Consolidated Diesel Electric Company MEP 007A, MEP 106A, MEP 116A Generator Set, MEP 007AWF, MEP 007AWE Winterization Kit, MEP 007AWM Wheel Mounting Kit Technical Manual

AIR FORCE T.O.35C2-3-442-2
TM5-6115-457-34
ARMY
NAVY
NAVFAC P-8-627-34
MARINE CORPS TM-07464A-35
TECHNICAL MANUAL
INTERMEDIATE [FIELD]
[DIRECT AND GENERAL SUPPORT]
AND DEPOT LEVEL MAINTENANCE
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL
SKID MTD., 100 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS
DOD MODELS
MEPO07A
MEP106A
MEP116A
CLASS
UTILITY
PRECISE
PRECISE
HERTZ
50/60
50/60
400
NSN
6115-00-133.9101
6115-00-133.9102
6115-00-133-9103
INCLUDING OPTIONAL KITS
DOD MODELS
MEPO07AWF
MEPO07AWE
MEPO07ALM
MEPO07AWM
NSN
NOMENCLATURE
WINTERIZATION KIT, FUEL BURNING 6115-00-463-9082
6115-00-463-9084
WINTERIZATION KIT, ELECTRIC
6115-00-463-9086
DUMMY LOAD KIT
WHEEL MOUNTING KIT
6115-00-463-9089
Consolidated Diesel Electric Company
Contract Number FO4606-70-D-0192 and F04606-78-C-0363
This publication incorporates PCN numbers 1 through 1301 and 1318
Published under authority of the
Departments of the Air Force, the Army, and the Navy
(Including U. S. Marine Corps)
15 JUNE 1973
AIR FORCE TO 35C2-3-442-2
TM5-6115-457-34
ARMY
NAVY
NAVFAC P-8-627-34
MARINE CORPS TM-07464A-34
TECHNICAL MANUAL
INTERMEDIATE (FIELD)
(DIRECT AND GENERAL SUPPORT)
AND DEPOT LEVEL MAINTENANCE
GENERATOR SET, DIESEL ENGINE DRIVEN,
TACTICAL SKID MTD., 100 KW, 3 PHASE,
4 WIRE, 120/208 AND 240/416 VOLTS
DOD MODELS
CLASS
HERTZ
MEP007A
MEP106A
MEP116A
UTILITY
PRECISE
PRECISE
50/60
50/60
400
FSN
6115-00-133-9101
6115-00-133-9102
6155-00-133-9103
INCLUDING OPTIONAL KITS
DOD MODELS
NSN
NOMENCLATURE
MEP007AWF WINTERIZATION KIT, FUEL BURNING
MEP007AWE WINTERIZATION KIT, ELECTRIC
MEP007AWM WHEEL MOUNTING KIT
6115-00-463-9082
6115-00-463-9084
6115-00-463-9089
CONSOLIDATED DIESEL ELECTRIC COMPANY
CONTRACT NUMBER F04606-70-D-0192 AND F04606-78-C-0363
DISTRIBUTION STATEMENT - Distribution authorized for public release; distribution is unlimited, 20 August 1991. Other
requests for this document must be referred to Sacramento ALC/TILBE, McClellan AFB, CA 95652-5990.
HANDLING AND DESTRUCTION NOTICE - Handle in compliance with distribution statement and destroy by any method
that will prevent disclosure of the contents or reconstruction of the document.
PUBLISHED UNDER AUTHORITY OF THE SECRETARY OF THE AIR FORCE
15 JUNE 1973
CHANGE 12- 20 AUGUST 1991
TO 35C2-3-442-2
LIST OF EFFECTIVE PAGES
Dates of issue for original and changed pages are:
Change . . . . . . . . . . 6........ 2 Jun 81
Change . . . . . . . . . . 7........ 20 May82
Change . . . . . . . . ..8...... . . 4 Apr 84
Change . . . . . . . . ..9...... ..18 Mar 86
Change . . . . . . . . .10 . . . . . . . .19 Oct 87
Change . . . . . . . . .ll . . . . . . ..10 May 89
Change . . . . . . . . .12 . . . . . . ..20 Aug 91
Total nurnber of pages in this publication is 730 consisting of the following:
Original . . . . . . . .0. . . . . . . .15 Mar
Change . . . . . . . . . .l . . . . . . . .3l Jun
Change . . . . . . . . ..2...... . . l May
Change . . . . . . . ...3..... . ..30 Jun
Change . . . . . . . . ..4...... ..15 Apr
Change . . . . . . . . ..5...... ..21 Sep
Page
No.
Change
*No.
Title . . . . . . . . . . . ...12
A - B . . . . . . . . . . . ...12
C. . . . . . . . . . . . . . . . . . 11
0l Blank . . . . . . . . ...8
02 Blank . . . . . . . . . . . 8
i - ii . . . . . . . . . . . . . 4
iiA Added . . . . . . . . . . 4
iiB Blank Added . . . . 4
i i i - vi . . . . . . . . . . . 3
vii - x . . . . . . . . . . . . 0
xi . . . . . . . . . . . . . . . . . 2
xii . . . . . . . . . . . . . . . . 6
xiiA Added . . . . . . . . . 4
xiiB Blank Added . . . 4
x i i i - xiv . . . . . . . . . 4
xv - xvi . . . . . . . . . ..3
xvii . . . . . . . . . . . . . . . 0
xviii . . . . . . . . . . . ...2
xix . . . . . . . . . . . . . ...3
xx Blank . . . . . . . . . ..3
xxi - xxii Deleted . 3
1-1 . . . . . . . . . . . . . . . . 4
1-2 . . . . . . . . . . . . . . . . 3
1 - 2A - 1 - 2B . . . . . . . . 4
1-3-1-4..........7
1 - 5 . . . . . . . . . . . . . ...10
l-6................7
1 - 6A . . . . . . . . . . . . . . . 3
1 - 6B . . . . . . . . . . . . . . . 7
1-7-1-9..........7
1 - 10 . . . . . . . . . . . . . . . 0
1 - 11 . . . . . . . . . . . . . . . 4
1 - 12 . . . . . . . . . . . . . . . 1
1 - 13 - 1 - 14 . . . . . . . . 3
Page
No.
73
75
77
77
78
79
Change
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l - 14A Added . . . . . . . . 3
1 - 14B Blank Added . . 3
1 - 15 . . . . . . . . . . . . . . . 0
1 - 16 . . . . . . . . . . . . . . . 7
1 - 17 - 1 - 18 . . . . . . . . 0
1 - 19 . . . . . . . . . . . . . . . 4
1 - 20 - 1 - 26 . . . . . . . . 0
1 - 27 . . . . . . . . . . . . . . . 1
1 - 28 - 1 - 41 . . . . . . . . 0
1 - 42 . . . . . . . . . . . . . . . 7
1 - 43 - 1 - 47 . . . . . . . . 0
1 - 48 . . . . . . . . . . . . . . . 3
1 - 49 - 1 - 61 . . . . . . . . 0
l - 62 Blank . . . . . . . . .0
1 - 63 . . . . . . . . . . . . . . . 1
l - 64 Blank . . . . . . . . .l
1 - 65 . . . . . . . . . . . . . ... . . 11
l - 66 Blank . . . . . . ...11
1 - 67 . . . . . . . . . . . . . . . 1
l - 68 Blank . . . . . . . . . 1
1 - 69 . . . . . . . . . . . . . . . 3
l - 70 Blank . . . . . . . . . 3
1 - 71 . . . . . . . . . . . . . . . 3
l - 72 Blank . . . . . . ...3
1 - 73 . . . . . . . . . . . . . . . 3
l - 74 Blank . . . . . . ...3
1 - 75 . . . . . . . . . . . . . . . 3
1 - 76 . . . . . . . . . . . . . . . 0
1 - 77 . . . . . . . . . . . . . . . 7
l - 78 Blank . . . . . . . . . 7
1 - 79 - 1 - 80 . . . . . . . . 0
1 - 81 . . . . . . . . . . . . . . . 1
l - 82 Blank . . . . . . . . . 1
1 - 83 - 1 - 84 . . . . . . . . 0
Page
No.
Change
*No.
1 - 85 . . . . . . . . . . . . ...10
l - 86 Blank . . . . . . ...10
1 - 87 . . . . . . . . . . . . ...0
l - 88 Blank . . . . . . . . .0
1 - 89 . . . . . . . . . . . . ...0
l - 90 Blank . . . . . . . . .0
1 - 91 . . . . . . . . . . . . . . . 8
l - 92 Blank . . . . . . . . . 8
1 - 93 . . . . . . . . . . . . . . . 8
l - 94 Blank . . . . . . . . . 8
1 - 95 . . . . . . . . . . . . . . . 3
l - 96 Blank . . . . . . ...3
1 - 97 . . . . . . . . . . . . ...8
l - 98 Blank . . . . . . . . . 8
1 - 99 . . . . . . . . . . . . . . . 1
l - 100 Blank . . . . . . . . 1
1 - 101 . . . . . . . . . . . . . . 1
l - 102 Blank . . . . . . . . 1
1 - 103 . . . . . . . . . . . ...0
l - 104 Blank . . . . . . . . 0
1 - 105 . . . . . . . . . . . . . . 0
l - 106 Blank . . . . . . . . 0
1 - 107 . . . . . . . . . . . . . . 0
l - 108 Blank . . . . . . . .0
1 - 109 . . . . . . . . . . . . . . 0
l - ll0 Blank . . . . . . ..0
1 - 111 - 1 - 114 . . . . ..0
1 - 115 . . . . . . . . . . . . . . 3
1 - 116 . . . . . . . . . . . . . . 1
1 - 117 - 1 - 118 . . . ...0
2-1................1
2 - 2 - 2 - 4.........0
2 - 5 - 2 - 6 . . . . . . . ...8
2-7 - 2-8..........3
*Zero in this column indicates an original page
A
Change 12
USAF
TO 35C2-3-442-2
LIST OF EFFECTIVE PAGES (Cont)
Page
No.
Change
*No.
2-8A Added . . . . . . . . . 3
2-8B Blank Added . . . 3
2-9 - 2-10 . . . . . . . . . 8
2-11 . . . . . . . . . . . . . . . 7
2-12 . . . . . . . . . . . . . . . 0
2-13- 2-14 . . . . . . . . 8
2-15 . . . . . . . . . . . . . . . 9
2-16 . . . . . . . . . . . . . . . 8
2-17- 2-22 . . . . . ...0
2-23 -2-24 . . . . . . . . 7
2-25 . . . . . . . . . . . . . . . 6
2-26 - 2-28 . . . . . ...0
2-29 . . . . . . . . . . . . . . . 1
2-30 . . . . . . . . . . . . . . . 0
2-31 . . . . . . . . . . . . . . . 7
2-32 . . . . . . . . . . . . . . . 0
2-33 . . . . . . . . . . . . . . . 6
2-34- 2-46 . . . . . . . . 3
2-47- 2-48 . . . . . . . . 0
2-49 . . . . . . . . . . . . . . . 1
2-50-2-56 . . . . . . . . 0
2-57-2-58 . . . . . . . . 8
2-59-2-64 . . . . . . . . 4
2-65-2-66 . . . . . . . . 8
3-1 -3-2 . . . . . . . . . . 0
3-3-3-6 . . . . . . . . . . 8
3-7 - 3-l0 . . . . . . . . . 3
4-1 - 4-4 . . . . . . . ...8
4-5 - 4-6 . . . . . . . . . . 1
4-7 - 4-8 . . . . . . . . . . 8
5-1 - 5-2 . . . . . . . . . . 8
5-3 - 5-11 . . . . . . ...0
5-12 - 5-13 . . . . . . . . 3
5-14 - 5-16 . . . . . . . . 0
6-1 - 6-4 . . . . . . . . . . 0
6-5 - 6-8 . . . . . . . . . . 8
6-9 . . . . . . . . . . . . . . . . 0
6-10 . . . . . . . . . . . . . . . 1
6-11 - 6-12 . . . . . . . . 8
6-13 . . . . . . . . . . . . . . . 0
6-14 . . . . . . . . . . . . . . . 3
6-15 . . . . . . . . . . . . . . . 0
6-16 Blank . . . . . . . . .0
6-17 . . . . . . . . . . . . . . . 0
6-18 Blank . . . . . . . . . 0
Page
No.
Change
*No.
6-19-6-20 . . . . . . . . 3
6-20A Added . . . . . . . . 3
6-20B Blank Added . . 3
6-21 . . . . . . . . . . . . . . . 3
6-22 . . . . . . . . . . . . . . . 0
6-23 - 6-24 . . . . . . . . 8
6-25 - 6-26 . . . . . . . . 0
6-27 - 6-28 . . . . . . . . 8
6-29 - 6-33 . . . . . . . . 0
6-34 . . . . . . . . . . . . . . . 4
6-35 - 6-37 . . . . . . . . 0
6-38 . . . . . . . . . . . . . . . 4
6-39 . . . . . . . . . . . . . . . 1
6-40 - 6-42 . . . . . . . . 0
6-43 - 6-45 . . . . . . . . 7
6-46 - 6-48 . . . . . . . .10
6-49 - 6-50 . . . . . . ..9
6-51 . . . . . . . . . . . . . . . 1
6-52 - 6-59 . . . . . . . . 0
6-60 . . . . . . . . . . . . ...9
6-61 - 6-64 . . . . . . . . 8
6-65 . . . . . . . . . . . . ...0
6-66 - 6-68 . . . . . . . . 1
6-69 - 6-74 . . . . . . . . 0
6-75 - 6-76 . . . . . . . . 8
6-77 - 6-81 . . . . . . . . 0
6-82 - 6-83 . . . . . . . . 3
6-84 . . . . . . . . . . . . . . . 7
6-85 - 6-86 . . . . . . . . 3
6-87 - 6-93 . . . . . . . . 8
6-94 - 6-95 . . . . . ...11
6-96 . . . . . . . . . . . . . . . 8
6-97 - 6-100 . . . . . . . 3
6-101 - 6-103 . . . . . . 8
6- 104 Blank . . . . . ...8
6-105 - 6-106 . . . . . . 3
6-107 - 6-109 . . . . . . 8
6-110 . . . . . . . . . . . . . . 9
6-111 - 6-116 . . . . . . 3
6-117 - 6-118 . . . ...8
6-119 . . . . . . . . . . . . . . 3
6-120 . . . . . . . . . . . . . . 9
6-120A - 6-120G . . . . 3
6-120H Blank . . . . . . . 3
6-120I - 6-120J . . . . 8
Page
No.
