ARMY TM 11-5855-313

TB 9-6115-641-13
TECHNICAL BULLETIN
OPERATOR, UNIT AND DIRECT SUPPORT
MAINTENANCE MANUAL
FOR
WINTERIZATION KIT
(NSN: 6115-01-476-8973) (EIC: N/A)
INSTALLED ON
GENERATOR SET, SKID MOUNTED,
TACTICAL QUIET,
5kW, 60 and 400 Hz
MEP-802A (60Hz) (6115-01-274-7387)
MEP-812A (400Hz) (6115-01-274-7391)
Introduction
1-1
Equipment Description and Data
1-2
Operating Instructions
2-1
Operator PMCS
2-3
Operator Maintenance
3-1
Unit Maintenance
4-1
Unit PMCS
4-5
Troubleshooting
4-8
Direct Support Maintenance
5-1
Maintenance Allocation Chart
B-1
RPSTL
C-1
Alphabetical Index
Index-1
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY
1 November 2001
TB 9-6115-641-13
WARNING SUMMARY
NOTE
The warnings in the generator set technical manuals must also be
considered.
WARNING
Solvent used to clean parts is potentially dangerous to personnel and
property. Clean parts in a well-ventilated area. Avoid inhalation of
solvent fumes. Wear goggles and rubber gloves to protect eyes and
skin. Wash exposed skin thoroughly. Do not smoke or use near open
flame or excessive heat. Failure to observe this warning could result in
severe injury or death.
WARNING
Generator cooling system operates at high temperatures. Personal
injury or death from burns or scalding can result from contact with high
pressure steam and/or liquid.
WARNING
Disconnect negative battery cable from right battery and the positive
battery cable from the left battery before doing the following
procedures. Failure to observe this warning could result in severe
personal injury or death.
WARNING
Before disconnecting any coolant lines, let generator cool from
operation, then relieve pressure by opening radiator cap carefully.
Coolant is hot and under pressure and may cause severe burns.
WARNING
Catch fuel in suitable container. Keep spilled fuel away from hot
engine and all fires, and wash with warm water after getting any on
skin. Fuel is highly flammable and is irritating to skin.
WARNING
Do not attempt any tasks inside generator housing with generator set
running. Failure to observe this warning could result in severe personal
injury or death.
WARNING
Do not attempt to perform any maintenance tasks on the kit while the
generator is operating. Serious electrical shock or death by
electrocution may result from failure to observe this warning.
a
TM 9-6115-641-13
WARNING
Keep spilled fuel away from hot engine and all fires. Wash with warm
water after getting any on skin. Fuel is highly flammable and is
irritating to skin.
WARNING
Muffler and flex hoses get hot. Allow them to cool before touching
them to avoid burn injury.
WARNING
Make sure generator set is shut down before performing any
maintenance. Failure to observe this warning could result in severe
personal injury or death.
WARNING
The coolant in the system shall contain the proper mixture of water and
antifreeze to prevent coolant from freezing or slushing. Failure could
cause engine damage and/or personal injury.
Refer to FM 21-11 for first aid.
b
TB 9-6115-641-13
INSERT LATEST CHANGED PAGES, DESTROY SUPERSEDED
PAGES
LIST OF EFFECTIVE PAGES
Note: The portion of the text effected by the changes is indicated by a vertical
line in the outer margins of the page. Changes to illustrations are indicated by
miniature pointing hands. Changes to diagrams are indicated by shaded
areas.
Dates of issue for original and changed pages are:
Original
1 November 2001
TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 162, CONSISTING OF THE FOLLOWING:
Page
No.
*Change
No.
Title .................................................. 0
Page
No.
*Change
No.
Page
No.
*Change
No.
Index-1 - Index-4............................. 0
A - B................................................. 0
A....................................................... 0
B Blank ........................................... 0
I - iv.................................................. 0
1-1 - 1-5 ........................................... 0
1-6 Blank.......................................... 0
2-1 - 2-8 ........................................... 0
3-1 - 3-4 ........................................... 0
4-1 - 4-50 ......................................... 0
5-1 - 5-15 ......................................... 0
5-16 Blank ...................................... 0
A-1 - A-2.......................................... 0
B-1 - B-7 .......................................... 0
B-8 Blank ........................................ 0
C-1 - C-30 ........................................ 0
D-1 - D-4.......................................... 0
E-1.................................................... 0
E-2 Blank ......................................... 0
F-1 - F-2 ........................................... 0
G-1 - G-4.......................................... 0
* Zero in this column indicates an original page.
A/(B-BLANK)
TB 9-6115-641-13
TECHNICAL BULLETIN
HEADQUARTERS
DEPARTMENT OF THE ARMY
Washington, D.C., 1 November 2001
NO 9-6115-641-13
OPERATOR, UNIT AND DIRECT SUPPORT MAINTENANCE MANUAL
for
WINTERIZATION KIT
(NSN: 6115-01-476-8973) (EIC: N/A)
INSTALLED ON
GENERATOR SET, SKID MOUNTED, TACTICAL QUIET
5kW, 60 AND 400 Hz
MEP-802A (60 Hz) 6115-01-274-7387
MEP-812A (400 Hz) 6115-01-274-7391
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If you find any mistakes, or if you know of a way to improve the
procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to
Publications and Blank Forms), or DA Form 2028-2 located in the back of this manual directly to:
Commander, U.S. Army Communications and Electronics Command and Fort Monmouth, ATTN:
AMSEL-LC-LEO-D-CS-CFO, Fort Monmouth, New Jersey 07703-5006. The fax number is 732-5321413, DSN: 992-1413. You may also e-mail your recommendations to AMSEL-LC-LEO-PUBSCHG@mail1.monmouth.army.mil.
In any case, we will send you a reply.
TABLE OF CONTENTS
Page
CHAPTER 1
Section I
Section II
Section III
CHAPTER 2
Section I
Section II
INTRODUCTION
..........................................................................................................................1-1
General Information ..............................................................................................................1-1
Equipment Description and Data
..................................................................................................1-2
Principles of Operation............................................................................................................1-5
OPERATING INSTRUCTIONS
...................................................................................................2-1
Description and Use of Operator’s Controls and Indicators....................................................2-2
Operator Preventive Maintenance Checks and Services (PMCS).........................................2-3
Section III
Operation Under Usual Conditions
.....................................................................................2-7
Section IV
Operation Under Unusual Conditions .....................................................................................2-8
i
TB 9-6115-641-13
TABLE OF CONTENTS – continued
Page
CHAPTER 3
OPERATOR MAINTENANCE
Section I
Troubleshooting.......................................................................................................................3-2
Section II
Maintenance Procedures......................................................................................................... 3-4
CHAPTER 4
UNIT MAINTENANCE
.................................................................................................. 4-1
Section I
Repair Parts; Special Tools; Measurement, and Diagnostic ...................................................
Equipment (TMDE); and Support Equipment ........................................................................ 4-2
Section II
Service Upon Receipt
Section III
Unit Lubrication ..................................................................................................................... 4-4
Section IV
..............................................................................................................................................
4-5
Unit
Preventitive Maintenance Checks and Services (PMCS)
Section V
Troubleshooting
.................................................................................................. 4-3
............................................................................................... 4-8
Section VI
Unit Maintenance Procedures ............................................................................................... 4-18
Section VII
Removal Instructions .............................................................................................................. 4-42
CHAPTER 5
DIRECT SUPPORT MAINTENANCE
..................................................................... 5-1
Section I
Repairs Parts; Special Tools; Test, Measurement, and Diagnostic.........................................
Equipment (TMDE); and Support Equipment ..................................................................... 5-2
Section II
Installation Instructions
APPENDIX A
REFERENCES .......................................................................................................................A-1
............................................................................................... 5-3
APPENDIX B
MAINTENANCE ALLOCATION CHART
APPENDIX C
UNIT AND DIRECT SUPPORT MAINTENANCE
REPAIR PARTS AND
.....................................................................................C-1
SPECIAL TOOLS LIST (RPSTL)
APPENDIX D
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS ............D-1
APPENDIX E
ADDITIONAL AUTHORIZATION LIST (AAL) ..................................................................E-1
APPENDIX F
EXPENDABLE AND DURABLE SUPPLIES AND MATERIALS LIST.............................F-1
APPENDIX G
ILLUSTRATED LIST OF MANUFACTURED ITEMS ........................................................G-1
ALPHABETICAL INDEX
ii
.................................................................................................... 3-1
........................................................B-1
....................................................................................................................... INDEX-1
TB 9-6115-641-13
LIST OF ILLUSTRATIONS
Figure
1-1
2-1
3-1
3-2
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-11
4-12
4-13
4-14
4-15
4-16
4-17
4-18
4-19
4-20
4-21
4-22
4-23
4-24
4-25
4-26
4-27
4-28
4-29
4-30
4-31
4-32
4-33
4-34
4-35
4-36
4-37
4-38
4-39
5-1
5-2
5-3
5-4
5-5
5-6
5-7
5-8
5-9
Title
Page
Location of Major Components for 5kW (MEP-802A, MEP-812A) .................................................................... 1-3
Operator PMCS Routing Diagram ........................................................................................................................ 2-5
Heater Function Codes Plate ................................................................................................................................. 3-2
Heater Is Not Operating ........................................................................................................................................ 3-3
Unit PMCS Routing Diagram ............................................................................................................................... 4-6
Heater Function Codes Plate ................................................................................................................................. 4-9
No Indication Of Heater Operation When Switch Is In On Position..................................................................... 4-10
(dash, dash) Heater Restart Attempted During Purge Cycle ................................................................................ 4-11
(dash, 5 dots, dash) Warning: Power Supply......................................................................................................... 4-11
(10 dots) Overheating............................................................................................................................................ 4-12
(dot, dot) Flame Sensor Short-Circuit ................................................................................................................... 4-12
(2 dots, 2 dots) Flame Cutout - Low...................................................................................................................... 4-13
(3 dots, 3 dots) Flame Cutout - High..................................................................................................................... 4-13
(4 dots, 4 dots) Glow Plug Defect ......................................................................................................................... 4-14
(dash, dash) Burner Motor Defect ......................................................................................................................... 4-14
(dash, dot, dash, dot) Under Voltage..................................................................................................................... 4-14
(dash, 2 dots, dash, 2 dots) Over Voltage.............................................................................................................. 4-15
(dash, 3 dots, dash, 3 dots) Non-Start.................................................................................................................... 4-15
(2 dots, dash, 2 dots, dash) Temperature Sensor Defective................................................................................... 4-16
(3 dots, dash, 3 dots, dash) Fuel Pump Short-Circuit ............................................................................................ 4-16
(2 dots, dash, 3 dots, dash, dot) Temperature Switch Defective............................................................................ 4-17
(4 dashes) Control Unit Defective......................................................................................................................... 4-17
(dot, dash, 3 dots, dash, 2 dots) Connection Error................................................................................................. 4-17
Control Unit Maintenance ..................................................................................................................................... 4-19
Heater Assembly Maintenance.............................................................................................................................. 4-21
Fuel Pump Maintenance........................................................................................................................................ 4-23
Heater Attachment Maintenance ........................................................................................................................... 4-25
Plate, Operation and Heater Switch Maintenance ................................................................................................. 4-27
Coolant Hose Maintenance ................................................................................................................................... 4-29
Air Inlet and Exhaust Hose Maintenance .............................................................................................................. 4-31
Wiring Harness Maintenance ................................................................................................................................ 4-33
Ignitor/Glow Plug and Resistor Maintenance ...................................................................................................... 4-35
Fuel Line Maintenance ......................................................................................................................................... 4-37
Function Codes Plate Maintenance ...................................................................................................................... 4-39
Coolant Pump Maintenance .................................................................................................................................. 4-41
Control Unit Removal ........................................................................................................................................... 4-43
Cover and Instrument Panel .................................................................................................................................. 4-44
Wiring Harness Removal ...................................................................................................................................... 4-45
Fuel System Removal............................................................................................................................................ 4-46
Fuel Pump Removal .............................................................................................................................................. 4-47
Exhaust System and Brace Removal..................................................................................................................... 4-48
Coolant System Removal ...................................................................................................................................... 4-49
Heater Assembly Removal.................................................................................................................................... 4-50
Control Unit Assembly .......................................................................................................................................... 5-4
Fuel System Assembly .......................................................................................................................................... 5-5
Bulkhead Housing ................................................................................................................................................. 5-6
Heater Assembly.................................................................................................................................................... 5-7
Fuel Pump Assembly............................................................................................................................................. 5-8
Expansion Plug ...................................................................................................................................................... 5-9
Coolant Hoses........................................................................................................................................................ 5-10
Exhaust Hose and Heater Brace............................................................................................................................. 5-11
Butt Joint ............................................................................................................................................................... 5-12
iii
TB 9-6115-641-13
LIST OF ILLUSTRATIONS - continued
Figure
5-10
5-11
Title
Page
Fuse And Wiring Harness ...................................................................................................................................... 5-13
Cover And Instrument Panel.................................................................................................................................. 5-14
LIST OF TABLES
Number
1-1
1-2
2-1
4-1
iv
Title
Page
Description of Major Components.........................................................................................................................1-2
Heater Operating Data ...........................................................................................................................................1-4
Operator Preventive Maintenance Checks and Services ........................................................................................2-6
Unit Preventive Maintenance Checks and Services ...............................................................................................4-7
TB 9-6115-641-13
CHAPTER 1
INTRODUCTION
Section I. GENERAL INFORMATION
1-1
SCOPE.
This technical bulletin is for your use in operating and maintaining the Winterization Kit installed on the 5kW
Tactical Quiet Generator Sets. The manual covers operator, unit maintenance, and direct support installation instructions
for the kit.
1-2
MAINTENANCE FORMS AND RECORDS.
Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA
PAM 738-750 (The Army Maintenance System (TAMMS) Maintenance Management UPDATE).
1-3
CORROSION PREVENTION AND CONTROL.
Corrosion Prevention and Control (CPC) of Army material is a continuing concern. It is important that any
corrosion problems with this item be reported so that the problem can be corrected and improvements can be
made to prevent the problem in the future items.
While corrosion is typically associated with rusting of metals, it can also include deterioration of other material,
such as rubber or plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a corrosion problem.
If a corrosion problem is identified, it can be reported using Standard Form 368, Product Quality Deficiency
Report (PQDR). Use of keywords such as “corrosion”, “rust”, “deterioration”, or “cracking” will ensure that the information
is identified as a CPC problem.
1-4
DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE.
Destruction of Army material to prevent enemy use shall be in accordance with TM 750-244-3.
1-5
PREPARATION FOR STORAGE AND SHIPMENT.
No procedure required. Refer to Generator TM 9-6115-641-24.
1-6
EQUIPMENT IMPROVEMENT RECOMMENDATION (EIR).
If the equipment in any of your kits needs improvement, let us know. Send us an EIR. You, the user, are the only
one who can tell us what you don’t like about your equipment. Let us know why you don’t like the design or
performance. Put it on SF 368 Product Quality Deficiency Report (PQDR). Mail it to us at Commander, U.S. Army
Communications and Electronics Command, ATTN: AMSEL-LC-LEO-D-CS-CFO, Fort Monmouth, New Jersey
07703-5006. We will send you a reply.
1-7
Hz
kW
RTV
1-8
LIST OF ABBREVIATIONS.
Hertz
Kilowatts
Room Temperature Vulcanizing
LEVELS OF MAINTENANCE.
Army users shall refer to the Maintenance Allocation Chart (MAC) for tasks and levels of maintenance to be
performed.
1-1
TB 9-6115-641-13
Section II. EQUIPMENT DESCRIPTION AND DATA
1-9
GENERAL.
The winterization kit is designed to be mounted in generator sets where extreme cold temperatures are anticipated. The kit
consists of a coolant heater, which allows the generator set to operate to -50°F (-45.6°C). The coolant heater circulates the
coolant from the generator set through the heater pump and heats the coolant by the heater and returns it back through the
radiator of the generator. Then, continues the cycle until the temperature reaches 176°F. The heater then goes into low heat.
If the coolant temperature drops to 158°F, then the heater will switch to high heat mode.
1-10
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES.
1-10.1 Characteristics. The Winterization Kit consists of a coolant heater, which allows the generator set to operate to
-50°F (-45.6°C).
1-10.1.2 Capabilities and Features. The heater burns fuel from the generator fuel tank to heat the coolant which is pumped
through the engine block. The kit consists of a heater and coolant pump, a control unit, an ON-OFF switch, a fuel pump and
line, coolant circulating lines, a wiring harness and mounting hardware to ensure operation to -50°F (-45.6°C).
1-11
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS.
Figure 1-1 illustrates the major components of the kit and shows their locations on the 5kW Tactical Quiet Generator Set.
(Refer to table 1-1 for item names).
Table 1-1. Description of Major Components.
Item
No.
Item Name
Winterization Kit
1-2
Description
A fuel-burning heater, pre-heats engine coolant permitting generator operation
to -50°F (-45.6°C).
1
Control Unit
2
Heater
3
Fuel Pump
Provides fuel for heater.
4
Fuel Lines
Provides a means of transporting fuel to heater.
5
Coolant Pump
Pumps coolant from generator to heater.
6
Coolant Lines
Provides a means of transporting coolant for circulation.
7
Switch/Lamp
Turns on/off heater and lamp indicates operations.
8
Wiring Harness
Controls heater operations.
Circulates coolant.
Provides a flow of electricity to different components to operate.
TB 9-6115-641-13
3
Figure 1-1. Location of Major Components for 5kW (MEP-802A, MEP-812A).
1-3
TB 9-6115-641-13
1-12
TABULATED/ILLUSTRATED DATA.
1-12.1
Tabulated Data for the heater is located in Table 1-2.
Table 1-2. Heater Operating Data.
1-4
Item Name
1. Winterization Kit
a. National Stock Number
b. Overall Length
c. Overall Width
d. Overall Height
e. Weight
Data
6115-01-476-8973
10.787 inches
5.984 inches
7.815 inches
15 lbs
2. Heater:
a. Manufacturer
b. Model
Active Gear
D5W
3. Heating
Capacity
Water Coolant
High: 17,000 BTU/Hr.
Low: 4250 BTU/Hr.
4.
24 Vdc
20 to 28 Vdc
Start: 20 Amps/Hr.
Running High: 1.8 Amps/Hr.
Running Low: 1.2 Amps/Hr.
Rated Voltage
a. Operating Voltage Range
b. Current at 24 Vdc
5. Fuel
Fuel Consumption
Diesel
High: 0.06 Gal/Hr.
Low: 0.04 Gal/Hr.
6.
250 Gal/Hr.
Coolant Pump Flow
TB 9-6115-641-13
Section III. PRINCIPLES OF OPERATION
1-13
GENERAL.
This section contains functional description of the winterization kit.
1-13.1 Functional Description. When the heater is switched on, the indicator lamp comes on, the combustion air fan
comes on high, then low, and the start cycle begins. The water circulating pump begins to run and after a short time, the fuel
pump begins to operate. The fuel is ignited by the ignition element and a flame detector turns off the ignition element when
combustion is established. When the coolant temperature has reached the operating point, the temperature sensor sends a
signal to the control unit to reduce the heat output. If the temperature remains at the upper limit, the heater turns off, but the
coolant pump continues to run. The heater will automatically restart once the system’s temperature has dropped to the lower
temperature switch point of the sensor. The heater continues in this mode until the ON/OFF switch is placed in the OFF
position. At this point the indicator lamp will go off, but the combustion air blower and the circulating pump will continue
running for several minutes and then shut off.
NOTE
Heater warms generator engine block sufficiently to start.
(1) The circulation pump, ceramic ignitor/glow plug, and combustion air fan start operation after
the heater is turned on.
(2) After approximately 50 seconds, the fuel pump starts, combustion starts, and the ceramic
ignitor/glow plug is turned off.
(3) When the coolant temperature reaches 176°F (80°C), the heater switches to low heat mode.
(4) If coolant temperature drops to 158°F (70°C), the heater switches to high heat mode.
(5) If coolant temperature rises to 185°F (85°C), the heater will switch off (coolant pump continues to
run).
