEST
NOTE - TM-9-6115-464-34_386
FREQUENCY AND VOLTAGE REGULATION, STABILITY, AND TRANSIENT RESPONSE TEST (SHORT-TERM)
Procedure - TM-9-6115-464-34_388
Results. - TM-9-6115-464-34_389
CAUTION - TM-9-6115-464-34_390
Figure 4-1. Overshoot and Undershoot Chart Recording
FREQUENCY ADJUST RANGE TEST
OVERSPEED PROTECTIVE DEVICE TEST
CIRCUIT INTERRUPTER TEST (SHORT CIRCUIT).
CIRCUIT INTERRUPTER TEST (OVERLOAD CURRENT) - TM-9-6115-464-34_395
CIRCUIT INTERRUPTER TEST (OVER VOLTAGE AND UNDER VOLTAGE).
Procedure II (Undervoltage).
LOW OIL PRESSURE PROTECTIVE DEVICE TEST - TM-9-6115-464-34_398
PHASE SEQUENCE TEST (ROTATION)
MAXIMUM POWER TEST
For Class II Sets
UNDER FREQUENCY PROTECTIVE DEVICE TEST
CHAPTER 5 FOR MATERIAL USED IN CONJUNCTION WITH THE GENERATOR SET
Table 5-1. FUEL BURNING WINTERIZATION KIT TROUBLESHOOTING CHART (Continued)
COOLANT PUMP FAILS TO RECIRCULATE LIQUID
LEAKAGE
HEATER CONTROL ASSEMBLY. - TM-9-6115-464-34_408
Assembly.
Figure 5-1. Fuel Burning Heater, Control Assembly
Figure 5-2. Fuel Burning Heater Control Assembly Wiring Diagram, Drawing 72-2863
HEATER ASSEMBLY
Cleaning, lnspection, and Repair
Figure 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_416
Testing and Adjustment
Figure 5-4 Coolant Pump Test Diagram
Figure 5-5. Fuel Burning Winterization Kit Wiring Harness, Drawing No. 72-2856
Figure 5-6. Fuel Burning Winterization Heater Control Assembly to Special Relay Assembly Wiring Harness Drawing No. 72-2875
Section Il. ELECTRIC WINTERIZATION KIT
Table 5-2. ELECTRIC WINTERIZATION KIT TROUBLESHOOTING CHART (Continued)
HEATER CONTROL ASSEMBLY. - TM-9-6115-464-34_423
Disassembly - TM-9-6115-464-34_424
Figure 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_427
Figure 5-9. Electric Winterization Kit Heater Control Assembly, Wiring Harness - TM-9-6115-464-34_428
Figure 5-9. Electric Winterization Kit Heater Control Assembly, Wiring Harness - TM-9-6115-464-34_429
HEATER ASSEMBLY. - TM-9-6115-464-34_430
COOLANT LINES AND FlTTINGS.
Figure 5-11. Electric Winterization Kit Wiring Harness, Drawing No. 72-2855
Section Ill. WHEEL MOUNTING KIT
AXLE ASSEMBLIES.
Cleaning, Inspection, and Repair - TM-9-6115-464-34_435
Assembly - TM-9-6115-464-34_436
Figure 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_439
Assembly - TM-9-6115-464-34_440
Figure 5-14. Load Bank Control Box Assembly, Exploded View
LOAD BANK HOUSING
Figure 5-15. Control Box Assembly Wiring Harness, Drawing No. 72-2868
Figure 5-16. Control Box Assembly Branched Wiring Harness (Sheet 1 of 2), Drawing No. 72-2828
Figure 5-16. Control Box Assembly Branched Wiring Harness (Sheet 2 of 2), Drawing 72-2828
Figure 5-17. Load Bank Housing, Exploded View
Figure 5-18. Load Bank Wiring Harness (Sheet 1 of 2), Drawing No. 72-2823
Figure 5-18. Load Bank Wiring Harness (Sheet 2 of 2), Drawing No. 72-2823
Figure 5-19. Top Load Bank Wiring Harness (Sheet 1 of 2), Drawing No. 72-2822
Figure 5-19. Top Load Bank Wiring Harness (Sheet 2 of 2) Drawing No. 72-2822
Figure 5-20. Bottom Load Bank Wiring Harness (Sheet 1 of 2), Drawing No. 72-2825
Figure 5-20. Bottom Load Bank Wiring Harness (Sheet 2 of 2), Drawing No. 72-2825
Figure 5-21. Load Bank Power Wiring Harness, Drawing No. 72-2829
Figure 5-22. Load Bank Signal Wiring Harness, Drawing No. 72-2830
Section V. APPLICATIONS KIT
Table 5-3. APPLICATIONS KIT TROUBLESHOOTING CHART
Figure 5-23. Plate and Sleeve Assembly Removal - TM-9-6115-464-34_457
Figure 5-23. Plate and Sleeve Assembly Removal - TM-9-6115-464-34_458
Remove tags from load terminal cables.
Figure 5-25. Application Kit Cable Harness Assembly Installation (Right Side)
Test. - TM-9-6115-464-34_461
Figure 5-27. Applications Kit Cable Harness Assembly Installation (Left Side)
Figure 5-28. Application Kit Components
NOTE - TM-9-6115-464-34_464
Figure 5-29. Remote Functions Assembly
Figure 5-30. Wiring Harness Assembly Diagram
REMOVAL/INSTALLATION REMOTE FUNCTIONS ASSEMBLY.
Figure 5-31. Relay Socket Replacement
Table 5-4. CABLE HARNESS ASSEMBLY WIRING LIST- Continued
Figure 5-32. Application Kit Cable Harness Diagram
Figure 5-33. Application Kit Electrical Schematic Diagram
Section VI. ACOUSTIC SUPPRESSION KIT
CAUTION
NOTE - TM-9-6115-464-34_474
CAUTION - TM-9-6115-464-34_475
NOTE - TM-9-6115-464-34_476
Figure 5-34. Roof Stiffeners, Sealing Angle, Oil Drain, Isolators, Bottom Panel Tray Assembly, and Trailer Brackets
Figure 5-35. Hole Locations on Skid Base Assembly
Figure 5-36. Mounting Hardware and Hole Location for Side Panel Assembly
Figure 5-37. Acoustic Suppression Kit Major Components
APPENDIX A REFERENCES - TM-9-6115-464-34_481
APPENDIX A REFERENCES - TM-9-6115-464-34_482
APPENDIX B FABRICATION/ASSEMBLY OF PARTS
Figure 2-1. Breakout Cable (Sheet 1 of 2)
Figure 2-1 Breakout Cable (Sheet 2 of 2)
ALPHABETICAL INDEX - TM-9-6115-464-34_487
ALPHABETICAL INDEX - TM-9-6115-464-34_488
ALPHABETICAL INDEX - TM-9-6115-464-34_489
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