Change
*No
6-120K . . . . . . . . . . ...10
6-120L - 6-120M . . . . 3
6-120N Blank . . . . . . . 3
6-121 - 6-124 . . . . . . 8
6-125 - 6-129 . . . . . . 3
6-130 . . . . . . . . . . . ...11
6-131 - 6-135 . . . . . . 3
6-136 Blank . . . . . . . . 3
6-137 . . . . . . . . . . . . . . 3
6-138 Blank . . . . . . . . 3
6-139 - 6-150 . . . . . . 3
6-151 . . . . . . . . . . . . . . 8
6-152 Blank . . . . . ...8
6-153 - 6-159 . . . . . . 3
6-160 Blank . . . . . . . . 3
6-161 - 6-162 . . . . . . 8
6-163 - 6-174 . . . . . . 3
6-175 - 6-176 . . . . . . 8
6-177 - 6-182 . . . . . . 3
6-182A . . . . . . . . . . ...12
6-182B Blank . . . . ...12
6-183 - 6-184 . . . . . . 8
6-185 - 6-188 . . . . . . 3
6-189 - 6-220
Deleted . . . . . . . . . . 3
7-1 . . . . . . . . . . . . . . . . 7
7-2 - 7-4 . . . . . . . ...0
7-5 - 7-6 . . . . . . . ...8
7-7 - 7-8 . . . . . . . . . . 9
7-8A Added . . . . . . . . . 9
7-8B Blank Added . . . 9
7-9 - 7-l0 . . . . . . . . . 0
7-11 - 7-12 . . . . . . . . 8
7-13 - 7-14 . . . . . . . . 0
7-15 - 7-16 . . . . . . . . 8
7-17 . . . . . . . . . . . . . . . 7
7-18 - 7-20 . . . . . . . . 0
7-21 - 7-22 . . . . . . . . 8
7-23 - 7-24 . . . . . . . . 0
7-25 . . . . . . . . . . . . . . . 1
7-26 Blank . . . . . . . . . 1
8- 1 - 8-2 . . . . . . . ...8
8-3-8-4 . . . . . . . . . . 0
8-5-8-6 . . . . . . . . . . 8
Change 12
B
TO 35C2-3-442-2
LIST OF EFFECTIVE PAGES (Cont)
Page
No.
*Change
No.
8-7 - 8-12 . . . . . . . . 0
8-13 - 8-14 . . . . . . . 8
8-15 - 8-16 . . . . . . . 1
8-17 - 8-26 . . . . . . . 8
8-26A Added . . . . . . . 8
8-26B Blank Added . 8
8-27 - 8-28 . . . . . . . 8
8-29 - 8-30 . . . . . . . 7
8-31 - 8-38 . . . . . . . 8
8-39 - 8-40 . . . . . . . 0
8-41 - 8-42 . . . . . . . 8
8-43 - 8-44 . . . . . . . 0
8-45 . . . . . . . . . . . . . . 1
8-46 . . . . . . . . . . . . . . 0
8-47 - 8-50 . . . . . . . 8
8-51 . . . . . . . . . . . . . . 1
8-52 - 8-54 . . . . . . . 0
8-55 - 8-58 . . . . . . . 8
8-59 . . . . . . . . . . . . . . 1
8-60 . . . . . . . . . . . . . . 0
8-61 - 8-62 . . . . . . . 8
8-63 - 8-66 . . . . . . . 0
8-67 - 8-68 . . . . . . . 8
8-69 . . . . . . . . . . . . . . 9
8-70 . . . . . . . . . . . . . . 2
8-71 . . . . . . . . . . . . . . 0
8-72 - 8-74 . . . . . . . 2
8-74A - 8-74B . . . . . 2
8-75 - 8-76 . . . . . . . 8
8-77 - 8-78 . . . . . . . 0
8-79 . . . . . . . . . . . . . . 6
8-80 - 8-84 . . . . . . . 0
8-85 - 8-86 . . . . . . . 2
8-87 - 8-88 . . . . . . . 0
8-89 - 8-92 . . . . . . . 8
8-93 . . . . . . . . . . . . . . 0
8-94 - 8-96 . . . . . . . 1
8-97 - 8-98 . . . . . . . 8
8-99 - 8-100 . . . . . . 0
8-101 - 8-106 . . . . . 8
8-107 . . . . . . . . . . . . . 7
8-108 . . . . . . . . . . . . . 0
8-109 - 8-114 . . . . . 8
8-115 - 8-117 . . . . . 1
C
Change 11
Page
No.
*Change
No.
8-118 . . . . . . . . . . . . .
8-119 - 8-120 . . . . .
8-121 - 8-122 . . . . .
8-123 . . . . . . . . . . . . .
8-124 - 8-130 . . . . .
8-131 - 8-134 . . . . .
8-135 - 8-136 . . . . .
8-137 - 8-138 . . . . .
8-139 - 8-140 . . . . .
8-141 - 8-144 . . . . .
8-145 - 8-146 . . . . .
8-147 - 8-148 . . . . .
9-1 - 9-8 . . . . . . . . .
9-9 . . . . . . . . . . . . . . .
9-10 Blank . . . . . . . .
9A-l . . . . . . . . . . . . . .
9A-2 Blank . . . . . . . .
10-1 - 10-2 . . . . . . .
10-3 - 10-6 . . . . . . .
10-7 . . . . . . . . . . . . . .
10-8 . . . . . . . . . . . . . .
11-1 - 11-2 . . . . . . .
11-3 . . . . . . . . . . . . . .
11-4 . . . . . . . . . . . . . .
11-5 - 11-6 . . . . . . .
11-7 - 11-11 . . . . . .
11-12 Blank . . . . . . .
12-1 - 12-2, . . . . . .
12-3 - 12-4 . . . . . . .
12-5 - 12-6, . . . . . .
12-7 - 12-11 . . . . . .
12-12 Blank . . . . . . .
13-1 - 13-2 . . . . . . .
13-3 - 13-4 . . . . . . .
13-5 - 13-6 . . . . . . .
13-7 - 13-8 . . . . . . .
13-9 - 13-10 . . . . . .
13-11 . . . . . . . . . . . . .
13-12 . . . . . . . . . . . . .
13-13 . . . . . . . . . . . . .
13-14 - 13-16 . . . . .
13-17 - 13-18 . . . . .
13-19 . . . . . . . . . . . . .
13-20 . . . . . . . . . . . . .
0
8
0
9
8
0
1
8
0
8
0
2
8
0
0
6
6
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0
7
0
8
1
0
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8
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8
4
1
4
0
8
0
1
Page
No.
*Change
No.
13-21 - 13-22 . . . . .
14-1 - 14-8
Deleted . . . . . . . . .
A-l . . . . . . . . . . . . . . .
A-2 - A-3 . . . . . . . . .
A-4 Blank . . . . . . . . .
I-1 - I-2 . . . . . . . . .
I - 3 - I-5 . . . . . . . . .
I-6 . . . . . . . . . . . . . . .
I-7 - I-9 . . . . . . . . .
I-10 . . . . . . . . . . . . . .
I-11 . . . . . . . . . . . . . .
I-12 . . . . . . . . . . . . . .
I-13 . . . . . . . . . . . . . .
I-14 - 1-18 . . . . . . .
I-19 . . . . . . . . . . . . . .
I-20 Blank . . . . . . . .
8
1
7
0
0
3
0
3
0
3
0
3
7
3
7
7
TO 35C2-3-442-2
AIR FORCE
TM5-6115-457-34
ARMY
NAVFAC P-8-627-34
NAVY
MARINE CORPS TM-07464A-34
TECHNICAL MANUAL
INTERMEDIATE (FIELD)
(DIRECT AND GENERAL SUPPORT)
AND DEPOT LEVEL MAINTENANCE
GENERATOR SET, DIESEL ENGINE DRIVEN,
TACTICAL SKID MTD., 100 KW, 3 PHASE,
4 WIRE, 120/208 AND 240/416 VOLTS
DOD MODELS
CLASS
MEP007A
MEP106A
MEP116A
UTILITY
PRECISE
PRECISE
HERTZ
FSN
50/60
50/60
400
6115-00-133-9101
6115-00-133-9102
6155-00-133-9103
INCLUDING OPTIONAL KITS
DOD MODELS
NSN
NOMENCLATURE
MEP007AWF
WINTERIZATION KIT, FUEL BURNING 6115-00-463-9082
MEP007AWE WINTERIZATION KIT, ELECTRIC 6115-00-463-9084
WHEEL MOUNTING KIT
MEP007AWM
6115-00-463-9089
CONSOLIDATED DIESEL ELECTRIC COMPANY
CONTRACT NUMBER F04606-70-D-0192 AND F04606-78-C-0363
DISTRIBUTION STATEMENT- Distribution authorized to U.S. Government agencies only, for administrative or operational
use, 19 October 1987. Other requests for this document shall be referred to Sacramento ALC/MMDDCC, McClellan AFB,
CA 95652-5609.
HANDLING AND DESTRUCTION NOTICE - Handle in compliance with distribution statement and destroy by any method
that will prevent disclosure of the contents or reconstruction of the document.
PUBLISHED UNDER AUTHORITY OF THE SECRETARY OF THE AIR FORCE
15 JUNE 1973
CHANGE 11 - 10 MAY 1989
TO 35C2-3-442-2
Dates of issue for original and changed pages are:
Original . . . . . . .0 . . . . . . .l5 Mar
Change . . . . . . . . .l . . . . . . . 31 Jun
Change . . . . . . . . .2. . . . . . . .l May
Change . . . . . . . . .3....... 30 Jun
Change . . . . . . . . .4....... 15 Apr
Change . . . . . . . ..5...... .21 Sep
73
75
77
77
78
79
Change
Change
Change
Change
Change
Change
. . . . . . . . .6 . . . . . . . . 2 Jun81
. . . . . . . . .7....... 20 May 82
. . . . . . . . .8. . . . . . . .4 Apr 84
. . . . . . . . .9....... 18 Mar 86
. . . . . . ..10 . . . . . . . 19 0ct 87
. . . . . . . .ll . . . . . ..l0 May 89
Total number of pages in this manual is 730 consisting of the following:
Page
‘Change
Page
*Change
No.
No.
No.
No.
Page
No.
Title . . . . . . . . . . . . . 11
A - C . . . . . . . . . . . . . 11
01 Blank . . . . . . . . . . 8
02 Blank . . . . . . . . . . 8
i - ii . . . . . . . . . . . . 4
iiA Added . . . . . . . . . 4
iiB Blank Added . . . 4
iii - vi . . . . . . . . . . 3
vii - x . . . . . . . . . . . 0
xi . . . . . . . . . . . . . . . . 2
xii . . . . . . . . . . . . . . . 6
xiiA Added . . . . . . . . 4
xiiB Blank Added . . 4
x i i i - xiv . . . . . . . . 4
xv - xvi . . . . . . . . . . 3
xvii . . . . . . . . . . . . . . 0
xviii . . . . . . . . . . . . . 2
xix . . . . . . . . . . . . . . . 3
xx Blank . . . . . . . . . . 3
xxi - xxii Deleted 3
1-1 . . . . . . . . . . . . . . . 4
1-2 . . . . . . . . . . . . . . . 3
1-2A - 1-2B . . . . . . . 4
1-3 - 1-4 . . . . . . . . . 7
1-5 . . . . . . . . . . . . . . . 10
1-6 . . . . . . . . . . . . . . . 7
1-6A . . . . . . . . . . . . . . 3
1-6B . . . . . . . . . . . . . . 7
1-7 - 1-9 . . . . . . . . . 7
l-l0 . . . . . . . . . . . . . . 0
1-11 . . . . . . . . . . . . . . 4
1-12 . . . . . . . . . . . . . . 1
1-13 - 1-14 . . . . . . . 3
1-83 - 1-84 . . . . . . . 0
1-85 . . . . . . . . . . . . . . 10
l-86 Blank . . . . . . . . 10
1-87 . . . . . . . . . . . . . . 0
l-88 Blank . . . . . . . . 0
1-89 . . . . . . . . . . . . . . 0
l-90 Blank . . . . . . . . 0
1-91 . . . . . . . . . . . . . . 8
l-92 Blank . . . . . . . . 8
1-93 . . . . . . . . . . . . . . 8
l-94 Blank . . . . . . . . 8
1-95 . . . . . . . . . . . . . . 3
l-96 Blank . . . . . . . . 3
1-97 . . . . . . . . . . . . . . 8
l-98 Blank . . . . . . . . 8
1-99 . . . . . . . . . . . . . . 1
1-100 Blank . . . . . . . 1
1-101 . . . . . . . . . . . . . 1
l-102 Blank . . . . . . . 1
1-103 . . . . . . . . . . . . . 0
l-104 Blank . . . . . . . 0
1-105 . . . . . . . . . . . . . 0
l-106 Blank . . . . . . . 0
1-107 . . . . . . . . . . . . . 0
l-108 Blank . . . . . . 0
1-109 . . . . . . . . . . . . . 0
1-110 Blank . . . . . . . 0
1-111 - 1-114 . . . . . 0
1-115 . . . . . . . . . . . . . 3
1-116 . . . . . . . . . . . . . 1
1-117 - 1-118 . . . . . 0
2-1 . . . . . . . . . . . . . . . 1
2-2 - 2-4 . . . . . . . . . 0
l-14A Added . . . . . . . 3
1-14B Blank Added . 3
1-15 . . . . . . . . . . . . . . 0
1-16 . . . . . . . . . . . . . . 7
1-17 - 1-18 . . . . . . . 0
1-19 . . . . . . . . . . . . . . 4
1-20 - 1-26 . . . . . . . 0
1-27 . . . . . . . . . . . . . . 1
1-28 - 1-41 . . . . . . . 0
1-42 . . . . . . . . . . . . . . 7
1-43 - 1-47 . . . . . . . 0
1-48 . . . . . . . . . . . . . . 3
1-49 - 1-61 . . . . . . . 0
l-62 Blank . . . . . . . . 0
1-63 . . . . . . . . . . . . . . 1
l-64 Blank . . . . . . . . 1
1-65 . . . . . . . . . . . . . . 11
l-66 Blank . . . . . . . . 11
1-67 . . . . . . . . . . . . . . 1
l-68 Blank . . . . . . . . 1
1-69 . . . . . . . . . . . . . . 3
l-60 Blank . . . . . . . . 3
1-71 . . . . . . . . . . . . . . 3
l-72 Blank . . . . . . . . 3
1-73 . . . . . . . . . . . . . . 3
l-74 Blank . . . . . . . . 3
1-75 . . . . . . . . . . . . . . 3
1-76 . . . . . . . . . . . . . . 0
1-77 . . . . . . . . . . . . . . 7
l-78 Blank . . . . . . . . 7
1-79 - 1-80 . . . . . . . 0
1-81 . . . . . . . . . . . . . . 1
l-82 Blank . . . . . . . . 1
l Change
No.
*Zero in this column indicates an original page.
USAF
A
Change 11
TO 35C2-3-442-2
LIST OF EFFECTIVE PAGES (Cont)
Page
No.
*Change
No.