(6) The heater continues to run as described above until the ON/OFF switch is placed in the OFF
position.
(7) When switched off, the fuel pump stops and the flame is extinguished. The combustion air fan and
coolant circulation pump continues to run for a cool down period of several minutes.
1-5/(1-6 BLANK)
TB 9-6115-641-13
CHAPTER 2
OPERATING INSTRUCTIONS
Subject Index
Section I
Page
Description and Use of Operator’s Controls and Indicators..........................................................................2-2
2-1
General.....................................................................................................................................................2-2
Section II
Operator Preventive Maintenance Checks and Services (PMCS) .................................................................2-3
2-2
General.....................................................................................................................................................2-3
Section III
Operation Under Usual Conditions .............................................................................................................. 2-7
2-3
2-4
2-5
Assembly and Preparation for Use.......................................................................................................... 2-7
Operating Instructions..............................................................................................................................2-7
Preparation for Movement .......................................................................................................................2-7
Section IV
Operation Under Unusual Conditions ...........................................................................................................2-8
2-6
Unusual Conditions..................................................................................................................................2-8
2-1
TB 9-6115-641-13
Section I. DESCRIPTION AND USE OF OPERATOR’S CONTROLS
AND INDICATORS
2-1
General: This section describes and illustrates winterization kit controls and indicators to ensure proper
operations.
2-1.1
Controls and Indicators. There are three controls. The Heater indicator light, a control unit, and an
on-off switch.
2-1.1.1 Heater Indicator Light. A light at the heater ON-OFF switch (item 7, figure 1-1) lights when the heater is
in operation. The light also serves as a troubleshooting code light (See paragraph 3-1.1).
2-1.1.2 Control Unit. The control unit is a sealed unit, mounted on the generator wall, that controls heater
operation.
2-1.1.3 ON-OFF Switch. The ON-OFF switch is a single-pole, single-throw toggle switch. Placed in the ON
position, the switch closes the 24Vdc circuit to the control unit.
2-2
TB 9-6115-641-13
Section II. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND
SERVICES (PMCS)
2-2
GENERAL.
Table 2-1 (Operator PMCS table) has been provided so you can keep your equipment in good operating condition
and ready for its primary mission.
2-2.1
Warnings, Cautions, and Notes. Always observe the WARNINGS, CAUTIONS, and NOTES appearing in
your PMCS table. Warnings and Cautions appear before applicable procedures. You must observe WARNINGS
to prevent serious injury to yourself and others. You must observe CAUTIONS to prevent your equipment from
being damaged. You must observe NOTES to ensure procedures are performed properly.
2-2.2
Explanation of Table Entries.
2-2.2.1 Item No. Column. Numbers in this column are for reference. When completing DA Form 2404
(Equipment Inspection and Maintenance Worksheet), or DD Form 5988E Computerized (Equipment Inspection and
Maintenance Worksheet), include the item number for the checks/service indicating a fault. Item numbers also appear in the
order that you must do checks and services for the intervals listed.
2-2.2.2 Interval Column. This column tells you when you must do the procedure in the procedure column.
“BEFORE” procedures must be done before you operate the generator with modification kit installed for its
intended mission. “DURING” procedures must be done during the time you are operating the modified generator
for its intended mission. “AFTER” procedures must be done immediately after shutting down the modified generator.
Perform “WEEKLY” procedures at the listed interval.
2-2.2.3 Location, Item to Check/Service Column. This column lists the location and the item to be checked or
serviced. The item location is underlined.
2-2.2.4 Procedure Column. This column gives the procedure for checking or servicing the item listed in the
location, item to check/service column. You must perform the procedure to know if the generator is ready or
available for its intended mission or operation. You must do the procedure at the time stated in the interval
column.
2-2.2.5 Not Fully Mission Capable if: Column. Information in this column tells you what faults will keep your
modified generator from being capable of performing its primary mission. If you make checks or services that
show faults listed in this column, do not operate the generator.
2-2.2.6 Reporting and Correcting Deficiencies. If Winterization Kit does not perform as required, refer to Chapter 3,
Section I. Troubleshooting.
2-2.3 Other Table Entries. Be sure to observe all special information and notes that appear in your table.
2-2.4 Special Instructions. Preventive maintenance is not limited to performing the checks and services listed
in the PMCS table. Covering unused receptacles, stowing unused accessories, and other routine procedures
such as equipment inventory, cleaning components, and touch up painting are not listed in the table. These are
things you should do any time you see that they need to be done. If a routine check is listed in the PMCS table, it
is because experience has shown that problems may occur with this item. Take along tools and cleaning cloths
needed to perform the required checks and services. Use the following information to help identify potential
problems before and during checks and services. Use the information in the following paragraphs to help you
identify problems at any time.
2-3
TB 9-6115-641-13
WARNING
Solvent used to clean parts is potentially dangerous to personnel and property. Clean parts
in a well-ventilated area. Avoid inhalation of solvent fumes. Wear goggles and rubber
gloves to protect eyes and skin. Wash exposed skin thoroughly. Do not smoke or use near
open flame or excessive heat. Failure to observe this warning could result in severe injury
or death.
CAUTION
Keep cleaning solvents, gasoline and lubricants away from rubber or soft plastic parts.
They will deteriorate material.
a.
Keep it clean. Dirt, grease, and oil get in the way and may cover up a serious problem. Use dry
cleaning solvent to clean metal surfaces.
b.
Use soap and water to clean rubber or plastic parts and material.
c.
Check all bolts, nuts, and screws to make sure they are not loose, missing, bent, or broken. Do not try
to check them all with a tool, but look for chipped paint, bare metal, or rust around bolt heads. If you
find one loose, tighten it or report it to unit level of maintenance.
d.
Inspect welds. Look for loose or chipped paint, rust, or gaps where parts are welded together. If a
broken weld is found, report it to unit level of maintenance.
e.
Inspect electrical wires, connectors, terminals, and receptacles. Look for cracked or broken insulation,
bare wires, and loose or broken connectors. Tighten loose connectors and make sure wires are in
good condition. Examine terminals and receptacles for serviceability. If deficiencies are found, report
them to unit level of maintenance.
f.
Inspect hoses and fluid lines. Look for wear, damage, and leaks. Make sure that clamps and fittings
are tight. Wet spots and stains around a fitting or connector can mean a leak. If a leak comes from a
loose connector, or if something is broken or worn out, report it to unit level of maintenance.
2-2.5 Leakage Definitions. You must know how fluid leakage affects the status of your equipment.
The following are definitions of the types/classes of leakage you need to know to be able to determine the
status of your equipment. Learn and be familiar with them. When in doubt, notify your supervisor.
Leakage
Class
Class I
Leakage Definition
Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops.
Class II
Leakage of fluid great enough to form drops, but not enough to cause drops to drip from the
item being checked/inspected.
Class III
Leakage of fluid great enough to form drops that fall from the item being checked/inspected.
2-2.6 Order in Which PMCS Will be Done. Figure 2-1 shows the order in which you are to perform
your PMCS. The figure shows a generator to which a kit has been added. The number call outs on Figure
2-1 correspond to the numbers in the Item No. column of Table 2-1, for BEFORE/DURING PMCS.
2-4
TB 9-6115-641-13
NOTE
Be sure Generator PMCS is completed first in accordance with TM 9-6115-641-10.
1
Figure 2-1. Operator PMCS Routing Diagram.
2-5
TB 9-6115-641-13
Table 2-1. Operator Preventive Maintenance Checks and Services.
Item
No.
Interval
Location
Item to Check/Service
Procedure
Not Fully Mission
Capable if:
NOTE
Refer Generator TM 9-6115-641-10.
1
2-6
Before
VISUAL INSPECTION
•
Heater assembly
a. Check for damage.
Damage that renders
equipment unsafe.
•
•
Heater control unit
Fuel and coolant lines
b. Check on, around and under
equipment for fuel, oil or
coolant leaks.
Class III coolant or any
class fuel leak is
detected.
Check for sufficient fuel supply.
Generator is low on
fuel.
2
Before
GENERATOR FUEL TANK
3
Before
GENERATOR COOLING
SYSTEM
WARNING
Generator cooling system
operates at high temperatures.
Personal injury or death from burns or
scalding can result from contact with high
pressure steam and/or liquid.
Generator is low on
coolant.
RADIATOR
Inspect for loose, damaged or missing
parts.
Class III leaks or
missing radiator cap.
HOSES
Inspect for leaks, cracks or missing parts.
Class III leaks or
missing clamps or
hoses.
Wiring is loose or
burned.
4
Before
HEATER WIRING
CONNECTIONS
Inspect wiring for burned or frayed
insulation or loose terminals.
5
During
HEATER CONTROL
SWITCH AND LIGHT
Check that indicator light is on when
heater is operating. Check Heater
Function Code Plate.
6
After
ITEMS 1 - 5
Repeat procedures for items 1 - 5.
TB 9-6115-641-13
Section III. OPERATION UNDER USUAL CONDITIONS
2-3
ASSEMBLY AND PREPARATION FOR USE.
The kit is installed on the generator. No assembly or preparation for use is required. For operation of the
generator, refer to TM 9-6115-641-10.
2-4
OPERATING INSTRUCTIONS.
2-4.1
Winterization Kit. Usual conditions for operating the heater imply extremely cold temperatures. The heater allows
the generator set to operate between -25°F and -50°F (-45.6°C). Both the MEP-802A and MEP-812A will start
without the winterization kit down to the ambient temperatures of -25°F. Although not required, use of the
winterization kit will aid starting and reducing engine wear in ambient air temperatures between -25°F to 32°F.
Heater operation is automatic after the ON/OFF switch is placed in the ON position.
NOTE
Depending on temperature, heater could take up to 1 hour to activate heater control circuits.
2-5
a.
At least 30 minutes before generator is to be started, put the heater switch on generator control panel in the
ON position to activate heater control circuits.
b.
When the coolant temperature reaches 176°F (80°C), the heater switches to low heat mode.
Check temperature gauge if you have a reading of 176°F.
c.
When generator is started, place heater ON-OFF switch in OFF position. The indicator light
should go off.
PREPARATION FOR MOVEMENT.
The kit is installed on the generator. No preparation for movement is required beyond that for moving the
generator.
2-7
TB 9-6115-641-13
Section IV. OPERATION UNDER UNUSUAL CONDITIONS
2-6.
UNUSUAL CONDITIONS.
Same operation under unusual conditions apply to the generator with the winterization kit. Refer to
TM 9-6115-641-10.
2-8
TB 9-6115-641-13
CHAPTER 3
OPERATOR MAINTENANCE
Subject Index
Page
Section I
Troubleshooting ............................................................................................................................................... 3-2
3-1
General .......................................................................................................................................................... 3-2
Section II
3-2
Maintenance Procedures
............................................................................................................................... 3-4
Operator Maintenance
................................................................................................................................. 3-4
3-1
TB 9-6115-641-13
Section I. TROUBLESHOOTING
3-1
GENERAL.
Refer to TM 9-6115-641-10 for generator troubleshooting instructions. This section lists common malfunctions you
may find during operation of the generator with the Winterization Kit installed and the generator set is running. You should
perform the tests/inspections and corrective actions in the order listed. Each malfunction listed on Figure 3-1 includes a
reference to the troubleshooting figure that contains a glow chart to help determine probable causes and corrective actions to
take. The troubleshooting symptom index cannot list all faults that may occur, nor all the tests or inspections and corrective
actions. If a malfunction is not listed or cannot be corrected by listed corrective actions, notify your supervisor.
3-1.1
Code Light Troubleshooting. The indicator light near the heater switch is designed to blink on codes
sequences to signal malfunctions in the system. (Refer to paragraph 3-1.1.1.)
3-1.1.1 Code Light Pulses. The indicator light near the heater ON-OFF switch will blink in different sequences of
long and short to indicate malfunctions. A plate (Figure 3-1) mounted on the generator control panel access door
(Figure 4-33) lists the malfunctions and shows each sequence of pulses. If you see any of these series of pulses, notify
next higher level of maintenance.
NOTE
For Location of Troubleshooting Procedures (Figures), see page 4-8.
Figure 3-1. Heater Function Codes Plate.
3-2
TB 9-6115-641-13
Figure 3-2. Heater Is Not Operating.
3-3
TB 9-6115-641-13
Section II. MAINTENANCE PROCEDURES
3-2
OPERATOR MAINTENANCE.
Refer to TM 9-6115-641-10 for generator maintenance instructions. Operator maintenance functions for the kit is
limited to those authorized in the MAC and described in Table 2-1, Operator Preventive Maintenance Checks and Services.
3-4
TB 9-6115-641-13
CHAPTER 4
UNIT MAINTENANCE
Subject Index
Section I
4-1
4-2
4-3
Page
Repair Parts; Special Tools; Test, Measurement, and Diagnostic Equipment
(TMDE); and Support Equipment ............................................................................................................
Common Tools and Equipment............................................................................................................
Special Tools, TMDE, and Support Equipment ...................................................................................
Repair Parts ..........................................................................................................................................
4-2
4-2
4-2
4-2
Section II
4-4
4-5
Service Upon Receipt ................................................................................................................................... 4-3
Service Upon Receipt of Materiel ........................................................................................................ 4-3
Removal Instructions............................................................................................................................ 4-3
Section III
4-6
Unit Lubrication .......................................................................................................................................... 4-4
Lubrication (not applicable to modification kits) ................................................................................. 4-4
Section IV
4-7
Unit Preventive Maintenance Checks and Services (PMCS) ....................................................................... 4-5
General ................................................................................................................................................. 4-5
Section V
4-8
Troubleshooting............................................................................................................................................ 4-8
General ................................................................................................................................................. 4-8
Section VI
4-9
4-10
4-11
4-12
4-13
4-14
4-15
4-16
4-17
4-18
4-19
4-20
Unit Maintenance Procedures.......................................................................................................................
Control Unit Maintenance ........................................................................................................................
Heater Assembly Maintenance .................................................................................................................
Fuel Pump Maintenance ...........................................................................................................................
Heater Attachment Maintenance ..............................................................................................................
Plate, Operation and Heater Switch Maintenance ....................................................................................
Coolant Hose Maintenance.......................................................................................................................
Air Inlet and Exhaust Hose Maintenance .................................................................................................
Wiring Harness Maintenance ...................................................................................................................
Ignitor/Glow Plug and Resistor Maintenance...........................................................................................
Fuel Line Maintenance .............................................................................................................................
Function Codes Plate Maintenance...........................................................................................................
Coolant Pump Maintenance......................................................................................................................
Section VII
4-21
Removal Instructions.................................................................................................................................... 4-42
Instructions to Unit Maintenance for Removal of Winterization Kit on the
5kW Tactical Quiet Generator Set........................................................................................................ 4-42
4-18
4-18
4-20
4-22
4-24
4-26
4-28
4-30
4-32
4-34
4-36
4-38
4-40
4-1
TB 9-6115-641-13
Section I. REPAIR PARTS; SPECIAL TOOLS; TEST, MEASUREMENT, AND
DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT
EQUIPMENT
4-1.
COMMON TOOLS AND EQUIPMENT.
For authorized common tools and equipment refer to the Modified Table of Organization and Equipment
(MTOE) applicable to your equipment.
4-2.
SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT.
No special tools or support equipment are required for maintenance of the modification kit.
4-3.
REPAIR PARTS.
Repair parts for the modification kit are listed and illustrated in Appendix C.
4-2
TB 9-6115-641-13
Section II. SERVICE UPON RECEIPT
4-4
SERVICE UPON RECEIPT OF MATERIEL.
If winterization kit is already installed on the generator, the normal service on receipt of the generator is
sufficient, and no separate service on receipt is required by unit for the winterization kit. If the kit is not installed,
refer to Chapter 5, Section II of this TB.
4-5
REMOVAL INSTRUCTIONS.
Refer to Chapter 4, Section VII of this TB.
4-3
TB 9-6115-641-13
Section III. UNIT LUBRICATION
4-6
LUBRICATION (NOT APPLICABLE TO MODIFICATION KITS).
No lubrication is required on the winterization kit .
4-4
TB 9-6115-641-13
Section IV. UNIT PREVENTIVE MAINTENANCE CHECKS
AND SERVICES (PMCS)
4-7
GENERAL.
Table 4-1 (Unit PMCS table) has been provided so you can keep your equipment in good operating condition and ready for
its primary mission.
4-7.1
Warning, Cautions, and Notes. Always observe the WARNINGS, CAUTIONS, and NOTES appearing in your
PMCS table. Warnings and Cautions appear before applicable procedures. You must observe WARNINGS to prevent serious
injury to yourself and others. You must observe CAUTIONS to prevent your equipment from being damaged. You must
observe NOTES to ensure procedures are performed properly.
Explanation of Table Entries.
4-7.2.1 Item No. Column. Numbers in this column are for reference. When completing DA Form 2404 (Equipment
Inspection and Maintenance Worksheet), or DD Form 5988E (Equipment Inspection and Maintenance Worksheet), include
the item number for the checks/service indicating a fault. Item numbers also appear in the order that you must do checks and
services for the intervals listed.
4-7.2.2 Interval Column. This column tells you when you must do the procedure in the Procedure column. Perform
procedures such as Monthly or Quarterly at the listed calendar interval. Perform procedures designated by number of hours
when the equipment has been operated for that many hours.
4-7.2.3 Item to be Checked or Serviced Column. This column lists the item to be checked or serviced.
4-7.2.4 Procedure Column. This column gives the procedure for checking or servicing the item listed in the location, item
to check/service column. You must perform the procedure to know if the generator is ready or available for its intended
mission or operation. You must do the procedure at the time stated in the interval column.
4-7.2.5 Not Fully Mission Capable if: Column. Information in this column tells you what faults will keep your equipment
from being capable of performing its primary mission. If you make checks or services that show faults listed in this column,
do not operate the equipment.
4-7.2.6 Reporting and Correcting Deficiencies. If Winterization Kit does not perform as required, refer to Chapter 4,
Section V. Troubleshooting.
4-7.3
Other Table Entries. Be sure to observe all special information and notes that appear in your table.
4-7.4
Special Instructions. Preventive maintenance is not limited to performing the checks and services listed in the
PMCS table. See Figure 4-1 for PMCS routing. Covering unused receptacles, stowing unused accessories, and other routine
procedures such as equipment inventory, cleaning components, and touch up painting are not listed in the table. These are
things you should do any time you see that they need to be done. If a routine check is listed in the PMCS table, it is because
experience has shown that problems may occur with this item. Take along tools and cleaning cloths needed to perform the
required checks and services.
4-5
TB 9-6115-641-13
4
Figure 4-1. Unit PMCS Routing Diagram.
4-6
TB 9-6115-641-13
Table 4-1. Unit Preventive Maintenance Checks and Services.
Item
No.
Interval
Item to be
Checked or Serviced
Procedure
Not Fully Mission
Capable if:
WINTERIZATION KIT
1
Before
HEATER CONTROL UNIT
Check electrical connections for
damage or disconnect.
Loose or damaged
electrical connections.
2
Before
FUEL PUMP AND LINES
Check pump connections.
Fuel leaks.
3
Before
EXHAUST SYSTEM
Check for loose connections.
Exhaust leaks.
4
Before
HEATER ON/OFF SWITCH
Turns heater on/off.
Doesn’t turn heater on.
4-7
TB 9-6115-641-13
Section V. TROUBLESHOOTING
4-8
GENERAL.
Refer to TM 9-6115-641-24 for generator troubleshooting procedures and to TM 9-2815-252-24 for engine troubleshooting
procedures. In this section a symptom index for the kit lists faults associated with kit operation. The kit has an indicator light
which flashes in a sequence to indicate faults. These pulses are shown visually on the Function Codes plate mounted inside
the generator control panel cover. Refer to Figure 3-1 and 4-2 for the Function Codes plate. Figure 4-3 through 4-19 show the
same information for the kit. Each malfunction listed on the Symptom Index includes a reference to the troubleshooting
figure that contains a chart that will help you determine probable causes and corrective actions to take. The symptom index
cannot list all faults that may occur, nor all the test or inspections and corrective actions. If a malfunction is not listed or
cannot be corrected by listed corrective actions, notify next higher level of maintenance for assistance.
SYMPTOM INDEX, WINTERIZATION KIT
NOTE
When the heater is switched on, the light will perform one of the sequences of light pulses shown
visually on the Function Codes Plate mounted inside the generator control panel cover (Figure 4-33).
Before each symptom, this index lists in parentheses the light sequence associated with it.
Troubleshooting
Symptom
Procedure
(Page)
No Indication of Heater Operation When Switch Is In ON Position ..................................................................................4-10
(dash, dash) Heater Restart Attempted During Purge Cycle...............................................................................................4-11
(dash, 5 dots, dash) Warning: Power Supply ......................................................................................................................4-11
(10 dots) Overheating .........................................................................................................................................................4-12
(dot, dot) Flame Sensor Short-circuit..................................................................................................................................4-12
(2 dots, 2 dots) Flame Cutout-LOW ...................................................................................................................................4-13
(3 dots, 3 dots) Flame Cutout-HIGH ..................................................................................................................................4-13
(4 dots, 4 dots) Glow Plug Defect.......................................................................................................................................4-14
(dash, dash) Burner Motor Defect.......................................................................................................................................4-14
(dash, dot, dash, dot) Under Voltage ..................................................................................................................................4-14
(dash, 2 dots, dash, 2 dots) Over Voltage ...........................................................................................................................4-15
(dash, 3 dots, dash 3 dots) Non-Start ..................................................................................................................................4-15
(2 dots, dash, 2 dots, dash) Temperature Sensor Defective ................................................................................................4-16
(3 dots, dash, 3 dots, dash) Fuel Pump Short Circuit ..........................................................................................................4-16
(2 dots, dash, 3 dots, dash, dot) Temperature Switch Defective .........................................................................................4-17
(4 dashes) Control Unit Defective ......................................................................................................................................4-17
(dot, dash, 3 dots, dash, 2 dots) Connection Error ..............................................................................................................4-17
4-8
TB 9-6115-641-13
NOTE
Before performing troubleshooting procedures turn off
heater and attempt restart.
Figure 4-2. Heater Function Codes Plate.
4-9
TB 9-6115-641-13
WARNING
DO NOT ATTEMPT ANY TASKS
INSIDE GENERATOR HOUSING
WITH GENERATOR SET RUNNING.
FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN
SEVERE PERSONAL INJURY OR
DEATH.
NO HEATER OPERATION
CHECK FUSE F1
NOT OK
REPLACE FUSE
OK
MEASURE +24 VDC AT S1-2
NOT OK
NOTIFY NEXT HIGHER LEVEL OF
MAINTENANCE
OK
PLACE SWITCH S1 IN ON POSITION
AND MEASURE +24 VDC AT S1-3
NOT OK
REPLACE S1
OK
NOT OK
REMOVE 6-(A2-TEST) FROM
CONTROL UNIT RECEPTACLE A AND
MEASURE CONTINUITY FROM PIN 3
TO GND
NOTIFY NEXT HIGHER LEVEL OF
MAINTENANCE
OK
REMOVE 2-PIN CONNECTOR (A2TEST) FROM CONTROL UNIT TEST
RECEPTACLE AND MEASURE +24
VDC AT PIN 5 WITH S1 IN ON
POSITION
NOT OK
NOTIFY NEXT HIGHER LEVEL OF
MAINTENANCE
OK
REPLACE CONTROL UNIT
(PARAGRAPH 4-9)
Figure 4-3. No Indication of Heater Operation When Switch Is In ON Position.
4-10
TB 9-6115-641-13
HEATER RESTART
ATTEMPTED DURING
PURGE CYCLE
YES
HAS PURGE (DELAYED
SHUT-OFF) CYCLE ENDED
START HEATER
NO
IS COOLANT
TEMPERATURE BELOW
TRIGGERING POINT OF
TEMPERATURE SENSOR
(70°C, 158°F)
YES
START HEATER
NO
NOTIFY NEXT HIGHER
LEVEL OF MAINTENANCE
TO CHECK TEMPERATURE
SENSOR AND REPLACE IF
NECESSARY
YES
START HEATER
NO
REPLACE HEATER
(PARAGRAPH 4-10)
Figure 4-4. (dash, dash) Heater Restart Attempted During Purge Cycle.
WARNING:
POWER SUPPLY
YES
IS BATTERY VOLTAGE
LESS THAN +21VDC?
CHECK BATTERY
ELECTROLYTE AND CHARGE
BATTERY (REFER TO
TM 9-6115-641-24)
NO
YES
IS BATTERY VOLTAGE
GREATER THAN +30VDC?
TROUBLESHOOT
BATTERY SYSTEM (REFER
TO TM 9-6115-641-24)
NO
RETURN TO SERVICE
Figure 4-5. (dash, 5 dots, dash) Warning: Power Supply.
4-11
TB 9-6115-641-13
OVERHEATING
NOT OK
CHECK COOLANT LEVEL
ADD COOLANT AS
REQUIRED (REFER TO TM
9-6115-641-24)
OK
MEASURE CONTINUITY OF
WIRING TO COOLANT
PUMP
NOT OK
NOTIFY NEXT HIGHER LEVEL
OF MAINTENANCE TO REPAIR
OR REPLACE WIRING
OK
TEST FOR POWER AT
WIRING CONNECTION TO
COOLANT PUMP
NOT OK
NOTIFY NEXT HIGHER LEVEL
OF MAINTENANCE TO REPAIR
OR REPLACE WIRING
OK
NOT OK
DOES COOLANT PUMP
RUN?
REPLACE PUMP
(PARAGRAPH 4-20)
OK
NOTIFY NEXT HIGHER
LEVEL OF MAINTENANCE
TO REPAIR OR REPLACE
WIRING
Figure 4-6. (10 dots) Overheating.
FLAME SENSOR SHORT
CIRCUIT
REPLACE HEATER
(PARAGRAPH 4-10)
Figure 4-7 (dot, dot) Flame Sensor Short-Circuit.
4-12
TB 9-6115-641-13
FLAME CUTOUT - LOW
CHECK FUEL LEVEL
NOT OK
ADD FUEL
OK
CHECK FOR OPERATION
OF FUEL PUMP
NOT OK
REPLACE FUEL PUMP
(PARAGRAPH 4-11)
OK
CHECK VOLTAGE AT C5
ON BLOWER CONTROL
UNIT
NOT OK
REPLACE CONTROL UNIT
(PARAGRAPH 4-9)
Figure 4-8. (2 dots, 2 dots) Flame Cutout – Low.
FLAME CUTOUT - HIGH
CHECK FUEL LEVEL
NOT OK
ADD FUEL
OK
CHECK FOR VAPOR LOCK
IN FUEL LINE
(PARAGRAPH 4-18)
NOT OK
MAKE SURE FULE LINE IS
NOT TOUCHING HOT
ENGINE SURFACES
OK
REPLACE HEATER
(PARAGRAPH 4-10)
Figure 4-9. (3 dots, 3 dots) Flame Cutout – High.
4-13
TB 9-6115-641-13
GLOW PLUG DEFECT
NOT OK
CHECK WIRING HARNESS
FROM CONTROL UNIT
CONNECTOR C3 TO GLOW
PLUG CONNECTOR ON
HEATER
SECURE WIRE
CONNECTION OR IF
DAMAGED NOTIFY NEXT
HIGHER LEVEL OF
MAINTENANCE TO
REPAIR OR REPLACE
OK
NOT OK
REPLACE SERIES
RESISTOR OR GLOW
PLUG
REPLACE HEATER
(PARAGRAPH 4-10)
Figure 4-10 (4 dots, 4 dots) Glow Plug Defect.
BURNER MOTOR DEFECT
CHECK AIR INTAKE AND
EXHAUST LINES FOR
OBSTRUCTIONS
NOT OK
CLEAR AIR PASSAGES OF
OBSTRUCTIONS
OK
REPLACE HEATER
(PARAGRAPH 4-10)
Figure 4-11 (dash, dash) Burner Motor Defect.
UNDER VOLTAGE
IS BATTERY LESS THAN
+21VDC?
YES
CHECK BATTERY
ELECTROLYTE CHARGE
BATTERY (REFER TO
TM 9-6115-641-24)
NO
CLEAN CORROSION FROM
ELECTRICAL CONNECTIONS
Figure 4-12 (dash, dot, dash dot) Under Voltage.
4-14
TB 9-6115-641-13
OVER VOLTAGE
YES
IS BATTERY VOLTAGE GREATER
THAN +30VDC?
CHECK BATTERY CHARGING
CIRCUIT FOR PROPER
OPERATION (REFER TO
TM 9-6115-641-24)
NO
CLEAN CORROSION FROM
ELECTRICAL CONNECTIONS
Figure 4-13 (dash, 2 dots, dash 2 dots) Over Voltage.
NON-START
NOT OK
ADD FUEL
CHECK FUEL LEVEL
OK
NOT OK
CHECK FOR DAMAGED WIRING
HARNESS
NOTIFY NEXT HIGHER LEVEL
OF MAINTENANCE TO
REPLACE OR REPAIR WIRING
HARNESS (PARAGRAPH 4-16)
OK
CHECK FOR VOLTAGE PULSES AT
FUEL PUMP
NOT OK
REPLACE CONTROL UNIT
(PARAGRAPH 4-9)
OK
CHECK FOR FUEL PUMP OPERATION
NOT OK
REPLACE FUEL PUMP
(PARAGRAPH 4-11)
OK
NOT OK
REPLACE GLOW PLUG
REPLACE HEATER
(PARAGRAPH 4-10)
Figure 4-14 (dash, 3 dots, dash 3 dots) Non-Start.
4-15
TB 9-6115-641-13
TEMPERATURE SENSOR
DEFECTIVE
REPLACE HEATER
(PARAGRAPH 4-10)
Figure 4-15 (2 dots, dash, 2 dots, dash) Temperature Sensor Defective.
FUEL PUMP SHORT-CIRCUIT
CHECK FUEL LEVEL
NOT OK
ADD FUEL
OK
CHECK FOR 24VDC AT PUMP
CHECK WIRING
OK
OK
NOT OK
CHANGE FUEL PUMP
NOT OK
NOT OK
SEND TO NEXT HIGHER
MAINTENANCE
Figure 4-16 (3 dots, dash, 3 dots, dash) Fuel Pump Short-Circuit.
4-16
REPAIR WIRING
TB 9-6115-641-13
OVERVOLTAGE
YES
IS BATTERY VOLTAGE
GREATER THAN +30VDC?
CHECK BATTERY CHARGING CIRCUIT
FOR PROPER OPERATION (REFER TO
TM 9-6115-641-24)
NO
RETURN TO SERVICE
Figure 4-17 (2 dots, dash, 3 dots, dash, dot) Temperature Switch Defective.
TEMPERATURE SWITCH
DEFECTIVE
NOT OK
CHECK WIRING HARNESS
REMOVE AND REPLACE WIRING
HARNESS (REFER TO
PARAGRAPH 4-16)
OK
REPLACE HEATER
Figure 4-18 (4 dashes) Control Unit Defective.
CONNECTION ERROR
NOT OK
CHECK WIRING HARNESS
CONNECTIONS
REMOVE AND REPLACE ALL
CONNECTORS
Figure 4-19 (dot, dash, 3 dots, dash, 2 dots) Connection Error.
4-17
TB 9-6115-641-13
Section VI. UNIT MAINTENANCE PROCEDURES.
WARNING
Do not attempt to perform any maintenance tasks on the kit while the generator is operating.
Serious electrical shock or death by electrocution may result from failure to observe this warning.
4-9
CONTROL UNIT MAINTENANCE.
This task covers:
a. Test
b. Remove
c. Replace
d. Install
INITIAL SETUP
Equipment Conditions
Tools
Tool Kit, General Mechanic’s
(item 1, appendix B)
Reference
Generator shut down, TM 9-6115-641-10
Heater shut off, Paragraph 2-4.1.c
Materials/Parts
TEST
Refer to troubleshooting procedures, Figures 4-3, 4-8, and 4-14.
REMOVAL
WARNING
Disconnect negative battery cable from right battery and the positive
battery cable from the left battery before doing the following
procedures. Failure to observe this warning could result in severe
personal injury or death.
WARNING
Before disconnecting any coolant lines, let generator cool from
operation, then relieve pressure by opening radiator cap carefully.
Coolant is hot and under pressure and may cause severe burns.
1.
Disconnect negative battery cable.
2.
Disconnect electrical connectors.
3.
Remove two screws (1), Figure 4-20. flat washers (2), lock washers (4), nuts (5), and control unit (3).
REPLACEMENT
1.
Perform steps 1 thru 3 of removal.
2.
Perform steps 1 thru 3 of install, substituting new control unit for the defective one.
4-18
TB 9-6115-641-13
INSTALLATION
1.
Install control unit (3), flat washers (2), screws (1), lock washers (4), and nuts (5).
2.
Reconnect electrical connectors to control unit.
3.
Reconnect negative battery cable.
Figure 4-20. Control Unit Maintenance.
4-19
TB 9-6115-641-13
4-10
HEATER ASSEMBLY MAINTENANCE.
This task covers:
a. Inspect
b. Test
c. Remove
d. Repair
e. Replace
f. Install
INITIAL SETUP
Equipment Conditions
Tools
Tool Kit, General Mechanic’s
(item 1, appendix B)
Reference
Generator shut down, TM 9-6115-641-10
Heater shut off, Paragraph 2-4.1.c
Materials/Parts
INSPECTION
Inspection is limited to visual inspection of components. Check for damaged and frayed wiring.
TEST
Refer to troubleshooting procedures, Figures 4-4, 4-7, 4-9, 4-10, 4-11, 4-14, 4-15, and 4-18.
REMOVAL
WARNING
Disconnect negative battery cable from right battery and the positive
battery cable from the left battery before doing the following
procedures. Failure to observe this warning could result in severe
personal injury or death.
WARNING
Before disconnecting any coolant lines, let generator cool from
operation, then relieve pressure by opening radiator cap carefully.
Coolant is hot and under pressure and may cause severe burns.
1.
Disconnect negative battery cable.
2.
Drain coolant system.
3.
Disconnect fuel line (1), Figure 4-21, from heater and drain any fuel from hose into a suitable container.
4.
Disconnect wiring harness connector A1, (Figure 4-34), from heater.
5.
Loosen screw clamps (3), Figure 4-21, and remove exhaust hose (13) from heater (2).
6. Position a suitable container under heater to catch coolant from hose, and loosen screw clamps (11) to
disconnect coolant inlet hose (12) and outlet hose (10) from heater (2).
7. Remove two screws (9), lock washers (8), flat washers (7), and heater (2), with mounting plate (5), from mounting
bracket (6). Loosen heater brace from top cover.
REPAIR
1. Repair of the Heater Assembly is limited to the replacement of the igniter/glow plug assembly, resistor, and the
coolant pump.
4-20
TB 9-6115-641-13
REPLACEMENT
1.
Perform steps 1 thru 7 of removal.
2.
Perform steps 1 thru 7 of install, substituting new heater assembly for the defective one.
INSTALLATION
1. Install heater (2) with attached mounting plate (5) on mounting bracket (6). Install flat washers (7), lockwashers (8)
and screws (9) to secure heater (2).
2. Connect coolant inlet and outlet hoses (12 and 10) to heater (2), securing them with screw clamps (11). Top off
radiator to replace any coolant lost in removing hoses.
3.
Attach exhaust hose (13) to heater unit (2), securing with screw clamp (3) connected to heater brace and tighten.
4.
Connect wiring harness A1 to the heater assembly, Figure 4-27.
5.
Connect fuel line (1) to heater assembly.
6.
Top off coolant.
7.
Reconnect negative battery cable.
Figure 4-21. Heater Assembly Maintenance.
4-21
TB 9-6115-641-13
4-11
FUEL PUMP MAINTENANCE.
This task covers:
a. Test
b. Remove
c. Replace
d. Install
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
(item 1, appendix B)
Equipment Conditions
Reference
Generator shut down, TM 9-6115-641-10
Heater shut off, Paragraph 2-4.1.c
Materials/Parts
TEST
1.
Disconnect fuel line at heater assembly.
2.
Place fuel line into container suitable for catching fuel.
3.
Apply 24 VDC to electrical input of pump. Pump should hum. Fuel will then start flowing into the container.
REMOVAL
WARNING
Disconnect negative battery cable from right battery and the
positive battery cable from the left battery before doing the
following procedures. Failure to observe this warning could
result in severe personal injury or death.
WARNING
Before disconnecting any coolant lines, let generator cool from
operation, then relieve pressure by opening radiator cap
carefully. Coolant is hot and under pressure and may cause
severe burns.
WARNING
Keep spilled fuel away from hot engine and all fires, and wash
with warm water after getting any on skin. Fuel is highly
flammable and is irritating to skin.
1.
Disconnect negative battery cable.
2.
Disconnect electrical leads (1) from connector, Figure 4-22, on fuel pump (2).
3. Loosen screw clamps (3) to disconnect fuel line (4) and butt splice (5) from input end of fuel pump (2). Drain any
fuel from line into a suitable container.
4. Loosen screw clamp (3) to disconnect butt splice (5) and fuel line (6) from output end of fuel pump (2).
Drain any fuel from line into a suitable container.
5.
Remove nut (8), lock washer (9), flat washer (10), and screw (11).
6.
Remove fuel pump (2) from clamp (7).
4-22
TB 9-6115-641-13
REPLACEMENT
1.
Perform steps 1 thru 6 of removal.
2.
Perform steps 1 thru 5 of install, substituting new fuel pump for the defective one.
.
INSTALLATION
1.
Install new fuel pump (2) in clamp (7) and secure with screw (11), flat washer (10), lock washer (9), and nut (8).
2.
Install butt splice (5) and fuel line (6) on outlet end of fuel pump (2) and secure with screw clamps (3).
3.
Install fuel line (4) and butt splices (5) on inlet end of fuel pump (2) and secure with screw clamps (3).
4.
Plug in electrical leads at connection (1) on fuel pump (2).
5.
Reconnect negative battery cable.
Figure 4-22. Fuel Pump Maintenance.
4-23
TB 9-6115-641-13
4-12
HEATER ATTACHMENT MAINTENANCE.
This task covers:
a. Replace
INITIAL SETUP
Tools
Equipment Conditions
Tool Kit, General Mechanic’s
(item 1, appendix B)
Reference
Generator shut down, TM 9-6115-641-10
Heater shut off, Paragraph 2-4.1.c
Materials/Parts
REPLACE
WARNING
Disconnect negative battery cable from right battery and the
positive battery cable from the left battery before doing the
following procedures. Failure to observe this warning could
result in severe personal injury or death.
WARNING
Keep spilled fuel away from hot engine and all fires, and wash
with warm water after getting any on skin. Fuel is highly
flammable and is irritating to skin.
1.
Turn Heater and generator off.
2. Open left and right access doors and disconnect negative battery cable from right battery and positive battery cable
from the left battery.
3. Support heater. Remove screws (1, 3, 4, Figure 4-23), washers (2, 7, and 8), nut (11), lockwashers (5, 6, and 9) and
heater from heater mounting brace (10), and heater mounting brace (10) from wall mounting bracket (12) and wall mounting
bracket (12) from generator house (14).
4.
Inspect all hardware (1-13) for damage and replace as required.
5.
Install wall mounting bracket (12) with screws (4), lockwashers (6) and washers (8) to generator housing (14).
6.
Install heater to heater mounting brace (10) with screws (1), washers (2), lockwashers (9) and nut (11).
7.
Install heater mounting brace (10) to wall mounting bracket (12) with screws (3), lockwashers (5), and washers (7).
8.
Reconnect batteries and close access doors.
4-24
TB 9-6115-641-13
14
Figure 4-23. Heater Attachment Maintenance.