2-5 - 2-6 . . . . . . . . . 8
2-7 - 2-8 . . . . . . . . . 3
2-8 A Added . . . . . . . . 3
2-8B Blank Added . . 3
2-9 - 2-10 . . . . . . . . 8
2-11 . . . . . . . . . . . . . . 7
2-12 . . . . . . . . . . . . . . 0
2-13 - 2-14 . . . . . . . 8
2-15 . . . . . . . . . . . . . . 9
2-16 . . . . . . . . . . . . . . 8
2-17 - 2-22 . . . . . . . 0
2-23 - 2-24. . . . . . . 7
2-25, . . . . . . . . . . . . . 6
2-26 - 2-28 . . . . . . . 0
2-29 . . . . . . . . . . . . . . 1
2-30 . . . . . . . . . . . . . . 0
2-31, . . . . . . . . . . . . . 7
2-32 . . . . . . . . . . . . . . 0
2-33 . . . . . . . . . . . . . . 6
2-34 - 2-46 . . . . . . . 3
2-47 - 2-48 . . . . . . . 0
2-49 . . . . . . . . . . . . . . 1
2-50 - 2-56 . . . . . . . 0
2-57 - 2-58 . . . . . . . 8
2-59 - 2-64 . . . . . . . 4
2-65 - 2-66 . . . . . . . 8
3-1 - 3-2 . . . . . . . . . 0
3-3 - 3-6 . . . . . . . . . 8
3-7 - 3-l0 . . . . . . . . 3
4-1 - 4-4 . . . . . . . . . 8
4-5 - 4-6 . . . . . . . . . 1
4-7 - 4-8 . . . . . . . . . 8
5-1 - 5-2 . . . . . . . . . 8
5-3 - 5-11 . . . . . . . . 0
5-12 - 5-13 . . . . . . . 3
5-14 - 5-16 . . . . . . . 0
6-1 - 6-4 . . . . . . . . . 0
6-5 - 6-8 . . . . . . . . . 8
6-9 . . . . . . . . . . . . . . . 0
6-10 . . . . . . . . . . . . . . 1
6-11 - 6-12 . . . . . . . 8
6-13, . . . . . . . . . . . . . 0
6-14 . . . . . . . . . . . . . . 3
6-15 . . . . . . . . . . . . . . 0
6-16 Blank . . . . . . . . 0
Page
No.
*Change
No.
6-17 . . . . . . . . . . . . . . 0
6-18 Blank . . . . . . . . 0
6-19 - 6-20 . . . . . . . 3
6-20A Addded . . . . . . 3
6-20B Blank Added . 3
6-21 . . . . . . . . . . . . . . 3
6-22 . . . . . . . . . . . . . . 0
6-23 - 6-24 . . . . . . . 8
6-25 - 6-26 . . . . . . . 0
6-27 - 6-28 . . . . . . . 8
6-29 - 6-33 . . . . . . . 0
6-34 . . . . . . . . . . . . . . 4
6-35 - 6-37 . . . . . . . 0
6-38 . . . . . . . . . . . . . . 4
6-39 . . . . . . . . . . . . . . 1
6-40 - 6-42 . . . . . . . 0
6-43 - 6-45 . . . . . . . 7
6-46 - 6-48 . . . . . . . 10
6-49 - 6-50 . . . . . . . 9
6-51 . . . . . . . . . . . . . . 1
6-52 - 6-59 . . . . . . . 0
6-60 . . . . . . . . . . . . . . 9
6-61 - 6-64 . . . . . . . 8
6-65 . . . . . . . . . . . . . . 0
6-66 - 6-68 . . . . . . . 1
6-69 - 6-74 . . . . . . . 0
6-75 - 6-76 . . . . . . . 8
6-77 - 6-81 . . . . . . . 0
6-82 - 6-83 . . . . . . . 3
6-84 . . . . . . . . . . . . . . 7
6-85 - 6-86 . . . . . . . 3
6-87 - 6-93 . . . . . . . 8
6-94 - 6-95 . . . . . . . 11
6-96 . . . . . . . . . . . . . . 8
6-97 - 6-100 . . . . . . 3
6-101- 6-103 . . . . . . 8
6-104 Blank . . . . . . . . 8
6-105 - 6-106 . . . . . 3
6-107 - 6-109 . . . . . 8
6-110 . . . . . . . . . . . . . 9
6-111 - 6-116 . . . . . 3
6-117 - 6-118 . . . . . 8
6-119 . . . . . . . . . . . . . 3
6-120 . . . . . . . . . . . . . 9
6-120A - 6-120G . . . 3
6-120H Blank . . . . . . 3
Page
No.
*Change
No.
6-1201 - 6-120J . . . 8
6-120K . . . . . . . . . . . . 10
6-120L - 6-120M . . . 3
6-120N Blank . . . . . . 3
6-121 - 6-124 . . . . . 8
6-125 - 6-129 . . . . . 3
6-130 . . . . . . . . . . . . . 11
6-131 - 6-135 . . . . . 3
6-136 Blank . . . . . . . 3
6-137 . . . . . . . . . . . . . 3
6-138 Blank . . . . . . . 3
6-139 - 60-150 . . . . 3
6-151 . . . . . . . . . . . . . 8
6-152 Blank . . . . . . . 8
6-153 - 6-159 . . . . . 3
6-160 Blank . . . . . . . 3
6-161 - 6-162 . . . . . 8
6-163 - 6-174 . . . . . 3
6-175 - 6-176 . . . . . 8
6-177 - 6-182 . . . . . 3
6-182A . . . . . . . . . . . . 9
6-182B Blank . . . . . . 9
6-183 - 6-184 . . . . . 8
6-185 - 6-188 . . . . . 3
6-189 - 6-220
Deleted . . . . . . . . . 3
7-1 . . . . . . . . . . . . . . . 7
7-2 - 7-4 . . . . . . . . . 0
7-5 - 7-6 . . . . . . . . . 8
7-7 - 7-8 . . . . . . . . . 9
7-8A Added . . . . . . . . 9
7-8B Blank Added . . 9
7-9 - 7-10 . . . . . . . . 0
7-11 - 7-12 . . . . . . . 8
7-13 - 7-14 . . . . . . . 0
7-15 - 7-16 . . . . . . . 8
7-17 . . . . . . . . . . . . . . 7
7-18 - 7-20 . . . . . . . 0
7-21 - 7-22 . . . . . . . 8
7-23 - 7-24 . . . . . . . 0
7-25 . . . . . . . . . . . . . . 1
7-26 Blank . . . . . . . . 1
8-1 - 8-2 . . . . . . . . . 8
8-3 - 8-4 . . . . . . . . . 0
8-5 - 8-6 . . . . . . . . . 8
Change 11
B
TO 35C2-3-442-2
LIST OF EFFECTIVE PAGES (Cont)
Page
No.
*Change
No.
8-7 - 8-12 . . . . . . . . 0
8- 13 - 8-14 . . . . . . . 8
8-15 - 8-16 . . . . . . . 1
8-17 - 8-26 . . . . . . . 8
8-26A Added . . . . . . . 8
8-26B Blank Added . 8
8-27 - 8-28 . . . . . . . 8
8-29 - 8-30 . . . . . . . 7
8-31 - 8-38 . . . . . . . 8
8-39 - 8-40 . . . . . . . 0
8-41 - 8-42 . . . . . . . 8
8-43 - 8-44 . . . . . . . 0
8-45 . . . . . . . . . . . . . . 1
8-46 . . . . . . . . . . . . . . 0
8-47 - 8-50 . . . . . . . 8
8-51 . . . . . . . . . . . . . . 1
8-52 - 8-54 . . . . . . . 0
8-55 - 8-58 . . . . . . . 8
8-59 . . . . . . . . . . . . . . 1
8-60 . . . . . . . . . . . . . . 0
8-61 - 8-62 . . . . . . . 8
8-63 - 8-66 . . . . . . . 0
8-67 - 8-68 . . . . . . . 8
8-69 . . . . . . . . . . . . . . 9
8-70 . . . . . . . . . . . . . . 2
8-71 . . . . . . . . . . . . . . 0
8-72 - 8-74 . . . . . . . 2
8-74A - 8-74B . . . . . 2
8-75 - 8-76 . . . . . . . 8
8-77 - 8-78 . . . . . . . 0
8-79 . . . . . . . . . . . . . . 6
8-80 - 8-84 . . . . . . . 0
8-85 - 8-86 . . . . . . . 2
8-87 - 8-88 . . . . . . . 0
8-89 - 8-92 . . . . . . . 8
8-93 . . . . . . . . . . . . . . 0
8-94 - 8-96 . . . . . . . 1
8-97 - 8-98 . . . . . . . 8
8-99 - 8-100 . . . . . . 0
8-101 - 8-106 . . . . . 8
8-107 . . . . . . . . . . . . . 7
8- 108 . . . . . . . . . . . . . 0
8-109 - 8-114 . . . . . 8
8-115 - 8-117 . . . . . 1
C
Change 11
Page
No.
*Change
No.
8-118 . . . . . . . . . . . . . 0
8-119 - 8-120 . . . . . 8
8-121 - 8-122 . . . . . 0
8-123 . . . . . . . . . . . . . 9
8-124 - 8-130 . . . . . 8
8-131 - 8-134 . . . . . 0
8-135 - 8-136 . . . . . 1
8-137 - 8-138 . . . . . 8
8-139 - 8-140 . . . . . 0
8-141 - 8-144 . . . . . 8
8-145 - 8-146 . . . . . 0
8-147 - 8-148 . . . . . 2
9-1 - 9-8 . . . . . . . . . 8
9-9 . . . . . . . . . . . . . . . 0
9-10 Blank . . . . . . . . 0
9A-l . . . . . . . . . . . . . . 6
9A-2 Blank . . . . . . . . 6
10-1 - 10-2 . . . . . . . 8
10-3 - 10-6 . . . . . . . 0
10-7 . . . . . . . . . . . . . . 7
10-8 . . . . . . . . . . . . . . 0
11-1 - 11-2 . . . . . . . 8
11-3 . . . . . . . . . . . . . . 1
11 -4 . . . . . . . . . . . . . . 0
11-5 - 11-6 . . . . . . . 8
11-7 - 11-11 . . . . . . 0
11-12 Blank. . . . . . . . . . 0
12-1 - 12-2 . . . . . . . 0
12-3 - 12-4 . . . . . . . 8
12-5 - 12-6 . . . . . . . 0
12-7 - 12-11 . . . . . . 8
12-12 Blank . . . . . . . 8
13-1 - 13-2 . . . . . . . 8
13-3- 13-4 . . . . . . . 0
13-5 - 13-6 . . . . . . . 8
13-7 - 13-8 . . . . . . . 0
13-9- 13-10 . . . . . . 8
13-11 . . . . . . . . . . . . . 4
13-12 . . . . . . . . . . . . . 1
13-13 . . . . . . . . . . . . . 4
13-14 - 13-16 . . . . . 0
13-17 - 13-18 . . . . . 8
13-19 . . . . . . . . . . . . . 0
13-20 . . . . . . . . . . . . . 1
Page
No.
*Change
No.
13-21 - 13-22 . . . . . 8
14-1 - 14-8
Deleted . . . . . . . . . 1
A-l . . . . . . . . . . . . . . . 7
A-2 - A-3 . . . . . . . . . 0
A-4 Blank . . . . . . . . . 0
I-l - I-2 . . . . . . . . . 3
I-3 - I-5 . . . . . . . . . 0
I-6 . . . . . . . . . . . . . . . 3
I-7 - I-9 . . . . . . . . . 0
I-10 . . . . . . . . . . . . . . 3
I- 11 . . . . . . . . . . . . . . 0
I- 12 . . . . . . . . . . . . . . 3
I-13 . . . . . . . . . . . . . . 7
I-14 - 1-18 . . . . . . . 3
I-19 . . . . . . . . . . . . . . 7
I-20 Blank . . . . . . . . 7
AIR FORCE T0 35C2-3-442-2
ARMY
TM5-6115-457-34
NAVY
NAVFAC P-8-627-34
MARINE CORPS TM-07464A-35
TECHNICAL MANUAL
INTERMEDIATE (FIELD)
(DIRECT AND GENERAL SUPPORT)
AND DEPOT LEVEL MAINTENANCE
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL
SKID MTD., 100 KW, 3 PHASE, 4 WIRE, 120/208 AND
240/416 VOLTS
DOD MODELS
CLASS
HERTZ
MEP007A
MEP106A
MEP116A
UTILITY
PRECISE
PRECISE
50/60
50/60
400
FSN
6115-00-133-9101
6115-00-133-9102
6115-00-133-9103
INCLUDING OPTIONAL KITS
DOD MODELS
MEP007AWF
MEP007AWE
MEP007AWM
NOMENCLATURE
WINTERIZATION KIT, FUEL BURNING
WINTERIZATION KIT, ELECTRIC
WHEEL MOUNTING KIT
NSN
6115-00-463-9082
6115-00-463-9084
6115-00-463-9089
CONSOLIDATED DIESEL ELECTRIC COMPANY
CONTRACT NUMBER F04606-70-D-0192 AND F04606-78-C-0363
DISTRIBUTION STATEMENT—Distribution authorized to U.S. Government agencies only for administrative or operational use (19 October
1987). Other requests for this document shall be referred to Sacramento AL C/MMEDTD, McClellan AFB, CA 95652-5609.
HANDLING AND DESTRUCTION NOTICE—Handle in compliance with distribution statement and destroy by any method that will prevent
disclosure of the contents or reconstruction of the document.
Published under authority of the Departments of the Air Force, the Army, end The Navy (including US Marine Corps)
15 JUNE 1973
Change 10 – 19 OCTOBER 1987
TO 35C2-3-442-2
TM 5-6115-457-34
P-8-627-34
TM-07464A-35
INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.
Dates of issue for original and changed pages are:
Change . . . . . . . . . . . ..4 . . . . . . . . 15 Apr 78
Original . . . . . . . . . . ..0 . . . . . . . 15 Mar 73
Change . . . . . . . . . . . ..5 . . . . . ...21 Sep 79
Change . . . . . . . . . . . ..1 . . . . . . ...31 Jun 75
Change . . . . . . . . . . . ..6 . . . . . . . . ...2 Jun 81
Change . . . . . . . . . . . ..2 . . . . . . . . . 1 May 77
Change . . . . . . . . . . . ..7 . . . . ...20 May 82
Change . . . . . . . . . . . ..3 . . . . . . ...30 Jun 77
Change . . . . . . . . . . . ..8 . . . . . . . ...4 Apr 84
Change . . . . . . . . . . . ..9 . . . . . . . 18 Mar 86
Change . . . . . . . . . . ..10 . . . . ...19 Oct 87
TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 30 CONSISTING OF THE FOLLOWING:
Page No.
*Change No.