4-25
TB 9-6115-641-13
4-13
PLATE, OPERATION AND HEATER SWITCH MAINTENANCE
This task covers:
a. Inspect
b. Test
c. Remove
d. Replace
e. Install
INITIAL SETUP
Tools
Equipment Conditions
Tool Kit, General Mechanic’s
(item 1, appendix B)
Reference
Generator shut down, TM 9-6115-641-10
Heater shut off, Paragraph 2-4.1.c
Materials/Parts
INSPECTION OF HEATER SWITCH
Inspection is limited to visual inspection of components. Check for damaged and frayed wiring.
WARNING
Disconnect negative battery cable from right battery and the positive
battery cable from the left battery before doing the following
procedures. Failure to observe this warning could result in severe
personal injury or death.
TEST OF HEATER SWITCH
1. Disconnect lead from terminal of switch (1), Figure 4-24, and use multimeter to measure for continuity across
switch terminals with switch in on position. With switch in off position there should be an open circuit.
2.
If readings are not as above, replace switch.
REMOVAL OF HEATER SWITCH
1.
Disconnect negative battery cable.
2.
Release control panel by turning two fasteners and carefully lowering control panel.
3.
At generator control panel (2), tag and disconnect all leads to switch (1).
4.
Remove knurled nut (3), mounting nut (4), from control panel (2).
5.
Tag and disconnect leads to light (5).
6.
Remove light (5) and clip (6), along with heater switch plate (7).
REPLACEMENT OF HEATER SWITCH
1.
Perform steps 1 thru 6 or removal.
2.
Perform steps 1 thru 5 of install, substituting new heater switch plate for the defective one.
INSTALLATION OF HEATER SWITCH
1.
Install heater switch plate (7) and light (5) with new clip (6). Discard rectangular clip that comes with lights.
2.
Connect all leads to light (5).
4-26
TB 9-6115-641-13
3.
Install switch (1), mounting nut (4), knurled nut (3), and reconnect leads to switch (1).
4.
Raise and secure control panel (2).
5.
Reconnect negative battery cable.
INSPECTION OF OPERATING PLATE, FUNCTION CODE PLATE, AND ID PLATE
1.
Inspect plate for illegible instructions, dents, cracks, etc.
REPLACEMENT OF OPERATING PLATE, FUNCTION CODE PLATE, AND ID PLATE
1.
Using electric drill with 1/8” drill bit, drill each of the rivets and punch out.
2.
Substitute new operation plate, function code plate, and id plate for defective ones. Install plates using blind rivets.
1
2
4
6
3
5
7
Figure 4-24. Plate, Operation and Heater Switch Maintenance.
4-27
TB 9-6115-641-13
4-14
COOLANT HOSE MAINTENANCE
This task covers:
a. Inspect
b. Remove
c. Replace
d. Install
INITIAL SETUP
Tools
Equipment Conditions
Tool Kit, General Mechanic’s
(item 1, appendix B)
Reference
Generator shut down, TM 9-6115-641-10
Heater shut off, Paragraph 2-4.1.c
INSPECTION
Inspection is limited to visual inspection of components. Check for leaks and cuts.
REMOVAL
WARNING
Before disconnecting any coolant lines, let generator cool from
operation, then relieve pressure by opening radiator cap carefully.
Coolant is hot and under pressure and may cause severe burns.
1.
Drain coolant.
2. Loosen screw clamps (1), Figure 4-25, to disconnect either or both coolant hoses, inlet (2) or outlet (3) from the
heater. Drain any coolant from the hose into a suitable container.
3.
Loosen screw clamp (1) to disconnect hose (2 and/or 3) to be replaced from motor block or water pump.
REPLACEMENT
1.
Perform steps 1 thru 3 of removal.
2.
Perform steps 1 thru 2 of install, substituting new coolant hose for defective one.
INSTALLATION
1.
Install hose (2 and/or 3) securing with screw clamps (1).
2.
Top off radiator coolant level to replace coolant lost in hose removal.
4-28
TB 9-6115-641-13
Figure 4-25 Coolant Hose Maintenance.
4-29
TB 9-6115-641-13
4-15
AIR INLET AND EXHAUST HOSE MAINTENANCE.
This task covers:
a. Inspect
b. Remove
c. Replace
d. Install
INITIAL SETUP
Equipment Conditions
Tools
Tool Kit, General Mechanic’s
(item 1, appendix B)
Reference
Generator shut down, TM 9-6115-641-10
Heater shut off, Paragraph 2-4.1c.
Materials/Parts
Sealeant
(item 1, appendix F)
INSPECTION
Inspection is limited to visual inspection of components. Check for cuts, air leaks, and crushed hoses.
REMOVAL
WARNING
Muffler and flex hoses get hot. Allow them to cool before touching them, to avoid burn injury.
1.
Loosen screw clamp (1), Figure 4-26, to remove air inlet hose (2) from heater (3).
2.
Loosen screw clamp (4) to remove air exhaust hose (5) from heater exhaust port (13).
3.
Remove nut (6), lock washer (7), flat washer (8), and screw (9), and clamp (10) from fan guard (11).
4.
Remove sealant from around air exhaust hose (5) at hole through fan shroud (12).
5.
Remove thermal sleeving from exhaust hose (5) and retain.
REPLACEMENT
1.
Perform steps 1 thru 5 of removal.
2.
Perform steps 1 thru 6 of install, substituting new air inlet and exhaust hose for the defective one.
INSTALLATION
1.
2.
right.
3.
Reinstall thermal sleeving on exhaust hose (5).
Attach air exhaust hose (5) through hole in fan shroud (12), and slightly bend end of exhaust hose (5), 90° to the
Attach air exhaust hose (5) to heater exhaust port (13) with screw clamp (4) and brace.
4. Attach exhaust clamp (10) to air exhaust hose (5) and attach to fan guard (11) using screw (9), flat washer (8), lock
washer (7) and nut (6).
5.
Put sealant around air exhaust hose (5) at hole in fan shroud (12) and fill in completely.
6.
Attach air inlet hose (2) to heater (3) with screw clamp (1).
4-30
TB 9-6115-641-13
13
Figure 4-26. Air Inlet and Exhaust Hose Maintenance.
4-31
TB 9-6115-641-13
4-16
WIRING HARNESS MAINTENANCE.
This task covers:
a. Inspect
b. Test
c. Remove
d. Repair
e. Replace
f. Install
INITIAL SETUP
Tools
Equipment Conditions
Tool Kit, General Mechanic’s
(item 1, appendix B)
Multimeter (item 5, appendix B)
Reference
Generator shut down, TM 9-6115-641-10
Heater shut off, Paragraph 2-4.1.c
Materials/Parts
None
WARNING
Make sure generator set is shut down before performing any
maintenance. Failure to observe this warning could result in severe
personal injury or death.
INSPECTION
Inspection is limited to visual inspection of components. Check for damaged and frayed wiring.
TEST
Test wiring for continuity. Replace any open or broken wires or connectors.
REMOVAL
1.
Refer to Figure 4-27 and tag all leads on wiring harness to be removed.
2.
Disconnect all leads and plugs. Remove wiring harness.
REPAIRMENT
Repair consists of replacing wires, connectors, and terminals. Follow standard shop practice in performing all repairs.
REPLACEMENT
1.
Perform steps 1 thru 2 of removal.
2.
Perform steps 1 thru 2 of install, substituting new wiring harness for the defective one.
INSTALLATION
1.
Position wiring harness in place.
2.
Refer to Figure 4-27 and connect leads and plugs.
4-32
TB 9-6115-641-13
Figure 4-27. Wiring Harness Maintenance.
4-33
TB 9-6115-641-13
4-17
IGNITOR/GLOW PLUG AND RESISTOR MAINTENANCE.
This tasks covers:
a. Test
b. Replace
INITIAL SETUP
Equipment Conditions
Tools
Tool Kit, General Mechanic’s
(item 1, appendix B)
Reference
Generator shut down, TM 9-6115-641-10
Heater shut off, paragraph 2-4.1.c
WARNING
Disconnect negative battery cable before doing the following
procedures. Failure to observe this warning could result in severe
personal injury or death.
TEST
1.
Disconnect negative battery terminal.
2.
Remove caps (5) from glow plug and resistor.
3.
Disconnect wires from glow plug and resistor.
4.
Check continuity between glow plug/ignitor and ground and the resistor and ground.
REPLACEMENT
1.
Disconnect negative battery cable.
2. Remove caps (5), Figure 4-28, from ignitor/glow plug (4) and resistor (1). Loosen hex nuts (2) on ignitor/glow plug
(4) and resistor (1). Remove cable (3).
3. Unscrew ignitor/glow plug (4) or resistor (1), as required, and remove it. Use an angled hook to clean the
ignitor/glow plug hole.
4.
Install ignitor/glow plug (4) or resistor (1).
5.
Install plug cable (3), hex nuts (2), and caps (5).
6.
Reconnect negative battery cable.
4-34
TB 9-6115-641-13
Figure 4-28. Ignitor/Glow Plug And Resistor Maintenance.
4-35
TB 9-6115-641-13
4-18
FUEL LINE MAINTENANCE.
This task covers:
a. Inspect
b. Remove
c. Replace
d Install
INITIAL SETUP
Equipment Conditions
Tools
Tool Kit, General Mechanic’s
(item 1, appendix B)
Reference
Generator shut down, TM 9-6115-641-10
Heater shut off, Paragraph 2-4.1.c
INSPECTION
Perform a visual inspection for deterioration leakage, dry-rot, etc.
REMOVAL
WARNING
Keep spilled fuel away from hot engine and all fires, and wash with
warm water after getting any on skin. Fuel is highly flammable and is
irritating to skin.
1. Loosen screw clamps (1), Figure 4-29, to remove butt splice (6), and fuel line (2) between primary fuel pump (3),
and fuel pump (4). Drain any fuel from line into a suitable container.
2.
Loosen screw clamps (5) to remove butt splices (9) and fuel line (7) between fuel pump (4) and heater (8).
REPLACEMENT
1.
Perform steps 1 thru 2 of removal.
2.
Perform steps 1 thru 2 of install, substituting new fuel line for the defective one.
INSTALLATION
NOTE
Ensure that fuel line is routed away from the engine and heater exhaust.
1. Install a fuel line (2) and butt splices (6) between primary fuel pump (3) and fuel pump (4), securing with screw
clamps (1).
2.
4-36
Install a fuel line (7) and butt splices (9) between fuel pump (4) and heater (8), securing with screw clamps (5).
TB 9-6115-641-13
Figure 4-29. Fuel Line Maintenance.
4-37
TB 9-6115-641-13
4-19
FUNCTION CODES PLATE MAINTENANCE.
This task covers:
a. Inspect
b. Replace
INITIAL SETUP
Tools
Equipment Conditions
Tool Kit, General Mechanic’s
(item 1, appendix B)
Reference
Generator shut down, TM 9-6115-641-10
Heater shut off, paragraph 2-4.1.c
Materials/Parts
INSPECTION
Inspect plate for illegible instructions, dents, cracks, etc.
REPLACEMENT
1.
Lift generator control panel cover (1), Figure 4-30.
2.
Remove four rivets (2) and plate (3).
3.
Install new code plate (3) and four rivets (2).
4.
Close control panel cover (1).
4-38
TB 9-6115-641-13
Figure 4-30. Function Codes Plate Maintenance.
4-39
TB 9-6115-641-13
4-20
COOLANT PUMP MAINTENANCE.
This task covers:
a. Test
b. Remove
c. Replace
d. Install
INITIAL SETUP
Equipment Conditions
Tools
Tool Kit, General Mechanic’s
(item 1, appendix B)
Sealant
(item 1, appendix F)
Reference
Generator shut down, TM 9-6115-641-10
Heater shut off, Paragraph 2-4.1.c
WARNING
Disconnect negative battery cable from right battery and the positive
battery cable from the left battery before doing the following
procedures. Failure to observe this warning could result in severe
personal injury or death.
TEST
Refer to troubleshooting procedure, Figure 4-6.
REMOVAL
1.
Disconnect negative battery cable.
2.
Remove electrical cover (1), Figure 4-31 and 12-pin connector (2).
3.
Remove 12-pin connector (2) and push out pins (3) to coolant pump (6).
4.
Remove clamp (7) attaching pump (6) to heater (8).
5.
Loosen clamp (4) and remove outlet hose (5) from pump (6), using a container to catch coolant from hose.
REPLACEMENT
1.
Perform steps 1 thru 5 of removal.
2.
Perform steps 1 thru 6 of installation, substituting new coolant pump for the defective one.
INSTALLATION
1.
Attach coolant pump (6) with clamp (7) to heater (8).
2.
Apply sealant to outlet and attach hose (5) with clamp (4).
3.
Push in 2 pins (3) with wire through 12-pin connector (2).
4-40
TB 9-6115-641-13
4. Replace 12-pin connector cover (2) and electrical cover (1).
5. Top off coolant if needed.
6. Reconnect negative battery cable.
8
Figure 4-31. Coolant Pump Maintenance.
4-41
TB 9-6115-641-13
Section VII. REMOVAL INSTRUCTIONS
4-21
INSTRUCTIONS TO UNIT MAINTENANCE FOR REMOVAL OF WINTERIZATION KIT ON THE
5kW TACTICAL QUIET GENERATOR SET.
The following instructions have been provided so you can remove, Heater Kit, 5kW Generator Set
NSN: 6115-01-476-8973 from your Generator Set.
WARNING
Disconnect negative battery cable from right battery and the positive battery cable from
the left battery before doing the following procedures. Failure to observe this warning
could result in severe personal injury or death.
WARNING
Before disconnecting any coolant lines, let generator cool from operation, then relieve
pressure by opening radiator cap carefully. Coolant is hot and under pressure and may
cause burns.
WARNING
Catch fuel in suitable container. Keep spilled fuel away from hot engine and all fires.
Wash with warm water after getting any on skin. Fuel is highly flammable and is
irritating to skin.
4-21.1
Removal Procedures.
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Tool Kit, Automotive
(Common No. I)
Equipment Conditions
Reference
Generator shut down
TM 9-6115-641-10
TM 9-6115-641-24
TM 9-2815-252-24
REMOVAL
1. Turn heater and generator off.
2. Open left and right access doors and disconnect negative battery from right battery and the positive battery
cable from the left battery.
3. Drain generator coolant system in accordance with TM 9-6115-641-10.
4. Remove generator air filter inlet hose if needed in accordance with TM 9-6115-641-24.
5. Open control panel access door (1), Figure 4-33.
6. Remove control unit, (3), from center bulkhead housing (4) with screws (1), flat washers (2), lock washers (5) and nuts
(6), Figure 4-32.
4-42
TB 9-6115-641-13
Figure 4-32. Control Unit Removal.
7. Open front storage box.
8. Remove electrical leads from P6-24, 25, 26 in accordance with wiring diagram, Figure 4-34.
9. Remove pins from J6-24, 26, and 25.
10. Remove toggle switch (5), indicator lamp (6), and heater switch label (7), Figure 4-33.
11. Remove rivets (4) from operating plate (2) and function code plate (3), Figure 4-2, from control panel door (1).
12. Remove fuse holder (1), Figure 4-34, from the wiring harness (2), from (+) terminal of slave receptacle, and reassemble
existing hardware.
13. Remove wiring harness (2).
14. Remove left side fan guard in accordance with TM 9-6115-641-24, and retain with hardware.
15. Remove fuel tubing (7 and 9), Figure 4-35, butt splices (12 and 6), clamps (11 and 5) from fuel pump (8), and heater fuel
intake (10), along with the adapter (4). Disconnect the fuel supply line (13), from tee fitting (3), remove elbow (2), then
remove tee (3) from primary fuel pump (1) and reconnect fuel supply line (13).
4-43
TB 9-6115-641-13
p/o
p/o
p/o
Figure 4-33. Cover and Instrument Panel.
4-44
TB 9-6115-641-13
Figure 4-34. Wiring Harness Removal.
4-45
TB 9-6115-641-13
13
Figure 4-35. Fuel System Removal.
4-46
TB 9-6115-641-13
Figure 4-36. Fuel Pump Removal.
16. Remove fuel pump (1) and clamp (2), Figure 4-36. Reinstall existing hardware, but do not tighten.
17. Remove both ends of metallic hose (1), Figure 4-37, clamps (2 and 4), brace (3), and attaching hardware.
18. Remove coolant hoses (1, 4 and 5), Figure 4-38, along with clamps (3 and 7) making sure to replace the expansion plug
(6), and remove adapter group if installed, and cap off the water pump.
19. Remove heater assembly (1), Figure 4-39, mounting plate (2), bracket (3), and hardware from left side control box panel,
and reattach top hinge and lower hinge and existing screws in accordance with TM 9-6115-641-24.
4-47
TB 9-6115-641-13
Figure 4-37. Exhaust System and Brace Removal.
4-48
TB 9-6115-641-13
ADAPTER GROUP
Figure 4-38. Coolant System Removal.
4-49
TB 9-6115-641-13
Figure 4-39. Heater Assembly Removal.
20. Reinstall left side fan guard with hardware taken off in step 14.
21. Top off coolant in accordance with TM 9-6115-641-10.
22. Check all hoses for leaks.
23. Reconnect the negative battery cable and positive battery cable.
4-50
TB 9-6115-641-13
CHAPTER 5
DIRECT SUPPORT MAINTENANCE
Subject Index
Page
Section I Repair Parts; Special Tools; Test, Measurement, and Diagnostic Equipment (TMDE);
and Support Equipment................................................................................................................5-2
5-1
5-2
5-3
Common Tools and Equipment ...................................................................................................5-2
Special Tools, TMDE, and Support Equipment...........................................................................5-2
Repair Parts..................................................................................................................................5-2
Section II
Installation Instructions................................................................................................................5-3
5-4
Instructions to Direct Support Maintenance for Installation of the Winterization Kit on
the 5kW Tactical Quiet Generator Set .........................................................................................5-3
5-1
TB 9-6115-641-13
Section I.
5-1
REPAIR PARTS; SPECIAL TOOLS; TEST, MEASUREMENT, AND
DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT
EQUIPMENT
COMMON TOOLS AND EQUIPMENT.
For authorized common tools and equipment refer to the Modified Table of Organization and Equipment (MTOE)
applicable to your unit.
5-2
SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT.
No special tools or support equipment are required for maintenance of the Winterization Kit. Refer to TM
9-6115-641-24P for the generator and to TM 9-2815-252-24P for the engine.
5-3
REPAIR PARTS.
Refer to TM 9-6115-641-24P for the generator set parts and to TM 9-2815-252-24P for the engine parts.
Winterization kit repair parts are listed in Appendix C.
5-2
TB 9-6115-641-13
Section II. INSTALLATION INSTRUCTIONS
5-4
INSTRUCTIONS TO DIRECT SUPPORT MAINTENANCE FOR INSTALLATION OF
WINTERIZATION KIT ON THE 5kW TACTICAL QUIET GENERATOR SET.
The following instructions have been provided so you can install, Heater Kit, 5kW Generator Set
NSN: 6115-01-476-8973 on your Generator Set.
WARNING
Disconnect negative battery cable from right battery and the positive battery cable from the left battery before
doing the following procedures. Failure to observe this warning could result in severe personal injury or death.
WARNING
Before disconnecting any coolant lines, let generator cool from operation, then relieve pressure by opening radiator cap
carefully. Coolant is hot and under pressure and may cause burns.
WARNING
Catch fuel in suitable container. Keep spilled fuel away from hot engine and all fires, and wash with warm water after getting
any on skin. Fuel is highly flammable and is irritating to skin.
5-4.1
Installation Procedures.
INITIAL SETUP
Equipment Conditions
Tools
Tool Kit, General Mechanic’s
Tool Kit, Automotive
(Common No. I)
Reference
Generator shut down
TM 9-6115-641-10
TM 9-6115-641-24
TM 9-2815-252-24
INSTALLATION
NOTE
Use packing list provided with kit.
1. Open left and right access doors and disconnect negative battery from right battery and the positive battery
cable generator housing from the left.
2. Drain generator coolant system in accordance with TM 9-6115-641-10.
3. Remove generator air filter inlet hose in accordance with TM 9-6115-641-10 if needed.
4. Drill two 3/16" diameter holes using control unit (3), Figure 5-1, as template in center bulkhead housing (4).
5. Install control unit, (3), to center bulkhead housing (4) with screws (1), flat washers (2), lock washers (5), and
nuts (6).
5-3
TB 9-6115-641-13
Figure 5-1. Control Unit Assembly.
6. Reinstall generator air filter inlet hose in accordance with TM 9-6115-641-24 if needed.
7. Remove left side fan guard in accordance with TM 9-6115-641-24.
NOTE
Seal all pipe threads with sealing compound contained in kit.
8. Disconnect the generator set fuel supply line and elbow from the generator set primary fuel pump in accordance with
TM 9-6115-641-24.
9. Attach tee, (3), to generator set primary fuel pump (1), Figure 5-2.
10. Attach the elbow (2), and adapter (4), to tee fitting (3), along with butt splices (12), fuel tubing (7), and clamps (11).
5-4
TB 9-6115-641-13
Figure 5-2. Fuel System Assembly.
5-5
TB 9-6115-641-13
Figure 5-3. Bulkhead Housing.
11. Remove dead crank switch bracket (4), Figure 5-3, from center bulkhead housing. Retain hardware for
reinstallation in accordance with TM 9-6115-641-24. Retain hardware for reinstallation.
12. Drill four 9/32 inch diameter holes (2 and 3) in center bulkhead housing (1).
13. Install dead crank switch bracket (4, removed in procedure 11) in holes (3) with screws, flat washers, and lock
washers.
5-6
TB 9-6115-641-13
28
26
27
Figure 5-4. Heater Assembly.
14. Loosen the heater head retaining screw (1), Figure 5-4, part of (2), and rotate the glow plug assembly (3), until the right
glow plug is above the coolant outlet (4), and tighten.
15. Loosen the heater holding clamp bracket (28), part of (2), and rotate the “black” heater shell bracket approximately 1 ½
inch space from the heater water pump. Do not retighten the clamp.
16. Install the heater (2), on the heater mounting plate, (5), using screws (6), flat washers (7), lock washers (8), and nuts (9).
17. Attach the heater air inlet flexible hose (25) to the heater water pump (26) using existing cable tie provided with heater,
(2). Ensure the inlet hose (27) does not interfere with the heater mounting bracket.
18. Remove the hinges (21) and associated hardware from the generator set.
19. Install blind rivet nuts (19) in holes on bulkhead housing (20). See holes (2) in Figure 5-3.
20. Remove existing two screws, washers, lock washers, and nuts from left side control box panel nearest door hinge and
retain them.
5-7
TB 9-6115-641-13
21. Install the wall mounting plate bracket (18), Figure 5-4, on the inside of the center bulkhead housing using screws (13),
flat washers (14), and lock washers (15) into rivet nuts (19).
22. Reinstall existing hardware from step 20.
23. Install the top hinge (21), on the outside of the center bulkhead housing (24), using screws (23), flat washers (22), lock
washers (17), and nuts (16), removed in procedure 18.
24. Install the heater/mounting plate assembly (5) to the wall mounting bracket (18), using screws (10), flat washers (11), and
lock washers (12).
25. Retighten the heater holding clamp from step 15 making sure the heater water pump inlet and heater air
inlet hoses do not interfere with dead crank switch bracket. Refer to TM 9-6115-641-24.
Figure 5-5. Fuel Pump Assembly.
26. Reinstall the bottom hinge on the outside of the bulkhead housing while installing clamp and pump (1 and 2), Figure 5-5,
on inside using hardware removed in step 18 and screw (3).
27. Reinstall left side door to hinges with the hinges to the outside of the door using hardware and hinges removed in step 18.
5-8
TB 9-6115-641-13
Figure 5-6. Expansion Plug.
28. Remove the starter from the Generator Set in accordance with TM 9-6115-641-24.
29. Remove freeze plug (1), Figure 5-6, from right side engine block. Apply retaining compound to the mating surface of
expansion plug (1). Install expansion plug (1), flush with the engine block.
30. Reinstall the starter onto the Generator Set in accordance with TM 9-6115-641-24.
5-9
TB 9-6115-641-13
Figure 5-7. Coolant Hoses.
31. Install 90° preformed coolant hose (5), Figure 5-7, from expansion plug (6) to heater coolant intake using clamps, (3).
Make sure to route the hose around and behind the engine. Secure with tie straps.
32. Remove cap and clamp from engine water pump. Install hose (4) to beaded hose fitting (p/o) water pump with clamp (3).
33. Install coolant hose (1) to water pump adapter (7) using clamp (3). Attach hose (1) to reducer (2), attach hose (4) to
reducer (2). Secure with clamps (3). (Cut hose (4) for fit). Secure hose (4) to heater with clamps (3).
5-10
TB 9-6115-641-13
Figure 5-8. Exhaust Hose and Heater Brace.
34. Install heater brace (3), Figure 5-8, by using heater brace as a template for location and mark. Drill hole, 5/16” and
mount to the inside top of the generator housing using screw (5), flat washer (6), lock washer (7), and nut (8).
35. Install thermal sleeving (16) over exhaust hose (15) and attach one end of exhaust hose (15), to heater (2), using
clamp (4). Before attaching clamp, remove the screw from the clamp and insert clamp screw through heater
brace (3) and then into the clamp (4).
5-11
TB 9-6115-641-13
36. Drill a 1-1/8" diameter hole in rear of front housing (1), Figure 5-8.
37. Install other end of exhaust hose (15), into hole provided in rear of front housing (1). Use sealant provided in kit, around
hose and hole to prevent movement. Bend excess hose 90° to the right into front side of housing.
38. Drill a 7/32" diameter hole in the left side fan guard (14).
39. Secure exhaust hose (15) to fan guard (14), using clamp (12), screw (13), flat washer (11), lock washer (10), and nut (9).
40. Install butt splice (6), Figure 5-2, to heater fuel intake (10) using clamp (5). Bend item (10) to approximately 90° (only if
it interferes or touches the door when closed) making sure not to kink the metal tube so it pinches off the fuel supply.
NOTE
Route fuel hose, tubing away from exhaust system.
NOTE
When assembling fuel component parts together or fuel component parts to tubing, Figure 5-9, the
proper connection is a butt joint.
Figure 5-9. Butt Joint.
41. Install butt splice (6), Figure 5-2, to fuel pump (8) using clamps (5). Install tubing (9), from butt splice (6) on heater fuel
intake to butt splice (6) on fuel pump using clamps (5).
42. Attach butt splices (12) to fuel pump and to adapter (4), using clamps (11).
43. Install tubing (7), between butt splices (12) from fuel pump to adapter (4), using clamps (11).
44. Open storage box door.
5-12
TB 9-6115-641-13
Figure 5-10. Fuse and Wiring Harness.
45. Remove pins from P6-24, 26, and 25, Figure 5-10.
46. Install wiring harness (2), and include ground cable in accordance with wiring diagram. Secure with straps.
5-13
TB 9-6115-641-13
Figure 5-11. Cover and Instrument Panel.
5-14
TB 9-6115-641-13
NOTE
Install fuse, (25 AMP, 32 V) if not already installed.
47. Connect fuse holder, Figure 5-10, (1) part of (2), to (+) terminal of the slave receptacle and mount on inside of bulk head
with existing hardware used to attach the slave receptacle cover chain.
48. Open control panel access door (1), Figure 5-11.
49. Locate operating instruction plate (2) and heater function codes plate (3) and match and drill holes in control panel access
door (1). Plates shall be readable when door is open.
50. Install rivets (4). Rivet head shall be on the outside of unit.
51. Locate heater switch label (7) and match and drill holes in control panel (8).
52. Install heater switch label (7), toggle switch (5), and indicator light (6).
53. Referencing Figure 5-10, remove connector J6 from control box, then remove pins from J6-24, 26, and 25.
54. Install electrical leads, in accordance with wiring diagram. Secure leads with straps.
WARNING
The coolant in the system shall contain the proper mixture of water and antifreeze to
prevent coolant from freezing or slushing. Failure could cause engine damage and/or
personal injury.
55. Add coolant to proper level in the winterization kit.
56. Connect the positive and negative battery cables.
57. Start and run engine until the radiator thermostat has opened.
58. Using a jumper wire start the heater coolant pump only by putting positive power to pin A6 on A2 of the control unit.
This will start the coolant pump only. Continue until pitch changes.
59. If necessary, top off coolant.
60. Disconnect positive lead from A6 on A2 of the control unit.
61. Double-check all hose connections for leaks.
62. With engine running, start heater. Check the heater code light, per the heater function codes plate for heater operation.
63. Turn off engine and allow heater to run until the coolant reaches temperature, at which time the heater will cycle to low
heat.
64. Switch heater off.
NOTE
The water pump and combustion air blower will continue to run for several minutes.
65. Locate identification plate, next to existing plates on front housing. Drill holes and install four rivets contained
in kit.
5-15/(5-16 BLANK)
TB 9-6115-641-13
APPENDIX A
REFERENCES
A-1
SCOPE.
This appendix lists all forms, regulations, pamphlets, specifications, standards, technical manuals, lubrication orders, and
field manuals referenced in this TB.
A-2
FORMS.
Recommended Changes to Publications and Blank Forms ...................................................................................DA Form 2028
Recommended Changes to Equipment Technical Publications......................................................................... DA Form 2028-2
Depreservation Guide for Vehicles and Equipment…………………………………...........................................DA Form 2258
Equipment Inspection and Maintenance Worksheet…………………………………. .........................................DA Form 2404
Computerized (Equipment Inspection and Maintenance Worksheet)................................................................. DD Form 5988E
Packaging Improvement Report ..................................................................................................................................DD Form 6
Product Quality Deficiency Report.....................................................................................................................................SF 368
A-3
ARMY REGULATIONS.
Dictionary of United States Army Terms .................................................................................................................... AR 310-25
A-4
DEPARTMENT OF THE ARMY PAMPHLETS.
The Army Maintenance Management System (TAMMS) ...............................................................................DA PAM 738-750
A-5
TECHNICAL MANUALS.
Unit, Direct Support and General Support Maintenance Instructions,
Diesel Engine Model No. DN2M, 2 Cylinder .9 Liter............................................................................. TM 9-2815-252-24
Unit, Direct Support and General Support Repair Parts and Special Tools List Maintenance Manual,
Diesel Engine Model No. DN2M, 2 Cylinder .9 Liter........................................................................... TM 9-2815-252-24P
Operator's Manual, Generator Set, Skid Mounted, Tactical, Quiet,
5kW, 60 and 400 Hz
MEP-802A (60 Hz) 6115-01-274-7387
MEP-812A (400 Hz) 6115-01-274-7391................................................................................................. TM 9-6115-641-10
Unit, Direct Support and General Support Repair Parts and Special Tools List Maintenance Manual, Generator Set,
Skid Mounted, Tactical, Quiet, 5kW, 60 and 400 Hz
MEP-802A (60 Hz) 6115-01-274-7387
MEP-812A (400 Hz) 6115-01-274-7391................................................................................................. TM 9-6115-641-24
Unit, Direct Support and General Support Maintenance Manual, Generator Set,
Skid Mounted, Tactical, Quiet, 5kW, 60 and 400 Hz
MEP-802A (60 Hz) 6115-01-274-7387
MEP-812A (400 Hz) 6115-01-274-7391............................................................................................... TM 9-6115-641-24P
A-1
TB 9-6115-641-13
A-6
LUBRICATION ORDERS.
Lubrication Order: Generator Set, Skid Mounted, Tactical, Quiet,
5kW, 60 and 400 Hz
MEP-802A (60 Hz) 6115-01-274-7387
MEP-812A (400 Hz) 6115-01-274-7391 ..................................................................................................LO 9-6115-641-12
A-7
FIELD MANUALS.
Electrical Power Generation in the Field .......................................................................................................................FM 20-31
First Aid .........................................................................................................................................................................FM 21-11
A-2
TB 9-6115-641-13
APPENDIX B
MAINTENANCE ALLOCATION CHART (MAC)
Section l. INTRODUCTION
B-1 GENERAL
B-1.1 This section provides a general explanation of all maintenance and repair functions authorized at various maintenance
levels.
B-1.2 The Maintenance Allocation Chart (MAC) in section II designates overall authority and responsibility for the performance
of maintenance functions on the identified end item or component. The application of the maintenance functions to the end item
or component will be consistent with the capacities and capabilities of the designated maintenance levels.
B-1.3 Section III lists the tools and test equipment (both special tools and common tool sets) required for each maintenance
function as referenced from section II.
B-1.4 Section IV contains supplemental instructions and explanatory notes for a particular maintenance function.
B-2 MAINTENANCE FUNCTIONS. Maintenance functions will be limited to and defined as below:
B-2.1 Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or electrical
characteristics with established standards through examination (e.g., by sight, sound, or feel).
B-2.2 Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or electrical characteristics of an
item and comparing those characteristics with prescribed standards.
B-2.3 Service. Operations required periodically keeping an item in proper operating condition, i.e., to clean (includes
decontaminate, when required), to preserve, to drain, to paint, or to replenish fuel, lubricants, chemical fluids, or gases.
B-2.4 Adjust. To maintain or regulate, within prescribed limits, by bringing into proper position, or by setting the operating
characteristics to specified parameters.
B-2.5
Align. To adjust specified variable elements of an item to bring about optimum or desired performance.
B-2.6 Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or test, measuring, and
diagnostic equipment used in precision measurement. Consists of comparisons to two instruments, one of which is a certified
standard of known accuracy, to detect and adjust any discrepancy in the accuracy of the instrument being compared.
B-1
TB 9-6115-641-13
B-2.7 Remove/Install. To remove and install the same item when required to perform service or other maintenance
functions. Install may be the act of emplacing, seating, or fixing into position a spare, repair part, or module (component or
assembly) in a manner to allow the proper functioning of an equipment or system.
B-2.8 Replace. To remove an unserviceable item and install a serviceable counterpart in its place. "Replace" is authorized
by the MAC and assigned maintenance level is shown as the third position code of the Source, Maintenance and Recoverability
(SMR) code.
B-2.9 Repair. The application of maintenance services1, including fault location/troubleshooting2, removal/installation, and
disassembly/assembly3 procedures, and maintenance actions4 to identify troubles and restore serviceability to an item by
correcting specific damage, fault, malfunction, or failure in a part, subassembly, module (component or assembly), end item, or
system.
That maintenance effort (service/action) prescribed to restore an item to a completely
B-2.10 Overhaul.
serviceable/operational condition as required by maintenance standards in appropriate technical publication. Overhaul is
normally the highest degree of maintenance performed by the Army. Overhaul does not normally return an item to like new
condition.
B-2.11 Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment to a like new
condition in accordance with original manufacturing standards. Rebuild is the highest degree of materiel maintenance applied to
Army equipment. The rebuild operation includes the act of returning to zero those age measurement (e.g., hour/miles)
considered in classifying Army equipment/components.
B-3 EXPLANATION OF COLUMNS IN THE MAC, SECTION II.
B-3.1 Column (1), Functional Group Number. Column (1) lists Functional Group Code (FGC) numbers, the purpose of
which is to identify maintenance significant components, assemblies, subassemblies, and modules with the Next Higher
Assembly (NHA).
B-3.2 Column (2), Component/Assembly. Column (2) contains the names of components, assemblies, subassemblies, and
modules for which a maintenance function is authorized.
B-3.3 Column (3), Maintenance Function. Column (3) lists the functions to be performed on the item listed in Column (2).
(For detailed explanation of these functions, refer to “Maintenance Functions” outlined in paragraph B-2).
B-3.4 Column (4), Maintenance Level. Column (4) specifies each level of maintenance authorized to perform each function
listed in column (3), by indicating work item required (expressed as man-hours in whole hours or decimals in the appropriate
sub column. This work-time figure represents the active time required to perform that maintenance function at the indicated
level of maintenance. If the number or complexity of the tasks within the listed maintenance function varies at different
maintenance levels, appropriate work time figures will be shown for each level. The work time figure represents the average
time required to restore an item (assembly, subassembly, component, module, end item, or system) to a serviceable condition
under typical field operating conditions. This time includes preparation time (including any necessary disassembly/assembly
time), troubleshooting/fault location time, and quality assurance/quality control time in addition to the time required to perform
1
Services - inspect, test, service, adjust, align, calibrate, and/or replace.
2
Fault location/troubleshooting - The process of investigating and detecting the cause of equipment malfunctioning; the act of isolating a fault within
a system or Unit Under Test (UUT).
3
Disassembly/assembly - The step-by-step breakdown (taking apart) of a spare/functional group coded item to the level of its least component (i.e.,
assigned an SMR code) for the level of maintenance under consideration (i.e., identified as maintenance significant).
4
B-2
Actions - Welding, grinding, riveting, straightening, facing, machining, and/or resurfacing.
TB 9-6115-641-13
the specific tasks identified for the maintenance functions authorized in the MAC. The symbol designations for the various
maintenance levels are as follows:
C ............... Operator or crew maintenance
O ............... Unit maintenance
F ............... Direct support maintenance
L ............... Specialized Repair Activity (SRA)5
H ............... General support maintenance
D ............... Depot maintenance.
B-3.5 Column (5), Tools and Equipment Reference Code. Column (5) specifies, by code, those common tool sets (not
individual tools), common Test, Measurement and Diagnostic Equipment (TMDE), and special tools, special TMDE, and
special support equipment required to perform the designated function. Codes are keyed to the entries in the tools and test
equipment table.
B-3.6 Column (6), Remarks Code. When applicable, this column contains a letter code, in alphabetical order, which is
keyed to the remarks table entries.
B-4 EXPLANATION OF COLUMNS IN TOOLS AND TEST EQUIPMENT REQUIREMENTS, SECTION III
B-4.1 Column (1), Tool or Test Equipment Reference Code. The tool and test equipment reference code correlates with a
code used column (5), Section II of the MAC.
B-4.2
Column (2), Maintenance Level. The lowest level of maintenance authorized to use the tool or test equipment.
B-4.3
Column (3), Nomenclature. Name or identification of the tool or test equipment.
B-4.4
Column (4), National Stock Number. The National Stock Number (NSN) of the tool or test equipment.
B-4.5
Column (5), Tool Number. The manufacturers part number.
B-5 EXPLANATION OF COLUMNS IN REMARKS, SECTION IV
B-5.1
Column (1), Remarks Code. The code recorded in Column (6), Section II of the MAC.
B-5.2 Column (2), Remarks. This column lists information pertinent to the maintenance functions being performed as
indicated in the MAC, Section II.
5
The “L” maintenance level is not included in Section II, column (4) of the MAC. Functions to this level of maintenance are identified by a work time figure
in the "H" column of Section II, column (4), and an associated reference code is used in the REMARKS, column (6). This code is keyed to the remarks and
the SRA complete repair application is explained there.