Title . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
A - C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
01 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
02 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
i - ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4
iiA Added . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4
iiB Blank Added . . . . . . . . . . . . . . . . . . . . . ...4
iii- vi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..3
vii - x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
xi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2
xii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...6
xiiA Added . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4
xiiB Blank Added . . . . . . . . . . . . . . . . . . . ...4
xiii - xiv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4
xv - xvi .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
xvii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
xviii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.
xix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
xx Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
xxi - xxii Deleted . . . . . . . . . . . . . . . . . . . . ...3
1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4
1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
1-2A - 1-2B . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4
1-3 -1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
1-6A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
1-6B -1-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
1-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
1-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4
1-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1
1-13-1-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
1-14A Added . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
1-14B Blank Added . . . . . . . . . . . . . . . ...3
1-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
1-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
1-17- 1-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
1-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4
1-20- 1-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
Page No.
*Change No.
1-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-28-1-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
1-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
1-43-1-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
1-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
1-49-1-61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
1-62 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
1-63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-64 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
1-66 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
1-67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-68 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
1-70 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
1-71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
1-72 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
1-73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
1-74 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
1-75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
1-76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
1-77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
1-78 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
1-79- 1-80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
1-81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-82 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-83-1-84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
1-85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1-86 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
1-88 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
1-89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
1-90 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
1-91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
1-92 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
1-93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
1-94 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
1-95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
1-96 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
Page No.
*Change No.
1-97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
1-98 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
1-99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-100 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-102 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
1-104 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
1-105 . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0
1-106 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
1-107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
l-108 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0
1-109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0
l-ll0 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0
1-111-1-114 . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
1-115 . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
1-116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-117- 1-118 . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2-2- 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
2-5- 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
2-7- 2-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
2-8A Added . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-8B Blank Added . . . . . . . . . . . . . . . . . ...3
2-9- 2-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
2-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
2-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
2-13-2-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
2-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9
2-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
2-17-2-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
2-23-2-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
2-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...6
2-26-2-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
2-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
2-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
2-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
2-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...6
“Zero in this column indicates an original page
A
Change 10
USAF
P-8-627-34
TM-07464A-35
TO 35C2-3-442-2
TM 5-6115-457-34
LIST OF EFFECTIVE PAGES (cont)
Page No.
*Change No.
2-34- 2-46., . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
2-47- 2-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
2-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2-50- 2-56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
2-57-2-58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
2-59- 2-64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4
2-65- 2-66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
3-1- 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
3-3- 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
3-7- 3-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
4-1 -4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
4-5- 4-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4-7- 4-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
5-1- 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
5-3-5-11 ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
5-12- 5-13, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
5-14- 5-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
6-1 -6-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
6-5- 6-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
6-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
6-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6-11- 6-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
6-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
6-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
6-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
6-16 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
6-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
6-18 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0
6-19- 6-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
6-20A Added . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
6-20B Blank Added . . . . . . . . . . . . . . . ...3
6-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
6-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
6-23- 6-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
6-25- 6-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
6-27- 6-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
6-29-6-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
6-34 ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4
6-35-6-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
6-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4
6-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6-40- 6-42, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
6-43- 6-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
6-46- 6-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...10
6-49- 6-50, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9
6-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6-52- 6-59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
6-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9
6-61-6-64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
6-65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
6-66- 6-68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Page No.
*Change No.
6-69-6-74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
6-75- 6-76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
6-77-6-81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
6-82-6-83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
6-84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
6-85- 6-86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
6-87- 6-96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
6-97- 6-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
6-101- 6-103 . . . . . . . . . . . . . . . . . . . . . . . ...8
6-104 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
6-105- 6-106 . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
6-107- 6-109 . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
6-110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9
6-111 -6-116 . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
6-117- 6-118 . . . . . . . . . . . . . . . . . . . . . . . . . ...8
6-119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
6-120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9
6-120A - 6-120G . . . . . . . . . . . . . . . . . . . . ...3
6-120H Blank . . . . . . . . . . . . . . . . . . . . . . . . . ...3
6-1201- 6-120J . . . . . . . . . . . . . . . . . . . . . . . ...8
6-120K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...10
6-120L - 6-120M. . . . . . . . . . . . . . . . . ...3
6-120N Blank . . . . . . . . . . . . . . . . . . . . . . . . . ...3
6-121- 6-124 . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
6-125- 6-135 . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
6-136 Blank. . . . . . . . . . . . . . . . . . . . . . . . . . ...3
6-137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
6-138 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
6-139- 6-150 . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
6-151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
6-152 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
6-153- 6-159 . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
6-160 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
6-161- 6-162 . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
6-163- 6-174 . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
6-175- 6-176 ... . . . . . . . . . . . . . . . . . . . . . . . ...8
6-177 -6-182 . . . . . . . . . . . . . . . . . . . . . . . . ...3
6-182A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9
6-182B Blank . . . . . . . . . . . . . . . . . . . . . . . . . ...9
6-183- 6-184, . . . . . . . . . . . . . . . . . . . . . . . . . ...8
6-185-6-188 . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
6-189-6-220 Deleted . . . . . . . . . . . . ...3
7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
7-2- 7-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
7-5- 7-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
7-7-7-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9
7-8A Added . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9
7-8B Blank Added . . . . . . . . . . . . . . . . . ...9
7-9- 7-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
7-11 - 7-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
7-13-7-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
Page No.
*Change No.
7-15- 7-16, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
7-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
7-18- 7-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
7-21- 7-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
7-23-7-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
7-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7-26 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8-1- 8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
8-3- 8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
8-5- 8-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
8-7- 8-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
8-13- 8-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
8-15- 8-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1
8-17- 8-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
8-26A Added . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
8-26B Blank Added . . . . . . . . . . . . . ...8
8-27- 8-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
8-29- 8-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
8-31-8-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
8-39- 8-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
8-41- 8-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
8-43-8-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
8-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
8-47- 8-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
8-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8-52-8-54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
8-55-8-58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
8-59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
8-61-8-62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
8-67-8-66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
8-67-8-68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
8-69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9
8-70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2
8-71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
8-72-8-74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2
8-74A - 8-74B . . . . . . . . . . . . . . . . . . . . . . . . ...2
8-75-8-76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
8-77-8-78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
8-79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...6
8-80 - 8-84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
8-85-8-86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2
8-87-8-88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
8-89-8-92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
8-93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
8-94-8-96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8-97-8-98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
8-99-8-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
8-101-8-106 . . . . . . . . . . . . . . . . . . . . . . . . . ...8
8-107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
Change 10 B
TO 35C2-3-442-2
P-8-627-34
TM 07464A-35 TM5-6115-457-34
LIST OF EFFECTIVE PAGES (cont)
Page No.
*Change No.
8-108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
8-109-8-114 . . . . . . . . . . . . . . . . . . . . . . . . . ...8
8-115-8-117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8-118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . ..0
8-119-8-120 . . . . . . . . . . . . . . . . . . . . . . . . . ...8
8-121-8-122 . . . . . . . . . . . . . . . . . . . . . . . . . ...0
8-123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9
8-124-8-130 . . . . . . . . . . . . . . . . . . . . . . . . . ...8
8-131-8-134 . . . . . . . . . . . . . . . . . . . . . . . . . ...0
8-135-8-136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8-137 -8-138 . . . . . . . . . . . . . . . . . . . . . . . . . ...8
8-139 -8-140 . . . . . . . . . . . . . . . . . . . . . . . . . ...0
8-141-8-144 . . . . . . . . . . . . . . . . . . . . . . . . . ...8
8-145-8-146 . . . . . . . . . . . . . . . . . . . . . . . . . ...0
8-147-8-148 . . . . . . . . . . . . . . . . . . . . . . . . . ...2
9-1 -9-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
9-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
9-10 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
9A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...6
9A-2 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...6
10-1 -10-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
C Change 10
Page No.
*Change No.
10-3 -10-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
10-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
10-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
11-1 -11-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
11-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
11-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
11-5 -11-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
11-7-11-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
11-12 Blank ., . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
12-1 -12-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
12-3 -12-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
12-5 -12-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
12-7-12-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
12-12 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
13-1 -13-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
13-3 -13-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
13-5 -13-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
13-7 -13-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
13-9-13-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8
13-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4
13-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1
Page No.
*Change No.
13-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4
13-14-13-16 . . . . . . . . . . . . . . . . . . . . . . . . . ...0
13-17-13-18 . . . . . . . . . . . . . . . . . . . . . . . . . ...8
13-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
13-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13-21-13-22 . . . . . . . . . . . . . . . . . . . . . . . . . ...8
14-1 – 14-8 Deleted . . . . . . . . . . . . . . . . ...1
A-l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
A-2 - A-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
A-4 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
I-1 - I-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
I-3 - I-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
I-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
I-7 - I-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
I-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . ...3
I-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...0
I-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
I-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
I-14 - I-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
I-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
I-20 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
AIR FORCE
TO 35C2-3-442-2
ARMY
TM5-6115-457-34
NAVY
NAVFAC P-8-627-34
MARINE CORPS TM-07464A-35
TECHNICAL MANUAL
INTERMEDIATE (FIELD)
(DIRECT AND GENERAL SUPPORT)
AND DEPOT LEVEL MAINTENANCE
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL
SKID MTD., 100 KW, 3 PHASE, 4 WIRE, 120/208 AND
240/416 VOLTS
DOD MODELS
MEP007A
MEP106A
MEP116A
CLASS
UTILITY
PRECISE
PRECISE
HERTZ
50/60
50/60
400
FSN
6115-00-133-9101
6115-00-133-9102
6115-00-133-9103
INCLUDING OPTIONAL KITS
DOD MODELS
MEP007AWF
MEP007AWE
MEP007ALM
MEP007AWM
NOMENCLATURE
WINTERIZATION KIT, FUEL BURNING
WINTERIZATION KIT, ELECTRIC
DUMMY LOAD KIT
WHEEL MOUNTING KIT
NSN
6115-00-463-9082
6115-00-463-9084
611540-463-9086
6115-00-463-9089
CONSOLIDATED DIESEL ELECTRIC COMPANY
CONTRACT NUMBER FO4606-70-D-0192 AND FO4606-78-C-0363
This publication incorporates PCN numbers 1 through 1302 and 1318.
This publication supersedes supplement TO 35C2-3-442-2S-3 dated 9 February 1983.
This publication is required for official use or for administrative or operational purposes only. Distribution is
limited to US Government agencies. Other requests for this document must be referred to Sacramento
ALC/MMEDTD, McClellan AFB CA 95652-5609.
Published under authority of the Departments of the Air Force, the Army, and the Navy (including US Marine Corps)
15 JUNE 1973
CHANGE 9 - 18 MARCH 1986
TO 35C2-3-442-2
P-8-627-34
TM-O7464A-35 TM 5-6115-457-34
INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.
Dates of issue for original and changed pages are:
Original. .0. .15 Mar 73
Change. .4. .15 Apr 78
Change. .8. . 4 Apr 84
Change. .5. .21 Sep 79
Change. .9. .18 Mar 86
Change. . . . 1. .31 Jun 75
Change. .6. . 2 Jun 81
Change. . . . 2. . 1 May 77
Change. .7. .20 May 82
Change. . . . 3. .30 Jun 77
TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 724 CONSISTING OF THE FOLLOWING:
Page
Page
Page
*Change
*Change
*Change
No.
No.
No.
No.
1-15..............0
1-85 . . . . . . . . . . . . . . . 1
Title . . . . . . . . . . . . . . 9
1-16. . . . . . . . . . . . . . . 7
A - C..............9
l-86. . . . . . . . . . ..... 1
1-17 - l-18 . . . . . . . . . 0
01 . . . . . . . . . . . . . . . . . 8
1-87 . . . . . . . . . . . . . . . 0
1-19 . . . . . . . . . . . . . . . 4
02 Blank . . . . . ... 8
l-88 Blank . . . . . . .. 0
l-20 - l-26 . . . . . . . . .0
i- i i . . . . . . . . . . . . . 4
1-89. . . . . . . . ... 0
1-27. . . . . . . . . . . . . . 1
iiA Added . . . . . . . . . . 4
l-90 Blank . . . . . . . . . 0
1-28 - 1-41. . . . . . . . 0
iiB Blank Added . . . . 4
1-91 . . . . . . . . . . . . . . . 8
1-42. . . . . . . . . . . . 7
i i i - vi . . . . ..... 3
l-92 Blank. . . . . . . .8
1-43 - 147 . . . . . . . . 0
v i i - x . . . . . . . 0
1-93. . . . . . . . . .. 8
1-48 . . . . . . . . . . . . . . . 3
xi . . . . . . . . .... .. 2
l-94 Blank . . . . . . . . . 8
1-49 - 1-61 . . . . . . . . 0
1-95 . . . . . . . . . . . . . . . 3
xii . . . . . . . . . . . . . . . . 6
1-62 Blank . . . . . . . . . 0
xiiA Added . . . . . . 4
l-96 Blank . . . . . . . . 3
1-63 . . . . . . . . . . . . . . . 1
1-97 . . . . . . . . . . . . . . . 8
xiiB Blank Added. . . . . . . 4
l-64 Blank . . . . . . . . . 1
xiii - xiv . . . . . . . . 4
l-98 Blank . . . . . . . 8
1-65 . . . . . . . . . . . . . . . 3
x v - xvi. . . . . . . . . . 3
1-99. . . . . . . . .. 1
l-66 Blank . . . . . . . . . 3
xvii . . . . . . . . . . . . . . 0
l-l00 Blank. . . . . . . . . . 1
1-67 . . . . . . . . . . . . . . . 1
xviii . . . . . . . . . . . 2
1-101 . . . . . . . . . . . . . . 1
l-68 Blank . . . . . . . . 1
xix. . . . . . . . . . . . . . . . 3
1-102 Blank . . . . . . . 1
149 . . . . . . . . . . . . . . . 3
1-103 . . . . . . . . . . . . . . 0
xx Blank . . . . .. . . . 3
l-70 Blank. . . . . . . . . 3
x x i - xxii Deleted. 3
l-l04 Blank . . . . . . . . 0
1-71 . . . . . . . . . . . . . . . 3
1-1 . . . . . . . . . . . . . . . . 4
1-105 . . . . . . . . . . . . . . 0
l-72 Blank . . . . . . . 3
l-l06 Blank. . . . . . . . . . . 0
1-2 . . . . . . . . . . . . . . . 3
1-73. . . . . . . . . . . . . . . 3
1-107 . . . . . . . . . . . . . . 0
1-2A - 1-28 . . . . . . . . 4
l-74 Blank. . . . . . . 3
1-3 - 1-6 . . . . . . . . . . 7
l-108 Blank. . . . . . . . . . . . . 0
1-75 . . . . . . . . . . . . . . . 3
1-109 . . . . . . . . . . . . . . 0
1-6A. . . . . . . . . . . . . . . 3
1-76 . . . . . . . . . . . . . . . 0
l-ll0Blank . . . . . . . . 0
1-6B - 1-9 . . . . . . . . . 7
1-77 . . . . . . . . . . . . . . . 7
1-111 - 1-114..000. 0
1-10 . . . . . . . . . . . . . . . 0
l-78 Blank . . . . . . . 7
1-11 . . . . . . . . . . . . . . . 4
1-115 . . . . . . . . . . . . . . 3
1-79 - 1-80 . . . . . . . . 0
1-12 . . . . . . . . . . . . . . . 1
1-116 . . . . . . . . . . . . . . 1
1-81 . . . . . . . . . . . . . . . 1
1-13 - 1-14.0 . . . . . . 3
1-117 - 1-118.0000. 0
1-82 Blank . . . . . . . . . 1
l-14A Added . . . . . . . . 3
2-1 . . . . . . . . . . . . . . . . 1
1-83 - 1-84 . . . . . . . . 0
2-2 - 2-4......0
1-14B Blank Added. .3
*Zero in this column indicates l original page.