B-3
TB 9-6115-641-13
Section II. MAINTENANCE ALLOCATION CHART
FOR
WINTERIZATION KIT, 5kW GENERATOR
(1)
GROUP
NUMBER
(2)
COMPONENT/ASSEMBLY MAINTENANCE
FUNCTION
UNIT
C
00
01
WINTERIZATION KIT
CONTROL UNIT
0.5
2.0
1.0
2.0
TEST
REMOVE
REPLACE
INSTALL
0.5
0.5
0.5
0.5
INSPECT
REPLACE
0.1
0201
FUNCTION CODE PLATE
INSPECT
REPLACE
0.1
0202
0203
OPERATING PLATE
HEATER SWITCH
MAINTENANCE LEVEL
DIRECT
SUPPORT
F
4.0
OPERATION AND
FUNCTION CODE PLATE
INDICATOR LIGHT
(5)
TOOLS
O
TEST
REMOVE
REPLACE
REPAIR
INSTALL
02
020101
(4)
(3)
GENERAL
SUPPORT
H
AND
DEPOT
EQUIPMENT
REFERENCE
CODE
D
A
1,2,5
1,2
1,2
1,2
A
0.1
0.5
D
E
REMOVE
REPLACE
INSTALL
0.2
0.3
0.2
1,2
1,2
1,2
INSPECT
REPLACE
0.1
0.5
1,2,3
0.1
0.3
0.5
0.5
0.5
5
1,2
1,2
1,2
0.1
D
B
E
1,2,3
0.1
REMARKS
CODE
1,2,5
1,2,
1,2, 3
1,2
1,2,3,4
0.5
INSPECT
TEST
REMOVE
REPLACE
INSTALL
(6)
D
E
D
E
A
D
03
FUEL SYSTEM AND
ATTACHMENTS
INSTALL
0301
FUEL PUMP
TEST
REMOVE
REPLACE
INSTALL
0.3
0.5
0.5
0.5
1,5
1,2
1,2
1,2
A
INSPECT
REMOVE
REPLACE
INSTALL
0.1
0.2
0.4
0.2
1,2
1,2
1,2
1,2
E
0302
B-4
FUEL LINE
0.1
D
D
TB 9-6115-641-13
MAINTENANCE ALLOCATION CHART
FOR
WINTERIZATION KIT, 5kW GENERATOR
(Continued)
(1)
GROUP
NUMBER
(2)
COMPONENT/ASSEMBLY MAINTENANCE
FUNCTION
UNIT
C
04
0401
HEATER ASSEMBLY
COOLANT PUMP
(4)
(5)
MAINTENANCE LEVEL
TOOLS
(3)
INSPECT
TEST
REMOVE
REPAIR
REPLACE
INSTALL
0.1
DIRECT GENERAL DEPOT
SUPPORT SUPPORT
O
F
H
D
(6)
AND
EQUIPMENT
REFERENCE
CODE
REMARKS
CODE
E
A
0.1
0.5
0.5
0.5
0.5
0.5
1,2
1,2
1,2
1,2
1,2
TEST
REMOVE
REPLACE
INSTALL
0,5
0,5
0.5
0.5
1,2
1,2
1,2
1,2
A
C
D
D
0402
RESISTOR
TEST
REPLACE
0.3
0.5
1,5
1,2
A
D
0403
IGNITOR/GLOW PLUG
TEST
REPLACE
0.3
0.5
1,5
1,2
A
D
05
HEATER ATTACHMENTS
REPLACE
1.0
1,2
D
06
COOLANT HOSES AND
ATTACHMENTS
INSPECT
REMOVE
REPLACE
INSTALL
0.1
0.1
0.5
0.5
0.5
1,2
1,2
1,2
INSPECT
REMOVE
REPLACE
INSTALL
0.1
0.1
0.5
0.5
0.5
1
1,2
1,2
INSPECT
TEST
REMOVE
REPAIR
REPLACE
INSTALL
0.1
0.1
0.8
0.5
1.0
1.0
0.4
1,2,5
1,2
1,2,4
1,2,4
1
07
08
AIR INLET/EXHAUST
HOSES
WIRING HARNESS
E
D
E
D
E
A
B
D
B-5
TB 9-6115-641-13
Section III. TOOL AND TEST EQUIPMENT REQUIREMENTS
FOR
WINTERIZATION KIT, 5kW GENERATOR
(4)
NATIONAL/NATO
STOCK NUMBER
TOOL KIT, GENERAL MECHANIC'S
5180-00-177-7033
SC 5180-95-CL-N26
O,F
SHOP EQUIPMENT, AUTOMOTIVE
MAINTENANCE
AND REPAIR: ORGANIZATIONAL MAINTENANCE
COMMON #1, LESS POWER
4910-00-754-0654
SC 4910-95-CL-A74
3
O,F
RIVETER, BLIND HEAD
5120-00-508-1588
GGG-R-00395
4
O,F
REMOVER, ELECTRICAL CONTACT
5120-00-020-5926
305183 (00779)
5
O,F
MULTIMETER
6625-01-265-6000
AN/PSM-45A
(2)
MAINTENANCE
LEVEL
1
O
2
B-6
(5)
TOOL
NUMBER
(3)
NOMENCLATURE
(1)
TOOL OR TEST
EQUIPMENT REF
CODE
TB 9-6115-641-13
Section IV. REMARKS
(1)
REMARKS
CODE
(2)
REMARKS
A
Testing of the Winterization Kit is limited to the heater switch, control unit, coolant pump, wiring
harness, light indicator, fuel pump, glow plug, and resistor.
B
Repair of the Winterization Kit is limited to the replacement of wiring harness (J1), coolant hoses, fuel
lines, fuel pump, heater switch, intake/exhaust hoses, control unit assembly, data plates, 25 AMP
fuse, and light indicator.
C
Repair of the Heater Assembly is limited to the replacement of the igniter/glow plug assembly,
resistor, and the coolant pump.
D
Replace wiring harness, heater assembly, glow plug, hoses, resistor, fuel lines, fuel pump, water
pump, control unit, heater switch, indicator light, exhaust assembly, operating plate, and heater
assembly attachments.
E
Inspection is limited to visual inspection of components. Check for damage and frayed wiring.
Check for illegible instructions, dents, cracks, etc.
B-7/(B-8 BLANK)
TB 9-6115-641-13
APPENDIX C
UNIT AND DIRECT SUPPORT MAINTENANCE
REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL)
TABLE OF CONTENTS
Page
Illus/Figure
Section I.
INTRODUCTION ..................................................................... C-2
Section II.
REPAIR PARTS LIST
Group 00
01
02
03
04
05
06
07
08
Winterization Kit ....................................................................... C-6
Control Unit............................................................................... C-8
Operating Plate and Switch ....................................................... C-10
Fuel System and Attachments.................................................... C-12
Heater Assembly........................................................................ C-14
Heater Assembly Attachments................................................... C-16
Coolant Hoses and Attachments ................................................ C-18
Exhaust Hoses and Heater Brace............................................... C-20
Wiring Harness, J1 .................................................................... C-22
Figure C-1
Figure C-2
Figure C-3
Figure C-4
Figure C-5
Figure C-6
Figure C-7
Figure C-8
Figure C-9
99
Lead, Electrical (98-2049-1)...................................................... C-24
Lead, Electrical (98-2049-2)...................................................... C-24
Lead, Electrical (98-2050) ........................................................ C-24
Figure C-10
Figure C-10
Figure C-10
Section III.
SPECIAL TOOLS LIST N/A.................................................... C-26
Section IV.
NATIONAL STOCK NUMBER AND PART NUMBER INDEXES
National Stock Number Index ................................................... C-27
Part Number Index..................................................................... C-29
C-1
TB 9-6115-641-13
SECTION I. INTRODUCTION
C-1
SCOPE.
This Repair Parts and Special Tools (RPSTL) lists and authorizes spares and repair parts; special tools; special Test,
Measurement, and Diagnostic Equipment (TMDE); and other special support equipment required for performance of unit
and direct support maintenance of the Winterization Kits for the MEP-802A/MEP-812A Tactical Quiet Generators (TQGs).
It authorizes the requisitioning, issue, and disposition of spares, repair parts and special tools as indicated by the Source,
Maintenance and Recoverability (SMR) codes.
C-2
GENERAL.
In addition to Section I, Introduction, RPSTL is divided into the following sections:
a. Section II. Repair Parts List. A list of spares and repair parts authorized by this RPSTL for use in the
performance of maintenance. The list also includes parts that must be removed for replacement of the authorized
parts. Parts lists are composed of functional groups in ascending alphanumeric sequence, with the parts in each
group listed in ascending figure and item number sequence. Bulk materials are listed by item name FIG BULK
at the end of the section. Repair parts kits or sets are listed separately in their own functional group within
Section II.
b. Section III. Special Tools List. There are no special tools for Generator’s Winterization Kit.
c. Section IV. National Stock Number and Part Number Indexes. A list, in National Item Identification
Number (NIIN) sequence, of all national stock numbered items appearing in the listings followed by a list in
alphanumeric sequence of all part numbers appearing in the listing. National Stock Numbers (NSNs) and part
numbers are cross-referenced to each illustration figure and item number appearance.
C- 3 EXPLANATION OF COLUMNS (Section II).
a.
b.
ITEM NO. (Column (1)). Indicates the number used to identify items called out in the illustration.
SMR CODE (Column (2)). The Source, Maintenance, and Recoverability (SMR) code is a 5-position
code containing supply/requisitioning information, maintenance category authorization criteria, and
disposition instruction, as shown in the following breakout:
Source Code
XX
Maintenance Code
XX
Recoverability Code
X
1st two positions
3rd position
4th position
5th position
How you get an item
Who can install,
replace or use
the item
Who can do
complete repair*
of the item
Who determines
disposition action on an
unserviceable item
*Complete repair maintenance capacity, capability, and authority to perform all corrective maintenance tasks of the "Repair"
function in a use/user environment in order to restore serviceability to a failed item.
(1) Source Code. The source code tells you how you get an item needed for maintenance, repair, or overhaul of an
end item/equipment. Explanations of source codes follow:
XB
C-2
Order by part number or obtain from salvage.
TB 9-6115-641-13
C-3
EXPLANATION OF COLUMNS (Section II) Con’t
XC
Installation drawing, diagram, instruction sheet, field service drawing that is identified
by manufacturer’s part number.
PA
Stocked items; use the applicable NSN to request/requisition items with these codes.
They are authorized to the category indicated by the code in the 3rd position of the
SMR code.
MO - (Made at
Unit Level)
Items with these codes are not to be requested/requisitioned individually. They must
be made from bulk material, which is identified by the NSN or part number in the
Bulk Material group of the repair parts list in this manual. If the item is authorized to
you by the 3rd position code of the SMR code, but the source code indicates it is made
at a higher level, order the item from the higher level of maintenance.
MF - (Made at DS
Level)
AO - (Assembled
at Unit Level)
AF - (Assembled
at Direct Support)
Items with these codes are not to be requested/requisitioned individually. The parts
that make up the assembled item must be requisitioned or fabricated and assembled at
the level of maintenance indicated by the source code. If the 3rd position code of the
SMR code authorizes you to replace the item, but the source code indicates the item is
assembled at a higher level, order the item from the higher level of maintenance.
NOTE
Cannibalization when authorized may be used as a source of supply for
items with the above source codes.
(2) Maintenance Code. Maintenance codes tell you the level(s) of maintenance authorized to USE and REPAIR
support items. The maintenance codes are entered in the third and fourth positions of the SMR Code as
follows:
The maintenance code entered in the third position tells you the lowest maintenance level authorized
to remove, replace, and use an item. The maintenance code entered in the third position will indicate
authorization to one of the following levels of maintenance.
Code
Application/Explanation
C
-Crew or operator maintenance done within organizational or aviation unit maintenance.
O
-Unit maintenance can remove, replace, and use the item.
F
-Direct support or aviation intermediate level can remove, replace, and use the item.
The maintenance code entered in the fourth position tells you whether or not the item is to be repaired
and identifies the lowest maintenance level with the capability to do complete repair (i.e., perform all
authorized repair functions).
NOTE
Some limited repair may be done on the item at a lower level of maintenance, if
authorized by the Maintenance Allocation Chart (MAC) and SMR codes. This
position will contain one of the following maintenance codes.
C-3
TB 9-6115-641-13
C-3 EXPLANATION OF COLUMNS (Section II) Con’t
Code
Application/Explanation
O
-Unit is the lowest level that can do complete repair of the item.
F
-Direct support or aviation intermediate is the lowest level that can do complete repair of the item.
Z
-Non-repairable. No repair is authorized.
B
-No repair is authorized. (No parts or special tools are authorized for the maintenance of a "B" coded
item.) However, adjusting, lubricating, etc., at the user level may recondition the item.
(3) Recoverability Code. Recoverability codes are assigned to items to indicate the disposition action on
unserviceable items. The recoverability code is entered in the fifth position of the SMR Code as follows:
Code
Application/Explanation
Z
-Non-reparable item. When unserviceable, condemn and dispose of the item at the level of maintenance
shown in 3rd position of SMR code.
O
-Reparable item. When uneconomically reparable, condemn and dispose of the item at aviation unit
level.
F
-Reparable item. When uneconomically reparable, condemn and dispose of the item at the direct support
or aviation intermediate level.
A
-Item requires special handling or condemnation procedures because of specific reasons (i.e., precious
Refer to appropriate
metal content, costly item, critical material, or hazardous material).
manuals/directives for specific instructions.
c.
NATIONAL STOCK NUMBER (Column (3)). The National Stock Number is used to request/requisition
items.
d. CAGE (Column (4)). The Commercial and Government Entity Code (CAGE) is used to identify the
manufacturer, distributor, or Government agency, etc., that supplies the item.
e.
PART NUMBER (Column (5)). Indicates the primary number used by the manufacturer (individual, company,
firm, corporation, or Government activity), which controls the design and characteristics of the item by means of
its engineering drawings, specifications, standards, and inspection requirements to identify an item or range of
items.
NOTE
When you use an NSN to requisition an item, the item you receive may have a
different part number from the part ordered.
f. DESCRIPTION (Column (6)). This column includes the following information:
(1) The Federal item name, and when required, a minimum description to identify the item.
(2) Items that are included in kits and sets are listed below the name of the kit or set.
C-4
TB 9-6115-641-13
C-3
EXPLANATION OF COLUMNS (Section II) Con’t
(3) Spare/repair parts that make up an assembled item are listed immediately following the assembled item line
entry.
(4) Part numbers for bulk material are referenced in this column in the line entry for the item to be
manufactured/fabricated.
(5) The statement END OF FIGURE appears just below the last item description in Column 6.
g. QTY (Column (7)). The QTY (quantity per figure) column indicates the quantity of the item used in the breakout
shown on the illustration figure, which is prepared for a functional group, sub-functional group, or assembly. A "V"
appearing in this column in lieu of a quantity indicates that the specific quantity is variable and the quantity may vary from
application to application.
C- 4
EXPLANATION OF COLUMNS (Section III). Special Tools List - Not Applicable
C- 5.
EXPLANATION OF COLUMNS (Section IV).
A.
NATIONAL STOCK NUMBER (NSN) INDEX.
(1) STOCK NUMBER (Column (1). This column lists the NSN by National Item Identification Number
(NIIN) sequence. The NIIN consists of the last nine digits of the NSN. An example is shown below.
NSN
(5305-01-674-1467).
NIIN
When using this column to locate an item, ignore the first four digits of the NSN. However, stock number should
use the complete NSN when ordering items.
(2) FIG. (Column (2)). This column lists the number of the figure where the item is identified/located. The
figures are in numerical order in Section II.
(3) ITEM (Column (3)). The item number identifies the item associated with the figure listed in the adjacent
FIG. Column. This item is also identified by the NSN listed on the same line.
B. PART NUMBER INDEX.
(1) PART NUMBER (Column (1)). Indicates the primary number used by the manufacturer (individual, firm,
corporation, or government activity), which controls the design and characteristics of the item by means of its
engineering drawings, specifications, standards, and inspection requirements to identify an item or range of
items.
(2) FIG. (Column (2)). This column lists the number of the figure where the item is identified/located in
Section II.
(3) ITEM (Column(3)). The item number identifies the item associated with the figure listed in the adjacent
FIG. column. This item is also identified by the NSN listed on the same line.
C- 6.
SPECIAL INFORMATION.
Fabrication Instructions. Bulk materials required to manufacture items are listed in the Bulk Material
Functional Group of this RPSTL. Part numbers for bulk materials are also referenced in the description column
of the line item entry for the item to be manufactured/fabricated. Detailed fabrication instructions for the items
source coded to be manufactured or fabricated are contained in Appendix G.
C-5
TB 9-6115-641-13
C-7
HOW TO LOCATE REPAIR PARTS.
a.
When National Stock Number or Part Number is Not Known:
First. Using the table of contents, determine the assembly group to which the item belongs. This is necessary
since figures are prepared for assembly groups and subassembly groups, and listings are divided into the same
groups.
Second. Find the figure covering the assembly group or subassembly group to which the item belongs.
Third. Identify the item on the figure and use the part number or NSN shown.
b. When National Stock Number or Part Number is Known:
Using National Stock Number or the Part Number Index, find the pertinent National Stock Number or Part
Number. The NSN Index is in National Item Identification Number (NIIN) sequence (see C-5). The part
numbers in the Part Number Index are listed in ascending alphanumeric sequence. Both indexes cross-reference
you to the illustration/figure and item number of the item you are looking for.
Section II. Repair Parts List
Figure C- 1. Winterization Kit 5kW, NSN: 6115-01-476-8973, PN: 98-2005
C-6
TB 9-6115-641-13
Section II. Repair Parts List - (Con’t)
(1)
ITEM
NO
(2)
SMR
CODE
(3)
NATIONAL STOCK
NUMBER
(4)
CAGE
(5)
PART
NUMBER
(6)
DESCRIPTION
(7)
QTY
Group 00
Figure C-1 Winterization
Kit
1
PAOZZ
2915-01-482-8924
38453
25 1600 50 00 00
CONTROL UNIT
See Figure C-2 for Parts
1
2
PAOOO
--
38453
501-103-0037
WIRING HARNESS, J1
See Figure C-9 for Parts
1
3
PAOOO
2990-01-483-4051
38453
25 1733 01
HEATER ASSEMBLY
See Figure C-5 for Parts
1
4
PAOZZ
2910-01-483-4069
38453
25 1600 45 00 00
FUEL PUMP
See Figure C-4 for Parts
1
5
MOOZZ
--
30554
98-2053-1
PLATE IDENTIFICATION
1
End of Figure
C-7
TB 9-6115-641-13
Section II. Repair Parts List (Con’t)
Figure C-2. Control Unit, NSN: 2915-01-482-8924, PN: 25 1600 50 00 00
(1)
ITEM
NO
(2)
SMR
CODE
(3)
NATIONAL
STOCK NUMBER
(4)
CAGE
(5)
PART
NUMBER
(6)
DESCRIPTION
(7)
QTY
Group 01
Figure C-2. Control Unit
1
XBOZZ
5305-01-378-7899
30554
88-20260-22
SCREW, CAP HEXAGON
2
2
XBOZZ
5310-00-014-5850
96906
MS27183-42
WASHER FLAT
2
3
XBOZZ
5310-00-045-3296
96906
MS35338-43
WASHER,LOCK
2
4
XBOZZ
5310-00-934-9751
96906
MS 35650-302
NUT,PLAIN,HEXAGON
2
End of Figure
C-8
TB 9-6115-641-13
THIS PAGE IS INTENTIONALLY LEFT BLANK
C-9
TB 9-6115-641-13
Section II. Repair Parts List (Con’t)
Figure C-3. Operating Plate and Switch
C-10
TB 9-6115-641-13
Section II. Repair Parts List (Con’t)
(1)
ITEM
NO
(2)
SMR
CODE
(3)
NATIONAL
STOCK NUMBER
(4)
CAGE
(5)
PART
NUMBER
(6)
DESCRIPTION
(7)
QTY
Group 02
Figure C-3. Operating Plate and
Switch
1
MOOZZ
—
30554
98-2041
PLATE, OPERATING INST
1
2
XBOZZ
5320-00-932-1972
97403
13214E3789-2
RIVET, BLIND
8
3
MOOZZ
—
30554
98-2001
PLATE, HEATER FUCTION
1
4
MOOOO
—
30554
98-2049-1
LEAD, ELECTRICAL
See Figure C-10 for Parts
1
5
MOOOO
—
30554
98-2049-2
LEAD, ELECTRICAL
See Figure C-10 for Parts
1
6
MOOOO
—
30554
98-2050
LEAD, ELECTRICAL,
See Figure C-10 for Parts
1
7
XBOZZ
5930-01-366-0048
81640
8906k4692
SWITCH, TOGGLE
1
8
XBOZZ
—
77122
PT312010PG
PUSH ON NUT
1
9
MOOZZ
—
30554
98-2021
LABEL, HEATER SWITCH
1
10
XBOZZ
—
91802
2191QU5-24V
LIGHT, INDICATOR
1
End of Figure
C-11
TB 9-6115-641-13
Section II. Repair Parts List (Con’t)
Figure C-4. Fuel Pump
C-12
TB 9-6115-641-13
Section II. Repair Parts List (Con’t)
(1)
ITEM
NO
(2)
SMR
CODE
(3)
NATIONAL
STOCK NUMBER
(4)
CAGE
(5)
PART
NUMBER
(6)
DESCRIPTION
(7)
QTY
Group 03
1
Figure C-4.