USAF
A
Change 9
P-8-627-34
TO 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
LIST OF EFFECTIVE PAGES (cont)
Page
l Change
No.
No.
2-5 - 2-6 . . . . . . . . . . 8
2-7 - 2-8 . . . . . . . . 3
2-8A Added. . . . . . . . . 3
2-8B Blank Added. . . 3
2-9 - 2-10. . . . . . . . 8
2-11 . . . . . . . . . . . . . . . 7
2-12 . . . . . . . . . . . . . . . 0
2-13 - 2-14. . . . . . . . . .. 8
2-15. . . . . . . . . . . . . . . 9
2-16 . . . . . .... 8
2-17 - 2-22 . . . . . . . . 0
2-23 - 2-24. . . . . . . . . . . . 7
2-25. . . . . . . . . . . . . . . 6
2-26 - 2-28. . . . . . . 0
2-29 . . . . . . . . . . . . . . 1
2-30 . . . . . . . . . . . . . . . 0
2-31 . . . . . . . . . . . . . . . 7
2-32 . . . . . . . . . . . . . 0
2-33. .. . . . . . . . . . 6
2-34 - 2-46 . . . . . . . . 3
2-47 - 2-48 . . . . . .. 0
2-49. .... . . . . . . . 1
2 - 5 0 - 2-56..... . . . . . . . . 0
2-57 - 2-58 . . . . ... 8
2-59 - 2-64 . . . . . ...4
2-65 - 2-66...................... 8
3-1 - 3-2. . . . . . . . . . . 0
3-3 - 3-6 . . . . . . . . . . 8
3-7- 3-l0 . . . . . . . . . 3
4-1 - 4-4.........8
4 - 5 - 4-6.. . . . . . . . . . 1
4-7 - 4-8. . . . . . . . . . . . . . .. 8
5-1 - 5-2 . . . . . . . . . . 8
5-3 - 5-11 . . . . . . . . . 0
5-12 - 5-13 . . . . . . . . 3
5-14 - 5-16 . . . . . . . . 0
6-1 - 6-40 . . . . . . . . 0
6-5 - 6-8 . . . . . . . . . . 8
6-9 . . . . . . . . . . . . . . . 0
6-10 . . . . . . . . . . . . . . . 1
6-11 - 6-12 . . . . . . . . 8
6-13. . . . . . . . . . . . . . . 0
6-14. . . . . . . . . . . . . . . . 3
6-15 . . . . . . . . . . . . . . . 0
6-16 Blanke . . . . . . . 0
6-17 . . . . . . . . . . . . . . . 0
6-18 Blank . . . . . . . . 0
6-19 - 6-20 . . . . . . . . . . . .3
6-20A Added . . . . . . . 3
6-208 Blank Added. . . 3
6-21 . . . . . . . . . . . . . . . 3
6-22 . . . . . . . ....... 0
Page
*Change
No.
No.
6-23 - 6-24 . . . . . . . . 8
6-25 - 6-26 . . . . . . . . 0
6-27 - 6-28 . . . . . . . . 8
6-29 - 6-33 . . . . . . . . 0
6-34 . . . . . . . . . . . . . . . 4
6-35 - 6-37 . . . . . . . . 0
6-38 . . . . . . . . . . . . . . . 4
6-39 . . . . . . . . . . . . . . . 1
640 - 642 . . . . . . . . 0
6 4 3 - 645 . . . . . . . . 7
646 . . . . . . . . . . . . . . . 0
6 4 7 - 648.0.0000. 7
6-49 - 6-50 . . . . . . . . 9
6-51 . . . . . . . . . . . . . . . 1
6-52 - 6-59 . . . . . . . 0
6-60 . . . . . . . . . . . . . . . 9
6-61 - 6-64 . . . . . . . . 8
6-65 . . . . . . . . . . . . . . . 0
6-66 - 6-68 . . . . . . . 1
6-69 - 6-74 . . . . . . . . 0
6-75 - 6-76 . . . . . . . . 8
6-77 - 6-81 . . . . . . . . 0
6-82 - 6-83 . . . . . . . 3
6-84 . . . . . . . . . . . . . . . 7
6-85 - 6-860.0 . . . . . 3
6-87 - 6-96 . . . . . . . . 8
6-97 -6-l00. . . . . 3
6-101 - 6-103 . . . . . . 8
6-104 Blank . . . . . . . . 8
6-105 - 6-106 . . . . . . 3
6-107 - 6-109 . . . . . . 8
6-110.............9
6-111 - 6-116 . . . . . . 3
6-117 - 6-1180 . . . . . 8
6-119 . . . . . . . . . . . . . . 3
6-120 . . . . . . . . . . . . . . 9
6-120 - 6-120G. . . . . 3
6-120H Blank . . . . . . . 3
6-1201 - 6-120J. . . . 8
6-120K- 6-120M . . . . 3
6-l0N Blank . . . . . . . 3
6-121 - 6-124 . . . . . . 8
6-125 - 6-130 . . . . . . 3
6-130A - 6-130D
Deleted . . . . . . . . . . 3
6-131 - 6-132C
Deleted . . . . . . . . . . 3
6-132D Blank
Deleted . . . . . . . . . . 3
6-133 - 6-135 . . . . . . 3
6-136 Blank . . . . . . . . 3
6-137 . . . . . . . . . . . . . . 3
*Change
Page
No.
No.
6-138 Blank. . . . . 3
6-139 - 6-150. . . . 3
6-151. . . . . . . . . . . . . 8
6-152 Blank . . . . . . . . . . . . 8
6-153 - 6-159. . . . . . . . . 3
6-160 Blank . . . . . . . . . . . .3
6-161 - 6-162 . . . . . . 8
6-163 - 6-174 . . . . . . 3
6-175 - 6-176 . . . . . . 8
6-177 - 6-182 . . . . . . 3
6-182A . . . . . . . . . . . . . 9
6-182B Blank . . . . . . . 9
6-183 - 6-184. . . . . 8
6-185 - 6-188 . . . . . . 3
6-189 - 6-220
Deleted . . . . . . . . . . 3
7-1 . . . . . . . . . . . . . . . . 7
7-2 - 7-4 . . . . . . . . . . 0
7-5 - 7-6 . . . . . . . . . . 8
7-7 - 7-8.. . . . . . 9
7-8A Added . . . . . . . . . 9
7-8B Blank Added. . . 9
7-9 - 7-10 . . . . . . . . . 0
7-11 - 7-12 . . . . . . . . 8
7-13 - 7-14 . . . . . . . . 0
7-15 - 7-16 . . . . . . . . 8
7-17 . . . . . . . . . . . . . . . 7
7-18 - 7-20 . . . . . . . . 0
7-21 - 7-22 . . . . . . . . 8
7-23 - 7-24 . . . . . . . . 0
7-25 . . . . . . . . . . . . . . . 1
7-26 Blank. . . . . . . . 1
8-1 - 8-2 . . . . . . . . . . 8
8-3 - 84 . . . . . . . . . . 0
8-5 - 8-6 . . . . . . . . . . 8
8-7 - 8-12 . . . . . . . . . 0
8-13 - 8-14 . . . . . . . . 8
8-15 - 8-16 . . . . . . . . 1
8-17 - 8-26 . . . . . . . . 8
8-26A Added. . . . . . 8
8-26B Blank Added. . 8
8-27 - 8-28 . . . . . . . . 8
8-29 - 8-30 . . . . . . . . 7
8-31 - 8-38 . . . . . . . . 8
8-39 - 840 . . . . . . . . 0
841 - 842 . . . . . . . . 8
843-844........ . . .. 0
845 . . . . . . . . . . . . . . . 1
8-46. . . . . . . . . . . . . . 0
8 4 7 - 8-50. . . . . . 8
8-51 . . . . . . . . . . . . . . . 1
8-52 - 8-54 . . . . . . . . 0
Change 9 B
TO 35C2-3-442-2
P-8-627-34
TM-07464A-35 TM 5-6115-457-34
LIST OF EFFECTIVE PAGES (cont)
*Change
Page
No.
No.
8-55 - 8-58 . . . . . . . . 8
8-59 . . . . . . . . . . . . . . 1
8-60 . . . . . .. . . . . . 0
8-61 - 8-62 . . . . . . . . 8
8-63 - 8-66. . . . . . 0
8-67 - 8-68 . . . . . . . . 8
8-69 . . . . . . . . . . . . . . . 9
8-70 . . . . . . . . . . . . . . . 2
8-71 . . . . . . . . . . . . . . . 0
8-72 - 8-74 . . . . . . . . 2
8-74A - 8-74B. . . . . . . 2
8-75 - 8-76 . . . . . . . . 8
8-77 - 8-78 . . . . . . . . 0
8-79 . . . . . . . . . . . . . . . 6
8-80 - 8-84 . . . . . . . . 0
8-85 - 8-86 . . . . . . . 2
8-87 - 8-88. . . . . 0
8-89 - 8-92 . . . . . . . . 8
8-93 . . . . . . . . . . . . . . . 0
8 - 9 4 - 8-96 . . . . . . . . 1
8-97 - 8 - 9 8 . . . . 8
8-99 - 8-100 . . . . . . . 0
8-101 - 8-106 . . . . . . 8
8-107 . . . . . . . . . . . . . . 7
8-108 . . . . . . . . . . . . . . 0
8-l09 - 8-114 . . . . . . 8
8-115 - 8-117 . . . . . . 1
8-118 . . . . . . . . . . . . . . 0
8-119 - 8-120 . . . . . . 8
8-121 - 8-122 . . . . . . 0
C
Change 9
Page
*Change
No.
No.
8-123 . . . . . . . . . . . . . . 9
8 - 1 2 4 - 8-130 . . . . . . 8
8-131 - 8-134. . . . 0
8-135 - 8-136 . . . . . . 1
8-137 - 8-138 . . . . . . 8
8-139 - 8-140 . . . . . . 0
8-141 - 8-144 . . . . . . 8
8-145 - 8-146. . . . . . . 0
8-147 - 8-148. . . . . . . 2
9-1 - 9-8 . . . . . . . . . . 8
9-9. . . . . . . . . 0
9-10 Blank . . . . . . . . . 0
9A-l . . . . . . . . . . . . . . . 6
9A-2 Blade . . . . . . . . . 6
10-1 - 10-2 . . . . . . . . 8
10-3 - 10-6 . . . . . . . 0
10-7 . . . . . . . . . . . . . . . 7
10-8 . . . . . . . . . . . . . . . 0
11-1 - 11-2 . . . . . . . . 8
11-3 . . . . . . . . . . .... 1
11-4. . . . . . . . . .. 0
11-5 - 11-6 . . . . . . . . 8
11-7 - 11-11. . . . . 0
11-12 Blank . . . . . . . . 0
12-1 - 12-2 . . . . . . . . 0
12-3 - 12-4. . . . . . . . . . 8
12-5 - 12-6. . . . . . . . 0
12-7 - 12-11 . . . . . . . 8
12-12 Blank . . . . . . . . 8
13-1 - 13-2. . . . . . . 8
Page
*Change
No.
No.
13-3 - 13-4. . . . . . . . . 0
13-5 - 13-6 . . . . . . . . 8
13-7 - 13-8 . . . . . . . . 0
13-9 - 13-10 . . . . . . . 8
13-11 . . . . . . . . . . . . . . 4
13-12 . . . . . . . . . . . . . . 1
13-13 . . . . . . . . . . . . . . 4
1 3 - 1 4 - 13-16 . . . . . . 0
13-17 - 13-18 . . . . . . 8
13-19 . . . . . . . . . . . . . . 0
13-20 . . . . . . . . . . . . . . 1
13-21 - 13-22 . . . . . . 8
14-1 - 14-8
Deleted . . . . . . . . . . 1
A-l . . . . . . . . . . . . . . . . 7
A-2 - A-3 . . . . . . . . . . 0
A-4 Blank . . . . . . . . . . 0
I - 1 - I-2 . . . . . . . . . . 3
I - 3 - I-5 . . . . . . . . . 0
I-6 . . . . . . . . . . . . . . . . 3
I - 7 - I-9 . . . . . . . . . . 0
I-10 . . . . . . . . . . . . . . . 3
I-11 . . . . . . . . . . . . . . . 0
I-12 . . . . . . . . . . . . . . . 3
I-13 . . . . . . . . . . . . . . . 7
I - 1 4 - I-18. . . . . . . . . . 3
I-19. . . . . . . . . . . . . 7
I-20 Blank . . . . . . . . . 7
AIR FORCE T0 35C2-3-442-2
ARMY
TM5-6115-457-34
NAVY
NAVFAC P-8-627-34
MARINE CORPS TM-07464A-35
TECHNICAL MANUAL
INTERMEDIATE (FIELD)
(DIRECT AND GENERAL SUPPORT)
AND DEPOT LEVEL MAINTENANCE
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL
SKID MTD., 100 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS
D0D MODELS
MEPO07A
MEP106A
MEP116A
CLASS
UTILITY
PRECISE
PRECISE
HERTZ
50/60
50/60
400
FSN
6115-OO-133-91O1
6115-OO-133-91O2
6115-OO-133-91O3
INCLUDING OPTIONAL KITS
DOD MODELS
MEP007AWF
MEPO07AWE
MEPO07ALM
MEPO07AWM
NOMENCLATURE
WINTERIZATION KIT, FUEL BURNING
WINTERIZATION KIT, ELECTRIC
DUMMY L0AD KIT
WHEEL MOUNTING KIT
NSN
6115-00-463-9082
6115-00-463-9084
6115-00-463-9086
6115-00-463-9089
Consolidated Diesel Electric Company
Contract Number FO4606.70.D.0192 and FO4606-78-C.-0363
This publication incorporates PCN numbers 1 through 1302 and 1318
Distribution Statement - This publication is required for official use or for administrative or
operational purposes only. Distribution is limited to US Government agencies. other requests for
this document must be referred to Sacramento ALC/MMEDTD, McClellan AFB, CA 95652-5609.
Published under authority of the
Departments of the Air Force, the Army, and the Navy
(Including U.S. Marine Corps)
15 JUNE 1973
CHANGE 8 - 4 APRIL 1984
T.O. 35C2-3-442-2
P-8-627-34
TM-07464A-35 TM 5-6115-457-34
Dates of issue for original and changed pages are:
0riginal..0..15 Mar 73 Change..3..30 Jun 77
Change . . . . 1..31 Jun 75 Change..4..15 Apr 78
Change . . . .2. . 1 May 77 Change..5..2l Sep 79
Change..6.. 2 Jun 81
Change..7..20 May 82
Change..8.. 4 Apr 84
TOTAL NUMBER OF PAGES IN THIS PUBLICATIONS IS 724 CONSISTING OF THE FOLLOWING:
Page
No.
* Change
No.
Title . . . . . . . . . . . . . . 8
A-C..............8
i - ii . . . . . . . . . . . . . 4
iiA Added . . . . . . . . . . 4
iiB Blank Added . . . . 4
i i i - vi . . . . . . . . . . . 3
vii - x . . . . . . . . . . . . 0
xi . . . . . . . . . . . . . . . 2
xii . . . . . . . . . . . . . . . . 6
xiiA Added . . . . . . . . . 4
xiiB Blank Added... 4
x i i i - xiv . . . . . . . . . 4
x v - xvi . . . . . . . . . . . 3
xvii . . . . . . . . . . . . . . . 0
xviii . . . . . . . . . . . . . . 2
xix . . . . . . . . . . . . . . . . 3
xx Blank . . . . . . . . . 3
xxi - xxii Deleted. 3
1-1 . . . . . . . . . . . . . . . . 4
1-2 . . . . . . . . . . . . . . . 3
1-2A - 1-2B . . . . . . . . 4
1-3 - 1-6 . . . . . . . . . . 7
1-6A. . . . . . . . . . . . . . . 3
1-6B - 1-9 . . . . . . . . . 7
l-l0 . . . . . . . . . . . . . . . 0
1-11 . . . . . . . . . . . . . . 4
1-12 . . . . . . . . . . . . . . . 1
1-13- 1-14 . . . . . . . . 3
l-14A Added . . . . . . . . 3
1-14B Blank Added.. 3
1-15 . . . . . . . . . . . . . . . 0
1-16 . . . . . . . . . . . . . . . 7
Page
No.
* Change
No.
1-17 - 1-18 . . . . . . . 0
1-19 . . . . . . . . . . . . . . . 4
1-20- 1-26 . . . . . . . . 0
1-27 . . . . . . . . . . . . . . . 1
1-28 - 1-41 . . . . . . . . 0
1-42 . . . . . . . . . . . . . . . 7
1-43- 1-47 . . . . . . . . 0
1-48 . . . . . . . . . . . . . . . 3
1-49- 1-61. . . . . . . . . . 0
l-62 Blank . . . . . . . . . 0
1-63 . . . . . . . . . . . . . . . 1
l-64 Blank . . . . . . . . . 1
1-65 . . . . . . . . . . . . . . . 3
l-66 Blank . . . . . . . . . 3
1-67 . . . . . . . . . . . . . . . 1
l-68 Blank . . . . . . . . . 1
1-69 . . . . . . . . . . . . . . . 3
l-70 Blank . . . . . . . . . 3
1-71 . . . . . . . . . . . . . . . 3
l-72 Blank . . . . . . . . . 3
1-73 . . . . . . . . . . . . . . . 3
l-74 Blank . . . . . . . . . 3
1-75 . . . . . . . . . . . . . . . 3
1-76 . . . . . . . . . . . . . . . 0
1-77 . . . . . . . . . . . . . . . 7
l-78 Blank . . . . . . . . . 7
1-79- 1-80 . . . . . . . . 0
1-81 . . . . . . . . ... 1
l-82 Blank . . . . . . . . . 1
1-83 - 1-84 . . . . . . . . 0
1-85 . . . . . . . . . . . . . . . 1
l-86 Blank . . . . . . . . . 1
Page
No l
* Change
No l
1-87 . . . . . . . . . . . . . . . 0
l-88 Blank . . . . . . . . . 0
1-89 . . . . . . . . . . . . . . . 0
l-90 Blank . . . . . . . . . 0
1-91. . . . . . . . . . . . . . 8
l-92 Blank . . . . . . . . . 8
1-93 . . . . . . . . . . . . . . . 8
l-94 Blank . . . . . . . . . 8
1-95 . . . . . . . . . . . . . . . 3
l-96 Blank . . . . . . . . . 3
1-97 . . . . . . . . . . . . . 8
l-98 Blank . . . . . . . . . 8
1-99 . . . . . . . . . . . . . . 1
l-100 Blank . . . . . . . . 1
1-101 . . . . . . . . . . . . . . 1
l-102 Blank . . . . . . . . 1
1-103 . . . . . . . . . . . . . . 0
l-104 Blank . . . . . . . . 0
1-105 . . . . . . . . . . . . . . 0
l-106 Blank . . . . . . . . 0
1-107 . . . . . . . . . . . . . . 0
l-108 Blank . . . . . . . . 0
1-109. . . . . . . . . . . . . 0
l-ll0 Blank. . . . . . . . . . . . . 0
1-111 - 1-114 . . . . . . 0
1-115 . . . . . . . . . . . . . . 3
1-116 . . . ........ 1
1-117 - 1-118
..... 0
2-1 . . . . .. . . . . . . . . . 1
2-2 - 2-4 . . . . . . . . . . 0
2-5 - 2-6 . . . . . . . . . . 8
2-7 - 2-8 . . . . . . . . . . 3
*Zero in this column indicates an original page.
USAF
A
Change 8
P-8-627-34 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
LIST OF EFFECTIVE PAGES (cont)
Page
No.
*Change
No.
2-8A Added . . . . . . . . . 3
2-8B Blank Added . . . 3
2-9 - 2-10 . . . . . . . . . 8
2-11.............7
2-12 . . . . . . . . . . 0
2-13 - 2-16 . . . . . . . . 8
2-17 -2-22. . . . . . 0
2-23 - 2-24 . . . . . . . . 7
2-25 . . . . . . . . . . . . . . . 6
2-26 - 2-28 . . . . . . . . 0
2-29 . . . . . . . . . . . . . . . 1
2-30. . . . . . . . . . . .. 0
2-31 . . . . . . . . . . . . . . . 7
2-32 . . . . . . . . . . . . . . . 0
2-33 . . . . . . . . . . . . . . . 6
2-34 - 2-46 . . . . . . . . 3
2-47 - 2-48 . . . . . ...0
2-49 . . . . . . . . . . . . . . . 1
2-50 - 2-56 . . . . . ...0
2-57 - 2-58 . . . . . . . . 8
2-59 - 2-64 . . . . . . . . 4
2-65 - 2-66 . . . . . . . . 8
3-1 - 3-2 . . . . . . . ...0
3-3 - 3-6 . . . . . . . . . . 8
3-7 - 3-10. . . . . . 3
4-1 - 4-4 . . . . . . . . . . 8
4-5 - 4-6 . . . . . . . . . . 1
4-7 - 4-8 . . . . . . . . . . 8
5-1 - 5-2 . . . . . . . . . . 8
5-3 - 5-110 . . . . . . . . 0
5-12 - 5-13 . . . . . . . . 3
5-14 - 5-16. . . . . . . 0
6-1 - 6-4 . . . . . . . . . . 0
6-5 - 6-8 . . . . . . . . . . 8
6-9 . . . . . . . . . . . . . . . . 0
6-10 . . . . . . . . . . . . . . . 1
6-11 - 6-12 . . . . . . . . 8
6-13 . . . . . . . . . . . . . . . 0
6-14 . . . . . . . . . . . . . . . 3
6-15 . . . . . . . . . . . . . . . 0
6-16 Blank . . . . . . . . . 0
6-17 . . . . . . . . . . . . . . . 0
6-18 Blank . . . . . . . . . 0
6-19 - 6-20 . . . . . . . . 3
6-20A Added . . . . . . . . 3
6-20B Blank Added.. 3
6-21 . . . . . . . . . . . . . . . 3
6-22 . . . . . . . . . . . . . . . 0
6-23 - 6-24 . . . . . . . . 8
6-25 - 6-26 . . . . . . . . 0
6-27 - 6-28 . . . . . . . . 8
Page
No.
*Change
No.
6-29 - 6-33 . . . . . . . . 0
6-34 . . . . . . . . . . . . . . . 4
6-35 - 6-37 . . . . . . . . 0
6-38 . . . . . . . . . . . . . . . 4
6-390 . . . . . . . . . . . . . . 1
6-40 - 6-42 . . . . . . . . 0
6-43 - 6-45 . . . . . . . . 7
6-46 . . . . . . . . . . . . . . . 0
6-47 - 6-48 . . . . . . . . 7
6-49 - 6-50 . . . . . . . . 8
6-51 . . . . . . . . . . . . . . . 1
6-52 - 6-59 . . . . . . . . 0
6-60 . . ..00 . . . . . . . . . 1
6-61 - 6-64 . . . . . . . . 8
6-65 . . . . . . . . . . . ... 0
6-66-6-68. . . . . . . . 1
6-69 - 6-74 . . . . . . . . 0
6-75 - 6-76 . . . . . . . . 8
6-77 - 6-81.. . . . . . 0
6-82 - 6-83 . . . . . . . . 3
6-84 . . . . . . . . . .. 7
6-85 - 6-86 . . . . . . . . 3
6-87 - 6-96 . . . . . . . . 8
6-97 - 6-100. . . . . . 3
6-101 - 6-103 . . . . . . 8
6-104 Blank. . . . . . . 8
6-105 - 6-106 . . . . . . 3
6-107 - 6-110. . . . . . . . 8
6-111 - 6-116. . . . . 3
6-117 - 6-118 . . . . . . 8
6-119 - 6-120. . . . 3
6-120A - 6-120G . . . . 3
6-120H Blank . . . . . 3
6-1201- 6-120J . . . . 8
6-120K - 6-120M. . . 3
6-120N Blank . . . . . . . 3
6-121 - 6-124 . . . . . . 8
6-125 - 6-130 . . . . . . 3
6-130A - 6-130D
Deleted . . . . . . . . . . 3
6-131 - 6-132C
Deleted . . . . . . . . . . 3
6-132D Blank
Deleted . . . . . . . . . . 3
6-133 - 6-135 . . . . . . 3
6-136 Blank . . . . . . . . 3
6-137 . . . . . . . . . . . . . . 3
6-138 Blank . . . . . . . . 3
6-139 - 6-150 . . . . . . 3
6-151 . . . . . . . . .. 8
6-152 Blank . . . . . . . . 8
Page
No.
*Change
No.
6-153 - 6-159 . . . . . . 3
6-160 Blank . . . . . . . . 3
6-161 - 6-162 . . . . . . 8
6-163 - 6-174 . . . . . . 3
6-175 - 6-176 . . . . . . 8
6-177 - 6-182 . . . . . . 3
6-182A . . . . . . . . . . . . . 8
6-182B Blank . . . . . . . 8
6-183 - 6-184 . . . . . . 8
6-185- 6-219 . . . . . . 3
6-220 Deleted . . . . . . 3
7-1 . . . . . . . . . . . . . . . . 7
7-2 - 7-4 . . . . . . . . . . 0
7-5 - 7-8 . . . . . . . . . . 8
7-9 - 7-10. . . . . 0
7-11 - 7-12 . . . . . . . . 8
7-13 - 7-140. . . . . .0
7-15- 7-16 . . . . . . . . 8
7-17. . . . . . . . . . . . . . . 7
7-18 - 7-20 . . . . . . . . 0
7-21 - 7-22 . . . . . . . . 8
7-23 - 7-24 . . . . . ...0
7-25 . . . . . . . . . . . . . . . 1
7-26 Blank . . . . . . . . . 1
8-1 - 8-2 . . . . . . . . . . 8
8-3 - 8-4 . . . . . . . ...0
8-5 - 8-6 . . . . . . . . . . 8
8-7 - 8-12 . . . . . . . . . 0
8-13 - 8-14 . . . . . . . . 8
8-15 - 8-16 . . . . . . . . 1
8-17 - 8-26 . . . . . . . . 8
8-26A Added . . . . . . . . 8
8-26B Blank Added.. 8
8-27 - 8-28 . . . . . . . . 8
8-29 -8-30. . . . . . 7
8-31 - 8-38 . . . . . . . . 8
8-39 - 8-40 . . . . . . . . 0
8-41 - 8-42 . . . . . . . . 8
8-43 - 8-44 . . . . . . . . 0
8-45 . . . . . . . . . . . . . . . 1
8-46 . . . . . . . . . . . . . . . 0
8-47 - 8-50 . . . . . . . . 8
8-51 . . . . . . . . . . . . . . . 1
8-52 - 8-54 . . . . . . . . 0
8-55 - 8-58 . . . . . . . . 8
8-59 . . . . . . . . . . . . . . . 1
8-60 . . . . . . . . . . . . . . 0
8-61 - 8-62 . . . . . . . . 8
8-63 - 8-66 . . . . . . . . 0
8-67 - 8-68 . . . . . . . . 8
8-69 . . . . . . . . . . . . . . . 0
Change 8 B
P-8-627-34
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
LIST OF EFFECTIVE PAGES (cont)
Page
No.
*Change
No.
8-70 . . . . . . . . . . . . . . . 2
8-71 . . . . . . . . . . . . . . . 0
8-72 - 8-74 . . . . . . . . 2
8-74A - 8-74B . . . . . . 2
8-75 - 8-76 . . . . . . . . 8
8-77 - 8-78 . . . . . . . . 0
8-79 . . . . . . . . . . . . . . . 6
8-80 - 8-84 . . . . . . . . 0
8-85 - 8-86 . . . . . . . . 2
8-87 - 8-88. . . . . . . 0
8-89 - 8-92 . . . . . . . . 8
8-93 . . . . . . . . . 0
8-94 - 8-96 . . . . . . . . 1
8-97 - 8-98 . . . . . . . . 8
8-99 - 8-100 . . . . . . . 0
8-101 - 8-106 . . . . . . 8
8-107 . . . . . . . . . . . . . . 7
8-108 . . . . . . . . . . . . . 0
8-109 - 8-114 . . . . . . 8
8-115 - 8-117 . . . . . . 1
8-118............0
8-119 - 8-120 . . . . . . 8
8-121 - 8-122 . . . ...0
8-123 - 8-130 . . . . . . 8
8-131 - 8-134 . . . ...0
8-135 - 8-136 . . . . . . 1
8-137 - 8-138 . . . . . . 8
C
Change 8
Page
No.
*Change
No.