Fuel Pump
1
XBOZZ
—
81343
J1508-10 TYPE D
CLAMP,HOSE
4
2
XBOZZ
—
81343
J30R7-TYPE15/32ID
HOSE, NONMETALLIC
2
3
XBOZZ
—
1C645
090 31 118
TUBING, 4X1.25MM,NAT
TUBING IS 30 IN. L
1
4
PAOZZ
—
38453
25 1600 45 00 00
PUMP, FUEL
1
5
XBOZZ
4730-01-240-6108
81343
4-4-130239B
ELBOW, PIPE
1
6
XBOZZ
4730-01-449-1233
93061
125HB-3-4
ADAPTER, STRAIGHT, PI
1
7
XBOZZ
—
81343
J1508-13 TYPE D
CLAMP, HOSE,TYPE D
4
8
XB0ZZ
4720-01-293-4415
81343
J30R7-TYPE13/16ID
HOSE NONMETALLIC HOSE
IS 2 INCH LONG
2
9
PAOZZ
—
1C645
090 31 125
TUBING, 6.2MM, BLACK,
TUBING IS 30 IN. L
1
10
PAOZZ
5305-01-381-9970
30554
88-20260-34
SCREW, CAP,HEXAGON,H
1
11
XBOZZ
—
22175
55LC1WD21SN
CLAMP, LOOP, CUSHION
1
12
XBOZZ
81343
4-4-4 140424B
TEE, PIPE
4
4730-01-268-2403
End of Figure
C-13
TB 9-6115-641-13
Section II. Repair Parts List (Con’t)
Figure C-5. Heater Assembly, NSN: 2990-01-483-4051, PN: 25 1733 01
(1)
ITEM
NO
(2)
SMR
CODE
(3)
NATIONAL
STOCK NUMBER
(4)
CAGE
(5)
PART
NUMBER
(6)
DESCRIPTION
(7)
QTY
Group 04
Figure C-5. Heater
Assembly
1
PAOZZ
—
38453
25 1384 01 00 02
GLOW PLUG
1
2
PAOZZ
—
38453
25 1667 01 00 01
RESISTOR
1
3
PAOZZ
—
38453
25 1671 25 01 00
WATER PUMP
1
4
XB0ZZ
_
38453
10 2064 03 20 50
CLAMP, COOLANT PUMP
1
End of Figure
C-14
TB 9-6115-641-13
THIS PAGE IS INTENTIONALLY LEFT BLANK
C-15
TB 9-6115-641-13
Section II. Repair Parts List (Con’t)
Figure C-6. Heater Assembly Attachments
C-16
TB 9-6115-641-13
Section II. Repair Parts List (Con’t)
(1)
ITEM
NO
(2)
SMR
CODE
(3)
NATIONAL
STOCK NUMBER
(4)
CAGE
(5)
PART
NUMBER
(6)
DESCRIPTION
(7)
QTY
Group 05
Figure C-6 Heater Assembly
Attachments
1
XBOZZ
5305-01-378-7899
30554
88-20260-22
SCREW, CAP, HEXAGON, H
4
2
XBOZZ
5310-00-014-5850
96906
MS27183-42
WASHER, FLAT
4
3
XBOZZ
5305-01-378-7891
30554
88-20260-52
SCREW,HEX,WASHERHEA
2
4
XBOZZ
5305-01-381-9970
30554
88-20260-34
SCREW, CAP, HEXAGON, H
2
5
XBOZZ
5310-00-637-9541
30554
88-20556-7
WASHER, LOCK
2
6
XBOZZ
5310-00-582-5965
96906
MS35338-44
WASHER, LOCK
2
7
PAOZZ
5310-01-280-5796
96906
MS27183-57
WASHER, FLAT
2
8
XBOZZ
5310-00-809-4058
96906
MS27183-10
WASHER, FLAT
2
9
PAOZZ
5310-00-045-3296
96906
MS35338-43
WASHER, LOCK
4
10
XBOZZ
—
30554
98-2028
BRACE, HEATER, MOUNTI
1
11
PAOZZ
5310-00-533-2743
97403
13218E0320-49
NUT, PLAIN, HEXAGON
4
12
XBOZZ
—
30554
98-2029
BRACKET, WALL MOUNTI
1
13
XBOZZ
5310-00-680-5903
97403
S25-80
NUT, PLAIN, BLIND, RIV
2
End of Figure
C-17
TB 9-6115-641-13
Section II. Repair Parts List (Con’t)
Figure C-7 Coolant Hoses and Attachments
C-18
TB 9-6115-641-13
Section II. Repair Parts List (Con’t)
(1)
ITEM
NO
(2)
SMR
CODE
(3)
NATIONAL
STOCK NUMBER
(4)
CAGE
(5)
PART
NUMBER
(6)
DESCRIPTION
(7)
QTY
Group 06
Figure C-7 Coolant Hoses and
Attachments
1
XBOZZ
—
81343
SAEJ20R1,
CLD-2, ½ ID
HOSE, COOLANT
HOSE IS 4” L
1
2
XBOZZ
__
38453
501 601 0011
REDUCER
1
3
XBOZZ
4730-01-122-3338
SAEJ1670
CLAMP, TYPE F, SIZE 10
6
4
PAOZZ
—
81300
80402
HOSE, PREFORMED 90 D
HOSE IS 18 IN. L
1
5
PAOZZ
—
81300
80405
HOSE, PREFORMED, 90
HOSE IS 36 IN. L
1
6
XBOZZ
—
30554
98-2034
PLUG, EXPANSION
1
7
XBOZZ
—
81343
10-6 430160B
ADAPTER, STRAIGHT
1
End of Figure
C-19
TB 9-6115-641-13
Section II. Repair Parts List (Con’t)
Figure C-8. Exhaust Hoses and Heater Brace
C-20
TB 9-6115-641-13
Section II. Repair Parts List (Con’t)
(1)
ITEM
NO
(2)
SMR
CODE
(3)
NATIONAL
STOCK NUMBER
(4)
CAGE
(5)
PART
NUMBER
(6)
DESCRIPTION
(7)
QTY
Group 07
Figure C-8. Exhaust Hoses and
Heater Brace
OK1P5
1.00 ID HT4100S
HOSE, METALLIC
HOSE IS 24 IN. L
1
03200
S-H-1, 1/2
SLEEVING, THERMAL 21” L
1
5305-01-056-1501
30554
88-20260-32
SCREW, CAP HEXAGON
1
XBOZZ
5310-01-103-6042
96906
MS51412-4
WASHER, FLAT
1
5
PAOZZ
5310-00-582-5965
96906
MS35338-44
WASHER, LOCK
1
6
PAOZZ
5310-01-466-6312
30554
88-22790-1
NUT, PLAIN, HEXAGON
1
7
PAOZZ
__
18076
MS122916
CLAMP, LOOP
1
8
XBOZZ
—
30554
98-2026
HEATER BRACE
1
9
PAOZZ
5310-00-533-2743
97403
13218E03020-49
NUT, PLAIN, HEXAGON
1
10
XBOZZ
—
052C4
R30
CLAMP, LOOP
1
11
XB0ZZ
5305-01-378-7899
30554
88-20260-22
SCREW, HEX WASHERHEAD
1
12
XB0ZZ
5310-00-014-5850
96906
MS27183-42
WASHER, FLAT
1
13
XB0ZZ
5310-00-045-3296
96906
MS35338-43
WASHER, LOCK
1
1
XBOZZ
2
XBOZZ
3
XBOZZ
4
—
End of Figure
C-21
TB 9-6115-641-13
Section II. Repair Parts List (Con’t)
2
Figure C-9. Wiring Harness, J1 (38453) PN 501-103-0037
(1)
ITEM
NO
(2)
SMR
CODE
(3)
NATIONAL
STOCK NUMBER
(4)
CAGE
(5)
PART
NUMBER
(6)
DESCRIPTION
(7)
QTY
Group 08
Figure C-9. Wiring Harness
1
XBOZZ
5999-01-170-0558
00779
66331-8
CONNECTOR, P-6
3
2
PAOZZ
5920-01-414-6436
80063
AA55569/02-009
FUSE, INCLOSED, LINK
1
End of Figure
C-22
TB 9-6115-641-13
Section II. Repair Parts List (Con’t)
WIRE LIST
TERMINATION
WIRE NO.
AWG.
1
FROM
TERMINATION
ITEM NAME
TO
TERMINATION
ITEM NAME
A1-1
Heater Assembly
A2C-2
Control Module
18
2
A1-2
Heater Assembly
GND
—
18
3
A1-3
Heater Assembly
GND
—
18
4
A1-4
Heater Assembly
A2C-5
Control Module
18
5
A1-6
Heater Assembly
A2C-5
Control Module
18
6
A1-5
Heater Assembly
A2C-1
Control Module
18
7
A1-7
Heater Assembly
A2A-1
Control Module
18
8
A1-8
Heater Assembly
A2A-1
Control Module
18
9
A1-9
Heater Assembly
A2A-3
Control Module
18
10
A1-10
Heater Assembly
A2A-5
Control Module
18
11
A1-11
Heater Assembly
A2B-1
Control Module
18
12
A1-12
Heater Assembly
A2B-2
Control Module
18
13
E1-1
Fuel Pump
A2B-2
Control Module
18
14
E1-2
Fuel Pump
A2A-4
Control Module
18
15
HR-1
Glow Plug
GND
—
10
16
HR-2
Glow Plug
A2C-3
Control Module
10
17
A2TEST-S
Control Unit
P6-24
Heater Switch
18
18
A2TEST-T
Control Unit
P6-26
Heater Switch
18
19
A2C-6
Control Unit
P6-25
Heater Switch
18
20
A2C-6
Control Unit
A2C-4
Control Module
18
21
XF1-2
Fuse
A2C-4
Control Module
10
22
XF1-1
Fuse
+24 VDC
—
10
23
E1-2
Fuel Pump
GND
—
18
WIRE
C-23
TB 9-6115-641-13
Section II. Repair Parts List (Con’t)
Figure C-10. Electrical Leads-Bulk Items
C-24
TB 9-6115-641-13
Section II. Repair Parts List (Con’t)
Part Number
Termination
From Find #
Termination
To Find #
Wire
Find #
Dimension
98-2049-1
J6-25 3
S-1-2 1
2*
44”
98-2050
J6-24 3
DS1+ 4
S1-3 5
S1-3 5
2*
2*
44”
5”
DS1- 3
2*
44”
98-2049-2
(1)
ITEM
NO
(2)
SMR
CODE
J6-26
4
(3)
NATIONAL STOCK
NUMBER
(4)
CAGE
(5)
PART
NUMBER
(6)
DESCRIPTION
(7)
QTY
Group 99
Figure C-10. Electrical Leads
Bulk Items
1
XBOZZ
5940-00-813-0698
81343
MS25036-101
TERMINAL, LUG
1
2
MOOZZ
6145-00-851-8505
30554
88-20540-2
WIRE, ELECTRICAL
AR
3
XBOZZ
5999-01-366-5119
00779
66332-8
PIN
3
4
XBOZZ
5940-01-126-3973
00779
640917-1
TERMINAL, QUICK DISC
1
5
XBOZZ
5940-00-283-5280
81343
MS25036-106
TERMINAL, LUG
1
6
MOOZZ
--
30554
98-2049-1
LEAD, ELECTRICAL
1
7
MOOZZ
--
30554
98-2049-2
LEAD, ELECTRICAL
1
8
MOOZZ
--
30554
98-2050
LEAD, ELECTRICAL
1
End of Figure
C-25
TB 9-6115-641-13
Section III.
Special Tools List
NOT APPLICABLE
C-26
TB 9-6115-641-13
Section IV. NATIONAL STOCK NUMBER (NSN) AND PART NUMBER
INDEXES
NATIONAL STOCK NUMBER INDEX
(1)
STOCK NUMBER
5310-00-014-5850
(2)
FIG.
C-2
(3)
ITEM
2
C-6
2
C-8
12
C-2
3
C-6
9
C-8
13
5940-00-283-5280
C-10
5
5310-00-533-2743
C-6
11
C-8
9
C-6
6
C-8
5
5310-00-637-9541
C-6
5
5310-00-680-5903
C-6
13
5310-00-809-4058
C-6
8
5940-00-813-0698
C-10
1
6145-00-851-8505
C-10
2
5320-00-932-1972
C-3
2
5310-00-934-9751
C-2
4
5305-01-056-1501
C-8
3
5310-01-103-6042
C-8
4
4730-01-122-3338
C-7
3
5940-01-126-3973
C-10
4
5999-01-170-0558
C-9
1
4730-01-240-6108
4730-01-268-2403
5310-01-280-5796
4720-01-293-4415
5930-01-366-0048
5999-01-366-5119
5305-01-378-7891
5305-01-378-7899
C-4
C-4
C-6
C-4
C-3
C-10
C-6
C-2
5
12
7
8
7
3
3
1
5310-00-045-3296
5310-00-582-5965
C-27
TB 9-6115-641-13
Section IV. National Stock Number Index (Con’t)
(1)
STOCK NUMBER
5305-01-378-7899
5305-01-381-9970
5920-01-414-6436
4730-01-449-1233
5310-01-466-6312
6115-01-476-8973
2915-01-482-8924
2990-01-483-4051
2910-01-483-4069
C-28
(2)
FIG.
C-6
C-8
C-4
C-6
C-9
C-4
C-8
C-1
C-1
C-2
C-1
C-5
C-1
(3)
ITEM
1
11
10
4
2
6
6
---1
---3
---4
TB 9-6115-641-13
Section IV. NATIONAL STOCK NUMBER (NSN) AND PART NUMBER
INDEXES (Con’t)
PART NUMBER INDEX
(1)
PART NUMBER
AA55569/02-009
J1508-10 TYPE D
J1508-13 TYPE D
J30R7-TYPE 1-3/16ID
J30R7-TYPE 1-5/32ID
MS122916
MS25036-101
MS25036-106
MS27183-10
MS27183-42
MS27183-57
MS35338-43
MS35338-44
MS35650-302
MS51412-4
PT312010PG
R30
S25-80
SAEJ1670
SAEJ20R1, CLD-2, 1/2ID
S-H-1, 1/2
090 31 118
090 31 125
1.00 ID HT4100S
10 2064 03 20 50
10-6 430160B
125HB-3-4
13214E3789-2
13218E0320-49
2191QU5-24V
25 1384 00 00 02
25 1600 45 00 00
25 1600 50 00 00
25 1667 01 00 01
25 1671 25 01 00
25 1733 01
4-4-130239B
4-4-4 140424B
(2)
FIG.
C-9
C-4
C-4
C-4
C-4
C-8
C-10
C-10
C-6
C-2
C-6
C-8
C-6
C-2
C-6
C-8
C-6
C-8
C-2
C-8
C-3
C-8
C-6
C-7
C-7
C-8
C-4
C-4
C-8
C-5
C-7
C-4
C-3
C-6
C-8
C-3
C-5
C-1
C-4
C-1
C-5
C-5
C-1
C-4
C-4
(3)
ITEM
2
1
7
8
2
7
1
5
8
2
2
12
7
3
9
13
6
5
4
4
8
10
13
3
1
2
3
9
1
4
7
6
2
11
9
10
1
4
4
1
2
3
3
5
12
C-29
TB 9-6115-641-13
Section IV. Part Number Index (Con’t)
(1)
PART NUMBER
501-103-0037
501-601-0011
55LC1WD21SN
640917-1
66332-8
66331-8
80402
80405
88-20260-22
88-20260-32
88-20260-34
88-20260-52
88-20540-2
88-20556-7
88-22790-1
8906K4692
98-2001
98-2021
98-2026
98-2028
98-2029
98-2034
98-2041
98-2049-1
98-2049-2
98-2050
98-2053-1
C-30
(2)
FIG.
C-1
C-7
C-4
C-10
C-10
C-9
C-7
C-7
C-2
C-6
C-8
C-8
C-4
C-6
C-6
C-10
C-6
C-8
C-3
C-3
C-3
C-8
C-6
C-6
C-7
C-3
C-3
C-10
C-3
C-10
C-3
C-10
C-1
(3)
ITEM
2
2
11
4
3
1
4
5
1
1
11
3
10
4
3
2
5
6
7
3
9
8
10
12
6
1
4
6
5
7
6
8
5
TB 9-6115-641-13
APPENDIX D
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS
Section I. INTRODUCTION
D-1.
SCOPE.
This appendix lists components of the end item and basic issue items for the Winterization Kit to help to inventory items
required for safe and efficient operation of the equipment.
D-2 .
GENERAL.
The Components of End Item (COEI) and Basic Issue Items (BII) Lists are divided into the following sections:
D-2.1 Section II, Components of End Item (COEI). This listing is for informational purposes only, and is not authority
to requisition replacements. The Repair Parts and Special Tools List or RPSTL in this TM is the authority to requisition
replacements for items in the COEI Listing. These items are part of the Winterization Kit but they are removed and
separately packaged for transportation or shipment. As part of the end item, these items must be with the end item whenever
it is issued or transferred between property accounts.
D-2.2 Section III, Basic Issue Items (BII). These essential items are required to place the Winterization Kit in operation,
operate it, and to do emergency repairs. Although shipped separately, BII must be with the Winterization Kit during
operation and when it is transferred between property accounts. The BII listing of these items is the authority to
request/requisition them for replacement based on authorization of the end item by the Table of Organizational
Equipment/Modified Table of Organizational Equipment (TOE/MTOE).
D-3.
EXPLANATION OF COLUMNS.
The following provides an explanation of columns found in the tabular listings:
D-3.1 Column (1), Item Number, gives the number of the item listed.
D-3.2 Column (2), National Stock Number, identifies the stock number of the item to be used for requisitioning
purposes.
D-3.3 Column (3), Description, CAGE, and Part Number identifies the Federal item name followed by a minimum
description when needed. The line below the description is the CAGE (Commercial and Government Entity) code (in
parentheses) and the part number.
D-1
TB 9-6115-641-13
D-3.
EXPLANATION OF COLUMNS. (Cont’d)
D-3.4 Column (4), U/I (Unit of Issue), indicates how the item is issued for the National Stock Number shown in
column two.
D-3.5
D-2
Column (5), Qty Rqd, indicates the quantity required.
TB 9-6115-641-13
Section II. COMPONENTS OF END ITEM
(1)
Item
Number
1
(2)
National Stock
Number
2
2990-01-483-4051
3
4
(3)
Description, CAGE and Part
Number
Wiring Harness, (30554)
98-2045
(4)
U/I
Ea
(5)
Qty
Rqd
1
Heater Kit, (30554)
98-2000
Ea
1
2915-01-482-8924
Control Unit, (38453)
25 1600 50 00 00
Ea
1
2910-01-483-4069
Fuel Pump, (30554)
98-2013
Ea
1
D-3
TB 9-6115-641-13
Section III. BASIC ISSUE ITEMS
(1)
Item
Number
(2)
National Stock
Number
(3)
Description, CAGE and Part Number
1
(4)
TB 9-6115-641-13
TECHNICAL BULLETIN
OPERATOR, UNIT AND DIRECT SUPPORT
TECHNICAL BULLETIN
WINTERIZATION KIT
(NSN: 6115-01-476-8973) (EIC: N/A)
INSTALLED ON
GENERATOR SET, SKID MOUNTED,
TACTICAL QUIET,
5kW, 60 and 400 Hz
MEP-802A (60Hz) (6115-01-274-7387)
MEP-812A (400Hz) (6115-01-274-7391)
U/I
(5)
Qty
Rqd
Ea
1
Introduction
1-1
Equipment Description and Data
1-2
Operator Instructions
2-1
Operating PMCS
2-3
Operator Maintenance
3-1
Unit Maintenance
4-1
Unit PMCS
4-5
Troubleshooting
4-8
Direct Support Maintenance
5-1
Maintenance Allocation Chart
B-1
RPSTL
C-1
Alphabetical Index
Index-1
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY
15 December 2001
D-4
TB 9-6115-641-13
APPENDIX E
ADDITIONAL AUTHORIZATION LIST (AAL)
Section I. INTRODUCTION
E-1.