8-139 - 8-140 . . . . . . 0
8-141 - 8 - 1 4 4 . . . . 8
8-145 - 8-146 . . . . . . 0
8-147 - 8-148 . . . . . . 2
9-1 - 9-8 . . . . . . . . . . 8
9-9............0
9-10 Blank . . . . . . . . . 0
10-1 - 10-2 . . . . ... 8
10-3 - 10-6 . . . . . . . . 0
10-7 . . . . ........ 7
10-8.. . . . ....... 0
11-1 - 11-2 . . . . . . . 8
11-3 . . . . . . . . . . . . . . . 1
11-4. . . . . . . . . . . . . . 0
11-5 - 11-6. . . . . . 8
11-7 - 11-110 . . . . . . 0
11-12 Blank . . . . . . . . 0
12-1 - 12-2 . . . . . . . . 0
12-3- 12-4 . . . . . . . . 8
12-5 - 12-6 . . . . . . . . 0
12-7 - 12-11 . . . . . . . 8
12-12 Blank . . . . . . . . 8
13-1- 13-2 . . . . . . . . 8
13-3 - 13-4 . . . . . . . . 0
13-5- 13-6 . . . . . . . 8
13-7 - 13-8 . . . . . . . . 0
13-9 - 13-10 . . . . . 8
Page
No.
*Change
No.
13-11 . . . . . . . . . . . . . . 4
13-12 . . . . . . . . . . . . . . 1
13-13 . . . . . . . . . . . . . . 4
13-14 - 13-16 . . . . . . 0
13-17 - 13-18 . . . . . . 8
13-19 . . . . . . . . ..... 0
13-20 . . . . . . . . . . . . . . 1
13-21 - 13-22 . . . . . . 8
14-1 - 14-8
Deleted . . . . . . . . . . 1
A-l . . . . . . . . . . . . . . . . 7
A-2 - A-3 . . . . . . . . . . 0
A-4 Blank . . . . . . . . . . 0
I-1 - I-2 . . . . . . . . . . 3
I-3 - 1-5 . . . . . . . . . . 0
I-6 . . . . . . . . . . . . . . . . 3
I-7 - 1-9... . . . . . 0
I-10 . . . . . . . . . . . . . . . 3
I-11 . . . . . . . . . . . . . . . 0
I-12 . . . . . . . . . . . . . . . 3
I-13 . . . . . . . . . . . . . . . 7
I-14 - 1-18. . . . . . . 3
I-19 . . . . . . . . . . . . . . . 7
I-20 Blank . . . . . . . . . 7
AIR FORCE T.O. 35C2-3-442-2
ARMY
TM5-6115-457-34
NAVY
NAVFAC P-8-627-34
MARINE CORPS TM-07464A-35
TECHNICAL MANUAL
INTERMEDIATE (FIELD)
(DIRECT AND GENERAL SUPPORT)
AND DEPOT LEVEL MAINTENANCE
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL
SKID MTD., 100 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS
DOD MODELS
MEPO07A
MEP106A
MEP116A
CLASS
UTILITY
PRECISE
PRECISE
HERTZ
50/60
50/60
400
FSN
6115-0O-133-91O1
6115-00-133-9102
6115-00-133-9103
INCLUDING OPTIONAL KITS
DOD MODELS
MEPO07AWF
MEPO07AWE
MEPO07ALM
MEPO07AWM
NOMENCLATURE
WINTERIZATION KIT, FUEL BURNING
WINTERIZATION KIT, ELECTRIC
DUMMY L0AD KIT
WHEEL MOUNTING KIT
NSN
6115-00-463-9082
6115-00-463-9084
6115-00-463-9086
6115-00-463-9089
Consolidated Diesal Electric Company
Contract Number FO4606-70-D.0192 and FO4606-78-C-0363
This publication incorporates PCN numbers 1 through 1302 and 1318
Distribution Statement. This publication is required for official use or for administrative or
operational purposes onlu. Distribution is limited to US Government agencies. Other requests
for this document must be referred to Sacremento ALC/MMEDPD< McClellan AFB, CA 95652.
Published under authority of the
Departments of the Air Force, the Army, and the Navy
(Including U. S. Marine Corps)
15 JUNE 1973
CHANGE 7-20 MAY 1982
P-9-TM-457-35 T O 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
LIST OF EFFECTIVE PAGES
Insert latest changed pages; dispose of superseded pages in accordance with aplicable regulations.
NOTE: On a changed page, the portion of the text affected by the latest change is indicated by a vertical
line, or other change symbol. in the outer margin of the page. Changes to illustrations are indicated by
miniature pointing hands. Changes to wiring diagrams are indicated by shaded areas.
Total number of pages in this manual is 724 consisting of the following:
Page No.
# Change No.
Title . . . . . . . . . . . . . . . . . . 7
A.................... 7
B.................... 7
c.................... 7
i - i i . . . . . . . . 4
iiA Added . . . . . . . . . 4
iiB Blank Added . . . . 4
iii-vi . . . . . . . . . . . 3
vii-x . . . . . . . . . . 0
xi . . . . . . . . . . . . 2
CFL . . . . . . . . . . 6
xiiA Added . . . . . . . . 4
xiiB Blank Added . . . . . 4
xiii-xiv . . . . . . . 4
xv-xvi . . . . . . . . . . 3
xvii . . . . . . . . . . . . 0
xviii . . . . . . . . . . 2
3
xix . . . . . . . .
xx Blank . . . . . . . . . 3
xxi-xxii Deleted . . . . . 3
1-1 . . . . . . . . . . . 4
1-2 . . . . . . . . .. 3
1-2A - 1-2B . . . . . . . . 4
1-3 - 1-6 . . . . . . . . . . ...7
1-6A . . . . . . . . . . . . . ...3
1-6B . . . . . . . . . . . . . . . ...7
1-7 - 1-9 . . . . . . . . . . . ...7
1-8 - 1-9 . . . . . . . . . 1
l-l0 . . . . . . . . . . . . 0
1-11 . . . ........ 4
1-12 . . . . . . . . .. 1
1-13-1-14 . . . . ... 3
l-l4A Added . . . . . . . 3
l-14B Blank Added . . . . 3
1-15 . . . . . . . . . . . . 0
1-16 . . . . . . . . . . . . 7
1-17-1-18 . . . . . . . . 0
1-19 . . . . . . . . . . . . 4
1-20 - 1-26 . . . . . . . . 0
A Change 7
# Change No.
1
1-27. . . . . . . . . . . . .
0
1-28 - 1-41 . . . . . .
7
1-42 . . . . . . . . . . .
0
1-43-1-47......
3
1-48 . . . . . . . . . . .
0
1-49 - 1-61 . . . . . . . .
0
l-62 Blank . . . . . . . .
1
1-63 . . . . . . . . . . . .
0
l-64 Blank . . . . . . . .
3
1-65 . . . . . . . . . . . .
0
l-66 Blank . . . . . . . .
1
1-67 . . . . . . . . . . .
0
l-68 Blank . . . . . . .
3
1-69 . . . . . . . . . . . .
0
l-70 Blank . . . . . . . .
3
1-71 . . . . . . . . . . .
0
l-72 Blank . . . . . . . .
3
1-73. . . . . . .
0
l-74 Blank . . . . . . . .
3
1-75 . . . . . . ...
0
1-76 . . . . . . . . . . . .
7
1-77 . . . . . . . . .
0
l-78 Blank . . . . . . . .
0
1-79 - 1-80 . . . . . . . .
1
1-81 . . . . . . . . . ..
0
l-82 Blank . . . . . . . .
0
1-83-1-64 . . . . . . . .
1
1-65 . . . . . . . . . . .
0
l-86 Blank . . . . . . . . .
0
1-87 . . . . . . . . . . . .
0
l-88 Blank . . . . .
0
1-89 . . . . . . . . . . .
0
l-90 Blank . . . . . . . .
3
1-91 . . . . . . . . . . . .
0
l-92 Blank . . . . . . . .
3
1-93 . . . . . . . . . . . .
0
l-64 Blank . . . . . . . .
3
1 - 9 5 . . . . . . . . . .
0
l-96 Blank . . . . . .
3
1-97 . . . . . . . . .
Page No.
Page No.
# Change No.
0
l-98 Blank . . . . . . . .
1-99 . . . . . . . . . . . .
1
0
l-100 Blank . . . . . . .
1
1-101 . . . . . . . .
0
l-102 Blank . . . . . . .
0
1-103.........
0
l-104 Blank . . . . . . .
0
l-l05 . . . . . ..
0
l-108 Blank . . . . . . .
0
l-l07 . . . . . . . . . .
0
l-108 Blank . . . . . .
0
1-108 . . . . . . . . . . .
0
l-ll0 Blank . . . . . . .
0
1-111 - 1-114 . . . . . .
3
1-115 . . . . . . . . .
1
1-116 . . . . . . . . . . .
0
1-117-1-118 . . . . . .
1
2-1. . . . . . . . . . . . . .
2-2 - 2-4 . . . . . . . . . . . ...0
2-5 . . . . . . . . . . . . . . . . . . 7
2-6 - 2-8 . . . . . . . . . . . . . 3
2-8A Added. . . . . . . . . . . . 33
2-8B Blank Added . . . . . . . .
2-9 - 2-10. . . . . . . . . . . . . 07
........
........ 0
2-13 . . . . . . . . . . . . . . . . . 10
2-14 . . . . . . . . . . . . . . . . . 1
2-15 . . . . . . . . . . . . . . . . . 0
2-16 - 2-23 . . . . . . . . . . . .
2-24 . . . . . . . . . . . . . . . . . 7
2-25 . . . . . . . . . . . . . . . . . 6
2-26 - 2-28 . . . . . . . . . . . . 0
2-29 . . . . . . . . . . . . . . . . . 1
2-30 . . . . . . . . . . . . . . . . . 0
2-31 . . . . . . . . . . . . . . . . 7
2-32 . . . . . . . . . . . . . . . ...0
2-33 . . . . . . . . . . . . . . . ...6
2-34 – 2-46 . . . . . . . . . . ...3
2-47–2-48 . . . . . . . . . . . ..0
2-49 . . . . . . . . . . . . . . . ...1
2-50 – 2-56 . . . . . . . . . . . ..0
2-57 - 2-66 . . . . . . . . . . ...4
3-1 - 3-6 . . . . . . . . . . . . . . 0
AIR FORCE T.O. 35C2-3-442-2
ARMY
TM5-6115-457-34
NAVY
NAVFAC P-8-627-34
MARINE CORPS TM-07464A-35
TECHNICAL MANUAL
INTERMEDIATE (FIELD)
(DIRECT AND GENERAL SUPPORT]
AND DEPOT LEVEL MAINTENANCE
GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL
SKID MTD., 100 KW, 3 PHASE, 4 WIRE, 120/208 AND 240/416 VOLTS
DOD MODELS
MEPO07A
MEP106A
MEP116A
CLASS
UTILITY
PRECISE
PRECISE
HERTZ
50/60
50/60
400
FSN
6115-00-133-9101
6115-00-133-9102
6115-00-133-9103
INCLUDING OPTIONAL KITS
DOD MODELS
MEPO07AWF
MEPO07AWE
MEPO07ALM
MEPO07AWM
NSN
NOMENCLATURE
WINTERIZATION KIT, FUEL BURNING 6115-00-463-9082
6115-00-463-9084
WINTERIZATION KIT, ELECTRIC
6115-00-463-9088
DUMMY L0AD KIT
6115-00-463-9089
WHEEL MOUNTING KIT
THIS PUBLICATION REPLACES TO 35c2-3-442-2s-2 DATED 8 JULY 1980 AND TO
3502-3-442-2C DATED 29 AUGUST 1978.
Consolidated Diesel Electric Company
Contract Number FO4606-70-D-0192 and FO4606-78-C-0363
This publication incorporates PCN numbers 1 through 1302 and 1318
Distribution Statement - This publication is required for official use or for administrative
operational purposes only. Distribution is limited to US Government agencies. Other requests
for this document must be referred to Sacramento ALC/MMEDPD, McClellan AFB, CA 95652.
Published under authority of the
Departments of the Air Force, the Army, and the Navy
(Including U.S. Marine Corps)
15 JUNE 1973
CHANGE 6-2 JUNE 1981
P-9-TM-457-35 T O 35C2-3-442-2
TM-07464A-35 TM 5-6115 -457-34
LIST OF EFFECTIVE PAGES
Insert latest changed pages; dispose of superseded pages in accordance with applicable regulations.
NOTE: On a changed page, the poetion of the text affected by the latest change is indicated by a vertical
line, or other change symbol, in the outer margin of the page. Changes to illustrations are indicated by
miniature pointing hands. Changes to wiring diagrams are indicated by shaded areas.
Total number of pages in this manual is 724 consisting of the following:
Page No.
# Change No.
Title . . . . . . . . . . . .
A . . . . . . . . . . ..
B . . . . . . . . . . . . .
c . . . . . . . . . . . . .
i-ii . . . . . . . . . . .
iiA Added . . . . . . . . .
iiB Blank Added . . . . . .
iii-vi . . . . . . . . . . .
vii - x . . . . . . . . . . .
xi . . . . . . . . . . . .
xii . . . . . . . . . . . .
xiiA Added . . . . . . . .
xiiB Blank Added . . . . .
xiii - xiv. . . . . . . . .
xv - xvi . . . . . . . . . .
xvii . . . . . . . . . . . .
xviii . . . . . . . . . . . .
xix . . . . . . . . . . . .
xx Blank . . . . . . . . .
xxi-xxii Deleted . . . . .
1-1 . . . . . . . . . . . .
1-2 . . . . . . . . . . . .
1-2A - 1-2B . . . . . . . .
1-3 . . . . . . . . . . . .
1-4 . . . . . . . . . . . .
1-5 - 1-6 . . . . . . . . .
1-6A - 1-6B Added . . . .
1-7 . . . . . . . . ...
1-8 - 1-9 . . . . . . . . .
l-l0 . . . . . . . . . . . .
1-11 . . . . . . . . . . . .
1-12 . . . . . . . . . . . .
1-13-1-14 . . . . . . . .
l-14A Added . . . . . . .
l-14B Blank Added . . . .
1-15 . . . . . . . . . . . .
1-16 . . . . . . . . . . . .
1-17-1-18 . . . . . . . .
1-19 . . . . . . . . . . . .
1-20-1-26 . . . . . . . .
A
Change 6
6
6
6
6
4
4
4
3
0
2
6
4
4
4
3
0
2
3
3
3
4
3
4
3
0
3
3
3
1
0
4
1
3
3
3
0
1
0
4
0
# Change No.
1
1-27 . . . . . . . . . . . . . .
0
1-28 - 1-41 . . . . . . . .
6
1-42. . . . . . . . . . . . . . .
0
1-43 -1-47 . . . . . . . .
3
1-48 . . . . . . . . . . . .
0
1-49 - 1-61 . . . . . . . .
0
l-62 Blank . . . . . . . .
1
1-63 . . . . . . . . . . . .
0
l-64 Blank . . . . . . . .
3
1-65 . . . . . . . . . . . .
0
l-66 Blank . . . . . . . .
1
1-67 . . . . . . . . . . . .
0
l-68 Blank . . . . . . .
3
1-69 . . . . . . . . . . . .