The Winterization Kit does not require additional authorized items.
E-1/(E-2 BLANK)
TB 9-6115-641-13
APPENDIX F
EXPENDABLE AND DURABLE SUPPLIES AND MATERIALS LIST
Section I. INTRODUCTION
F-1
SCOPE.
This appendix lists expendable and durable items that are needed to operate and maintain the Winterization Kit. This listing
is for informational purposes only and is not authority to requisition the listed items. These items are authorized to you by
CTA 50-790, Expendable/Durable Items (except medical, class V, repair parts, and heraldic items), or CTA 8-100, Army
Medical Department Expendable/Durable Items.
F-2
EXPLANATION OF COLUMNS.
a. Column 1 - Item Number. This number is assigned to the entry in the listing and may be referenced in the narrative
instructions to identify the item (e.g., "Use detergent, general purpose, item 3, Appendix E").
b. Column 2 - Level. This column identifies the lowest level of maintenance that requires the item. One of the
following codes appears in column 2.
C - Operator/Crew Maintenance
O - Unit Maintenance
F - Direct Support Maintenance
c. Column 3 - National Stock Number. This is the national stock number assigned to the item; use it to requisition the
item.
d. Column 4 - Item Name, Description, Commercial and Government Entity (CAGE) code, and Part Number. This
provides the other information needed to identify the item.
e. Column 5 - Unit of Measure (U/M). This code shows the physical measurement or count of an item, such as gallon,
gross, etc.
F-1
TB 9-6115-641-13
Section II. TABLE OF EXPENDABLE AND DURABLE SUPPLIES AND
MATERIALS
(1)
Item
Number
F-2
(2)
Level
C
(3)
National Stock
Number
8030-00-118-0012
C
8030-01-268-5917
C
8040-01-145-1768
(4)
Item Name, Description, CAGE, Part Number
(5)
U/M
Sealing Compound
(05792) 57141
Retaining Compound
(05972) 62040
Adhesive
(01139) RTV106
CC
CC
OZ
TB 9-6115-641-13
APPENDIX G
ILLUSTRATED LIST OF MANUFACTURED ITEMS
G-1 INTRODUCTION.
This appendix includes complete instructions for making items authorized to be manufactured or fabricated at unit, direct
support, and general support maintenance levels.
A part number index in alphanumeric order is provided for cross-referencing the part number of the item to be manufactured
to the figure which covers fabrication criteria.
All bulk materials needed for manufacture of an item are listed by part number or specification number in a tabular list on the
illustration.
G-2 MANUFACTURED ITEMS PART NUMBER INDEX.
Part Number of Manufactured Item
Applicable Figure
98-2049-1
G-1
98-2049-2
G-2
98-2050
G-3
G-3 GENERAL INSTRUCTIONS
The manufacture of items listed above consists of cutting wires to length specified on figures and soldering terminal lugs or
connectors on appropriate wires. Use standard shop procedures in the manufacture of these items.
G-1
TB 9-6115-641-13
Figure G-1. Electrical Lead P/N 98-2049-1
TERMINATION
TERMINATION
WIRE
DIMENSION
FROM
TO
FIND NO.
44”
J6-25
FIND NO.
3
FIND NO.
S-1-2
1
2
PARTS LIST
Find No.
1
2
3
G-2
Part No.
88-21941
88-20540-2
13226E0107-3
Quantity Required
1
AR
1
Description
Pin 24-20 (AWG)
Wire, Electrical (20 AWG)
Terminal, Lug, (22-18 AWG, .138 Stud)
TB 9-6115-641-13
Figure G-2. Electrical Lead P/N 98-2049-2
TERMINATION
TERMINATION
WIRE
DIMENSION
FROM
TO
FIND NO.
44”
J6-26
FIND NO.
4
FIND NO.
DS1-
3
2
PARTS LIST
Find No.
1
2
4
Part No.
88-21941
88-20540-2
95-8105-2
Quantity Required
1
AR
1
Description
Pin 24-20 (AWG)
Wire, Electrical (20 AWG)
Terminal Quick Disconnect
G-3
TB 9-6115-641-13
Figure G-3. Electrical Lead P/N 98-2050
TERMINATION
TERMINATION
WIRE
FROM FIND NO.
TO
FIND NO.
J6-24
DS1+
S1-3
S1-3
3
4
FIND NO.
5
5
2
2
DIMENSION
44”
5”
PARTS LIST
Find No.
1
2
4
5
G-4
Part No.
88-21941
88-20540-2
95-8105-2
13226E0107-11
Quantity Required
1
AR
1
1
Description
Pin 24-20 (AWG)
Wire, Electrical (20 AWG)
Terminal Quick Disconnect
Terminal, Lug, (16-14 AWG, .138 STD)
TB 9-6115-641-13
ALPHABETICAL INDEX
Subject
Paragraph,
Figure, Table,
Number
A
Air Inlet and Exhaust Hose Maintenance ............................................................................................................. F 4-26
Assembly
Assembly and Preparation for Use ................................................................................................................ 2-3
B
Bulkhead Housing ................................................................................................................................................ F 5-3
Burner Motor Defect ............................................................................................................................................ F 4-11
Butt Joint .............................................................................................................................................................. F 5-9
C
Common Tools and Equipment ............................................................................................................................ 4-1, 5-1
Connection Error .................................................................................................................................................. F 4-19
Control Unit Assembly ......................................................................................................................................... F 5-1
Control Unit Defective ......................................................................................................................................... F 4-18
Control Unit Removal .......................................................................................................................................... F 4-32
Control Unit Maintenance .................................................................................................................................... F 4-20
Coolant Hoses....................................................................................................................................................... F 5-7
Coolant Hose Maintenance................................................................................................................................... F 4-25
Coolant Pump Maintenance.................................................................................................................................. F 4-31
Coolant System Removal ..................................................................................................................................... F 4-38
Corrosion Prevention and Control ........................................................................................................................ 1-3
Cover and Instrument Panel.................................................................................................................................. F 4-33, F 5-11
D
Description of Major Components ....................................................................................................................... T 1-1
Destruction of Army Material to Prevent Enemy Use.......................................................................................... 1-4
E
Equipment Characteristics, Capabilities, and Features......................................................................................... 1-10
Equipment Improvement Recommendation (EIR) ............................................................................................... 1-6
Exhaust System and Brace Removal .................................................................................................................... F 4-37
Exhaust Hose and Heater Brace ........................................................................................................................... F 5-8
Expansion Plug..................................................................................................................................................... F 5-6
Index-1
TB 9-6115-641-13
Subject
Paragraph,
Figure, Table,
Number
F
Flame Cutout-High ...............................................................................................................................................F 4-9
Flame Cutout-Low ................................................................................................................................................F 4-8
Flame Sensor Short-Circuit...................................................................................................................................F 4-7
Fuel Line Maintenance .........................................................................................................................................F 4-29
Fuel Pump Assembly ............................................................................................................................................F 5-5
Fuel Pump Maintenance .......................................................................................................................................F 4-22
Fuel Pump Removal..............................................................................................................................................F 4-36
Fuel Pump Short-Circuit .......................................................................................................................................F 4-16
Fuel System Assembly..........................................................................................................................................F 5-2
Fuel System Removal ...........................................................................................................................................F 4-35
Function Codes Plate Maintenance.......................................................................................................................F 4-30
Fuse and Wiring Harness ......................................................................................................................................F 5-10
G
General
Equipment Description and Data ...................................................................................................................1-9
Description and Use of Operator's Controls and Indicators...........................................................................2-1
Operator PMCS .............................................................................................................................................2-2
Principles of Operation ..................................................................................................................................1-13
Troubleshooting (Ch 3)..................................................................................................................................3-1
Troubleshooting (Ch 4)..................................................................................................................................4-8
Unit PMCS ...................................................................................................................................................4-7
Glow Plug Defect..................................................................................................................................................F 4-10
H
Heater Assembly...................................................................................................................................................F 5-4
Heater Assembly Maintenance .............................................................................................................................F 4-21
Heater Assembly Removal ...................................................................................................................................F 4-39
Heater Attachment Maintenance...........................................................................................................................F 4-23
Heater Function Codes Plate.................................................................................................................................F 3-1, F4-2
Heater is Not Operating ........................................................................................................................................F 3-2
Heater Operating Data ..........................................................................................................................................T 1-2
Heater Restart Attempted During Purge Cycle .....................................................................................................F 4-4
I
Ignitor/Glow Plug and Resistor Maintenance .......................................................................................................F 4-28
Installation Instructions.........................................................................................................................................5-4
L
Leakage Definitions ..............................................................................................................................................2-2.5
Levels of Maintenance..........................................................................................................................................1-8
List of Abbreviations ............................................................................................................................................1-7
Location and Description of Major Components..................................................................................................1-11
Location of Major Components for 5kW (MEP-802A, MEP-812A)....................................................................F 1-1
Lubrication............................................................................................................................................................4-6
Index-2
TB 9-6115-641-13
Subject
Paragraph,
Figure, Table,
Number
M
Maintenance
Forms and Records ........................................................................................................................................ 1-2
Operator Maintenance ................................................................................................................................... 3-2
Operator's PMCS........................................................................................................................................... 2-2
Unit PMCS .................................................................................................................................................... 4-7
Control Unit Maintenance ............................................................................................................................. 4-9
Heater Assembly Maintenance...................................................................................................................... 4-10
Fuel Pump Maintenance ................................................................................................................................ 4-11
Heater Attachment Maintenance ................................................................................................................... 4-12
Plate, Operation and Heater Switch Maintenance ......................................................................................... 4-13
Coolant Hose Maintenance............................................................................................................................ 4-14
Air Inlet and Exhaust Hose ........................................................................................................................... 4-15
Wiring Harness Maintenance ........................................................................................................................ 4-16
Ignitor/Glow Plug, and Resistor Maintenance............................................................................................... 4-17
Fuel Line Maintenance .................................................................................................................................. 4-18
Function Codes Plate Maintenance ............................................................................................................... 4-19
Coolant Pump Maintenance .......................................................................................................................... 4-20
N
No Indication of Heater Operation When Switch is in ON Position .................................................................... F 4-3
Non-Start .............................................................................................................................................................. F 4-14
O
Operator PMCS Routing Diagram........................................................................................................................ F 2-1
Operator Preventive Maintenance Checks and Services....................................................................................... T 2-1
Operating Instructions .......................................................................................................................................... 2-4
Overheating .......................................................................................................................................................... F 4-6
Over Voltage ........................................................................................................................................................ F 4-13
P
Plate, Operation and Heater Switch Maintenance ................................................................................................ F 4-24
Preparation for Movement.................................................................................................................................... 2-5
Preparation for Storage and Shipment .................................................................................................................. 1-5
R
Removal
Instructions .................................................................................................................................................... 4-5, 4-21
Repair Parts .......................................................................................................................................................... 4-3, 5-3
S
Scope .................................................................................................................................................................... 1-1
Service Upon Receipt of Materiel ........................................................................................................................ 4-4
Special Tools, TMDE, and Support Equipment ................................................................................................... 4-2, 5-2
Index-3
TB 9-6115-641-13
Subject
Paragraph,
Figure, Table,
Number
T
Tabulated/Illustrated Data........................................................................................................................................ 1-12
Temperature Sensor Defective................................................................................................................................. F 4-15
Temperature Switch Defective................................................................................................................................. F 4-17
Troubleshooting
Operator’s Troubleshooting Instructions (Ch 3) ............................................................................................... 3-1
Unit Troubleshooting Instructions (Ch 4)......................................................................................................... 4-8
U
Under Voltage.......................................................................................................................................................... F 4-12
Unit PMCS Routing Diagram.................................................................................................................................. F 4-1
Unit Preventive Maintenance Checks and Services................................................................................................. T 4-1
Unusual Conditions.................................................................................................................................................. 2-6
W
Warning: Power Supply........................................................................................................................................... F 4-5
Wiring Harness Maintenance................................................................................................................................... F 4-27
Wiring Harness Removal......................................................................................................................................... F 4-34
Index-4
RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS
SOMETHING WRONG
WITH THIS PUBLICATION
FROM: (PRINT YOUR UNIT'S COMPLETE ADDRESS)
THEN ... JOT DOWN THE INFO
ABOUT IT ON THIS FORM.
CAREFULLY TEAR IT OUT.
FOLD IT AND DROP IT IN THE
MAIL.
PUBLICATION NUMBER
PUBLICATION DATE
TM 11-5840-340-20
TEAR ALONG DOTTED LINE
PARA
GRAPH
2-25
2-28
FIGURE
NO
DATE SENT
10 July 1975
PUBLICATION TITLE
23 Jan 74
Radar Set AN/PRC-76
IN THIS SPACE TELL WHAT IS WRONG
AND WHAT SHOULD BE DONE ABOUT IT:
BE EXACT PIN-POINT WHERE IT IS
PAGE
NO
Commander
Stateside Army Depot
ATTN: AMSTA-US
Stateside, N.J. 07703-5007
TABLE
NO
Recommend that the installation antenna alignment
procedure be changed throughout to specify a 20 IFF
antenna lag rather than 10.
REASON: Experience has shown that with only a 10 lag,
the antenna servo system is too sensitive to wind gusting in
excess of 25 knots, and has a tendency to rapidly accelerate
and decelerate as it hunts, causing strain to the drive train.
Hunting is minimized by adjusting the lag to 20 without
degradation of operation.
3-10
3-3
Item 5, Functional column. Change •2 dB" to •3 dB".
3-1
REASON: The adjustment procedure for the TRANS POWER
FAULT indicator calls for a 3 dB (500 watts) adjustment to light
the TRANS POWER FAULT indicator.
5-6
Add new step f.1 to read, •Replace cover plate removed in
step e.1, above."
5-8
REASON: To replace the cover plate.
Zone C 3. On J1-2, change •+24 VDC" to •+5 VDC".
FO-3
REASON: This is the output line of the 5 VDC power supply.
+24 VDC is the input voltage.
PRINTED NAME, GRADE OR TITLE AND TELEPHONE NUMBER
SSG I. M. DeSpiritof
DA
FORM
1 JUL 79
2028-2
SIGN HERE
999-1776
PREVIOUS EDITIONS
ARE OBSOLETE
P.S. - IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR
RECOMMENDATION MAKE A CARBON COPY OF THIS
AND GIVE IT TO YOUR HEADQUARTERS.
REVERSE OF DA FORM 2028-2
FOLD BACK
DEPARTMENT OF THE ARMY
PLEASE
AFFIX
STAMP
POSTAGE
REQUIRED
OFFICIAL BUSINESS
Commander
U.S. Army Communications-Electronics Command
and Fort Monmouth
ATTN: AMSEL-LC-LEO-D-CS-CFO
Fort Monmouth, New Jersey 07703-5006
TEAR ALONG DOTTED LINE
FILL IN YOUR
UNIT'S ADDRESS
RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS
SOMETHING WRONG WITH THIS PUBLICATION
FROM: (PRINT YOUR UNIT'S COMPLETE ADDRESS)
THEN ... JOT DOWN THE INFO
ABOUT IT ON THIS FORM.
CAREFULLY TEAR IT OUT.
FOLD IT AND DROP IT IN THE
MAIL.
PUBLICATION NUMBER
PUBLICATION DATE
BE EXACT PIN-POINT WHERE IT IS
PARA
GRAPH
FIGURE
NO
TABLE
NO
PUBLICATION TITLE
IN THIS SPACE TELL WHAT IS WRONG
AND WHAT SHOULD BE DONE ABOUT IT:
TEAR ALONG DOTTED LINE
PAGE
NO
DATE SENT
PRINTED NAME, GRADE OR TITLE AND TELEPHONE NUMBER
JUL 792028-2
DA 1FORM
PREVIOUS EDITIONS
ARE OBSOLETE
SIGN HERE
P.S. - IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR
RECOMMENDATION MAKE A CARBON COPY OF THIS
AND GIVE IT TO YOUR HEADQUARTERS.
REVERSE OF DA FORM 2028-2
FOLD BACK
DEPARTMENT OF THE ARMY
PLEASE
AFFIX
STAMP
POSTAGE
REQUIRED
OFFICIAL BUSINESS
Commander
U.S. Army Communications-Electronics Command
and Fort Monmouth
ATTN: AMSEL-LC-LEO-D-CS-CFO
Fort Monmouth, New Jersey 07703-5006
TEAR ALONG DOTTED LINE
FILL IN YOUR
UNIT'S ADDRESS
RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS
SOMETHING WRONG WITH THIS PUBLICATION
FROM: (PRINT YOUR UNIT'S COMPLETE ADDRESS)
THEN ... JOT DOWN THE INFO
ABOUT IT ON THIS FORM.
CAREFULLY TEAR IT OUT.
FOLD IT AND DROP IT IN THE
MAIL.
PUBLICATION NUMBER
PUBLICATION DATE
BE EXACT PIN-POINT WHERE IT IS
PARA
GRAPH
FIGURE
NO
TABLE
NO
PUBLICATION TITLE
IN THIS SPACE TELL WHAT IS WRONG
AND WHAT SHOULD BE DONE ABOUT IT:
TEAR ALONG DOTTED LINE
PAGE
NO
DATE SENT
PRINTED NAME, GRADE OR TITLE AND TELEPHONE NUMBER
JUL 792028-2
DA 1FORM
PREVIOUS EDITIONS
ARE OBSOLETE
SIGN HERE
P.S. - IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR
RECOMMENDATION MAKE A CARBON COPY OF THIS
AND GIVE IT TO YOUR HEADQUARTERS.
REVERSE OF DA FORM 2028-2
FOLD BACK
DEPARTMENT OF THE ARMY
PLEASE
AFFIX
STAMP
POSTAGE
REQUIRED
OFFICIAL BUSINESS
Commander
U.S. Army Communications-Electronics Command
and Fort Monmouth
ATTN: AMSEL-LC-LEO-D-CS-CFO
Fort Monmouth, New Jersey 07703-5006
TEAR ALONG DOTTED LINE
FILL IN YOUR
UNIT'S ADDRESS
RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS
SOMETHING WRONG WITH THIS PUBLICATION
FROM: (PRINT YOUR UNIT'S COMPLETE ADDRESS)
THEN ... JOT DOWN THE INFO
ABOUT IT ON THIS FORM.
CAREFULLY TEAR IT OUT.
FOLD IT AND DROP IT IN THE
MAIL.
PUBLICATION NUMBER
PUBLICATION DATE
BE EXACT PIN-POINT WHERE IT IS
PARA
GRAPH
FIGURE
NO
TABLE
NO
PUBLICATION TITLE
IN THIS SPACE TELL WHAT IS WRONG
AND WHAT SHOULD BE DONE ABOUT IT:
TEAR ALONG DOTTED LINE
PAGE
NO
DATE SENT
PRINTED NAME, GRADE OR TITLE AND TELEPHONE NUMBER
JUL 792028-2
DA 1FORM
PREVIOUS EDITIONS
ARE OBSOLETE
SIGN HERE
P.S. - IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR
RECOMMENDATION MAKE A CARBON COPY OF THIS
AND GIVE IT TO YOUR HEADQUARTERS.
REVERSE OF DA FORM 2028-2
FOLD BACK
DEPARTMENT OF THE ARMY
PLEASE
AFFIX
STAMP
POSTAGE
REQUIRED
OFFICIAL BUSINESS
Commander
U.S. Army Communications-Electronics Command
and Fort Monmouth
ATTN: AMSEL-LC-LEO-D-CS-CFO
Fort Monmouth, New Jersey 07703-5006
TEAR ALONG DOTTED LINE
FILL IN YOUR
UNIT'S ADDRESS
By Order of the Secretary of the Army:
ERIC K. SHINSEKI
General, United States Army
Chief of Staff
Official:
0129901
DISTRIBUTION:
To be distributed in accordance with the initial distribution number (IDN) 256700 requirements
for TB 9-6115-641-13.
PIN: 079379-000
Download PDF
Similar pages