0
l-70 Blank . . . . . . . .
3
1-71 . . . . . . . . . . . .
0
l-72 Blank . . . . . . . .
3
1-73 . . . . . . . . . . . .
0
l-74 Blank . . . . . . . .
3
1-75 . . . . . . . . . . . .
0
1-76 . . . . . . . . . . . .
1
1-77 . . . . . . . . . . . .
0
l-78 Blank . . . . . . . .
0
1-79 - 1-80 . . . . . . . .
1
1-81 . . . . . . . . . . . .
0
l-82 Blank . . . . . . . .
0
1-83 - 1-64 . . . . . . . .
1
1-85 . . . . . . . . . . . .
0
l-86 Blank . . . . . . . .
0
1-87 . . . . . . . . . . . .
0
l-88 Blank . . . . . . . .
0
1-89 . . . . . . . . . . . .
0
l-90 Blank . . . . . . . .
3
1-91 . . . . . . . . . . . .
0
l-92 Blank . . . . . . . .
3
1-93 . . . . . . . . . . . .
0
l-94 Blank . . . . . . . .
3
1-95 . . . . . . . . . . . .
0
l-96 Blank . . . . . . . .
3
1-97 . . . . . . . . . . .
Page No.
Page No.
#Change No.
l-96 Blank . . . . . . . .
0
1 - 9 9 . . . . . . . . .
1
0
l-100 Blank . . . . . . .
1
1-101 . . . . . . . . . . .
0
l-102 Blank . . . . . . .
0
1-103 . . . . . . . . . . .
0
l-104 Blank . . . . . . .
0
1-105 . . . . . . . . . . .
0
l-106 Blank . . . . . . .
0
1-107 . . . . . . . . . . .
0
l-108 Blank . . . . . . .
0
1-109 . . . . . . . . . . .
0
1-110 Blank . . . . . . .
0
1-111 - 1-114 . . . . . .
3
1-115 . . . . . . . . . . .
1
1-116 . . . . . . . . . . .
0
1-117 - 1-118 . . . . . .
1
2-1 . . . . . . . . . . . .
0
2-2 - 2-5 . . . . . . . . .
3
2-6 - 2-8 . . . . . . . . .
3
2-8A Added . . . . . . .
3
2-8B Blank Added . . . .
0
2-9 - 2-10 . . . . . . . .
4
2-11 . . . . . . . . . . .
0
2-12 . . . . . ...
1
2-13 . . . . . . . . . . .
0
2-14 . . . . . . . . . .
1
2-15 . . . . . . . . . . .
2-16 - 2-24 . . . . . . . . 0
2-25 . . . . . . . . . . 6
2-26 - 2-28. . . . . . . . . 0
2-29. . . . . . . . . . . . . . . 1
2-30-2-32. . . . . . . . . . . . . 0
243 . . . . . . . . . ...6
2-34 -246 . . . . . . ...3
2-47-2-48 . . . . . . . 0
249 . . . . . . . . . . . 1
2-50-2-58 . . . . . . . 0
2-57-2-66 . . . . . . . 4
3-1 -3-6 . . . . . . . . 0
P-9-TM-457-35 T O 35C2-3-442-2
TM-07464A-35 TM 5-6115 -457-34
LIST OF EFFECTIVE PAGES
Change 7 B
P-9-TM-457-35 T O 35C2-3-442-2
TM-074641-35 TM 5-6115-457 -34
Reproduction for non-military use of the information or illustrations contained in thid publication is not permitted. The policy for military use reproduction is established for the Army
in AR 380 5. for the Navy and Marine Corps in OPNAVINST 5510.1.B. and for the Air Force
in Air Force Regulation 205-1.
LIST OF EFFECTIVE PAGES
NOTE:
On a changed page, the portion of the text affected by the latest change is indicated by a vertical
Inc. or other change symbol, in the outer margin of the page. Changes to illustrations are indicated by
miniature pointing hands. Changes to wiring diagrams are indicated by shaded areas.
Page No.
# Change No.
13-1 . . . . . . . . . . 1
13-2 - 13-4 . . . . . . . 0
13-5 . . . . . . . 1
13-6 - 13-10 . . . . . . . 0
13-11 . . . . . . . . . . 4
13-12 . . . . . . . . . . . 1
13-13 . . . . . . . . . . . 4
13-14 - 13-17 . . . . . . 0
13-18 . . . . . . . . . . . 4
13-19 . . . . . . . . . . . 0
13-20 - 13-21 . . . . . . 1
13-22. . . . . . . .. 4
14-1 - 14-8 Deleted . . . . 1
A-1 . . . . . . . . . . . . . . . ...7
A-2 – A-3 . . . . . . . . . . . . . .0
A4 Blank . . . . . . . . . . . . . .0
I-l - I-2 . . . . . . . . . . . . ...3
I-3 – I-5 . . . . . . . . . . . . ...0
I-6 . . . . . . . . . . . . . . . . ...3
I-7 – I-9 . . . . . . . . . . . ...0
I-10 . . . . . . . . . . . . . . ...3
I-11 . . . . . . . . . . . . . . . ...0
I-12 . . . . . . . . . . . . . . . ...3
I-13 . . . . . . . . . . . . . . . ...7
I-14 – I-18 . . . . . . . . . . ...3
I-19 . . . . . . . . . . . . . . . ...7
I-20 Blank . . . . . . . . . . . ...7
NOTE: THE CORRECT DEPARTMENT OF NAVY NUMBER IS NAVFAC P-8-627-34.
C Change 7
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
TABLE OF CONTENTS
Page
Section
LIST OF ILLUSTRATIONS . . . . . .
xiii
LIST OF TABLES . . . . . . . . . . . .
xix
SAFETY SUMMARY . . . . . . . . . .
xxi
III
II
GENERAL . . . . . . . . . . .
1-1. Scope . . . . . . .
1-2. Forms and Records
1-2A. Time Compliance
Technical Orders
DESCRIPTION AND DATA
1-3.
1-4.
..
. .
. .
1-1
1-1
1-1
IV
1-2A
1-2A
CHAPTER 2- GENERAL
MAINTENANCE INSTRUCTIONS
I
REPAIR PARTS, SPECIAL
TOOLS , AND
EQUIPMENT. . . . . . . 2-1
2-1.
2-2.
2-3.
II
Special Tools and
Equipment . . . . . . . 2-1
Organizational, Intermediate (Field)
(Direct Support and
General Support) and
Depot Maintenance
Repair Parts . . . . . 2-1
Specially Designed
(Fabricated) Tools
and Equipment . . . . 2-1
TROUBLESHOOTING . . . . . . 2-3
2-4
General . . . . . . . . . . 2-3
.
.
.
.
.
2-3
2-3
2-4
2-11
2-17
General . . . . . . . .
Engine Removal,
D333C(T) Engine . . .
2-12. Removal of Salvageable
Components from the
D333C(T) Engine . .
2-13. Installation of Components, D3306(T)
Engine . . . . . . .
2-58
General . . . . . .
Control Cubicle . . .
Generator . . . . .
Engine D333C(T) .
Wheel Mounting Kit
.
.
.
.
.
ENGINE CHANGE INSTRUCTIONS, D3306(T) ENGINE
2-10.
2-11.
. . 1-2
. . .1-2
Description. . . . . . . .
Tabulated Data . . . . .
REMOVAL AND INSTALLATION
OF MAJOR COMPONENTS
AND AUXILIARIES . . . . . 2-3
2-5.
2-6.
2-7.
2-8.
2-9.
CHAPTER 1 - INTRODUCTION
I
Page
Section
2-58
2-58
2-58
CHAPTER 3 - HOUSING AND
LIFTING FRAME ASSEMBLY
REPAIR INSTRUCTIONS
I
HOUSING FRAME . . . . . .
3-1
3-1.
3-2.
.. ..
3-1
.
.
.
.
.
.
.
.
3-1
3-4
3-4
3-4
. . .
3-4
LIFTING FRAME
ASSEMBLY . . . . . . . .
3-5
3-7.
3-5
3-3.
3-4.
3-5.
3-6.
II
General . .
Removal and
Disassembly .
Cleaning . . . .
Inspection . . .
Repair . . . . .
Reassembly and
Installation . .
.
.
.
.
General . . . . . . .
Change 4
i
T.O. 35C2-3-442-2
P-9-TM-457-35
TM-07464A-35 TM 5-6115-457-34
TABLE OF CONTENTS (Continued)
Page
Section
3-8.
3-9.
3-10.
3-11.
ii
Removal . .
Disassembly
Cleaning .
Inspection .
Change 4
.
.
.
.
. . .
. .
. .
. . .
. 3-5
. 3-5
...3-5
. 3-5
Section
3-12.
3-13.
3-14.
Page
Repair . . . . . . . . . 3-6
Reassembly . . . . . . 3-7
Installation . . . . . . 3-7
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
TABLE OF CONTENTS (Continued)
Section
Page
Section
4-32. Reassembly . . . . . ..4-7
4-33. Installation . . . . . . .4-7
CHAPTER 4 - RADIATOR AND
SHUTTER ASSEMBLY REPAIR
INSTRUCTIONS
I
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.
II
CHAPTER 5 - ELECTRICAL CONTROLS
WIRING HARNESSES REPAIR
INSTRUCTIONS
RADIATOR ASSEMBLY . . . . .4-1
4-1.
4-2.
General . . . . . . . . .4-l
Upper and Lower
Shroud and Shroud
Plate . . . . . . . . . ..4-l
Removal . . . . . . . . . .4-l
Arming . . . . . . . . .4-l
Inspection. . . . . . . . . 4-1
Repair . . . . . . . . . . .4-l
Installation . . . . . . . 4-1
Radiator........4-l
Removal . . . . . . . . . .4-l
Test . . . . . . . . . . ..4-l
Disassembly . . . . . . 4-2
Cleaning . . . . . . . . .4-2
Inspection . . . . . . . .4-3
Repair . . . . . . . . . . .4-3
Reassembly . . . . . . . 4-4
Installation . . . . . . . . 4-4
SHUTTER AND CONTROL
ASSEMBLY. . . . . . . .4-4
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.
General . . . . . . . ...4-4
Control Assembly . . .4-4
Removal. . . . . . . . . .4-4
Disassembly . . . . . . .4-4
Cleaning . . . . . . . ...4-4
Inspection. . . . . . . . .4-5
Repair . . . . . . . . ...4-5
Reassembly . . . . . ..4-5
Installation . . . . . . 4-6
Shutter. . . . . . . . . .4-6
Removal. . . . . . . . . .4-6
Disassembly . . . . . . .4-6
Cleaning. . . . . . . . . .4-6
Inspection. . . . . . . . . 4-7
Repair . . . . . . . . ...4-7
Page
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
General . . .
Removal . . .
Cleaning . . .
Inspection. . .
Rebuild . . . .
Installation . .
.
.
.
.
.
.
. . . ...5-l
. . . . .5-2
. . . . .5-2
. . . . 5-2
. . . . ..5-2
. . . . 5-3
CHAPTER 6 - GENERATOR SET
CONTROL GROUP REPAIR
INSTRUCTIONS
I
CONTROL CUBICLE
6-1.
6-2.
6-3.
6-4.
6-5.
6-6.
6-7.
6-8.
6-9.
6-10.
6-11.
6-12.
6-13.
6-14.
6-15.
6-16.
6-17.
6-18.
6-19.
6-20.
6-21,
6-22.
6-1
General . . . . . . . . .6-l
Thermal Watt
Converter (Al) . . . . 6-1
Test on Equipment . . 6-1
Cleaning . . . . . . . . 6-2
Inspection . . . . . . . . 6-2
Test . . . . . . . . ...6-2
Installation . . . . . . . 6-2
Frequency Meter (M6)
and Transducer (A2) . 6-2
Test on Equipment . . 6-2
Cleaning . . . . . . ...6-3
Inspection . . . . . . . . 6-4
Test . . . . . . . . . ...6-4
Installation . . . . . . . 6-4
Control Box Relay
Assembly (A4) . . . . 6-4
Test on Equipment . . . 6-4
Test . . . . . . . . . ..6-5
Disassembly . . . . . . 6-6
Cleaning . . . . . . ...6-6
Inspection . . . . . . . . 6-6
Repair, , . . . . . ...6-8
Reassembly . . . . . . . 6-8
Installation . . . . . . . 6-9
Change 4
iiA/(iiB blank)
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
TABLE OF CONTENTS (Continued)
Section
6-23.
6-24.
6-25.
6-26.
6-27.
6-28.
6-29.
6-30,
6-31.
6-32.
6-33.
6-34.
6-35.
6-36.
6-37.
6-38.
6-39.
II
AC Current Meter (M8) 6-9
Test on Equipment . . 6-9
Cleaning . . . . . . . . .6-l0
Inspection . . . . . . . . 6-10
Test . . . . . . . . . ...6-10
Installation . . . . . . . 6-10
Control Cubicle . . . . 6-10
Test on Equipment. . . 6-10
Disassembly . . . . . . 6-10
Cleaning . . . . . . . . .6-11
Inspection . . . . . . . . 6-11
Repair . . . . . . . . . .6-11
Rebuild . . . . . . . . . .6-l3
Reassembly . . . . . . . 6-13
Test . . . . . . . . . ...6-13
Installation . . . . . . 6-13
Adjustment . . . . . . . 6-13
Section
IV
General . . . . . . . . . .6-20
Removal. . . . . . . . .6-20
Disassembly . . . . . ..6-20
Cleaning. . . . . . . . . 6-20
Inspection . . . . . . . .6-20
Repair . . . . . . . . . . .6-21
Reassembly . . . . . . 6-21
Installation . . . . . . . . 6-21
6-59.
6-60.
6-61.
6-62.
6-63.
6-64.
6-65.
6-66,
FAULT LOCATING INDICATOR
BOX. . . . . . . . .6-22
6-48.
6-49.
6-50.
6-51.
6-52.
6-53.
6-54.
6-55.
6-56.
General . . . . . . . ...6-22
Test On Equipmerit . . . . . . . . ...6-22
Test . . . . . . . . . ...6-23
Disassembly . . . . . . .6-23
Cleaning . . . . . . . ...6-23
Inspection. . . . . . . . .6-23
Repair . . . . . . . ...6-27
Reassembly . . . . . .6-27
Installation . . . . . . . .6-29
6-67,
6-68.
6-69.
6-70.
6-71.
6-72.
6-73.
V
Page
CONVENIENCE RECEPTACLE
ASSEMBLY . . . . . ...6-33
6-57.
6-58.
DC CIRCUIT BREAKER
BOX. . . . . . . . . . .6-20
6-40.
6-41.
6-42.
6-43.
6-44.
6-45.
6-46.
6-47.
III
Page
General . . . . . . . ...6-33
50/60 Hertz Convenience Receptacle
Assembly . . . . . ...6-33
Removal . . . . . ...6-33
Disassembly . . . . .. 6-33
Cleaning . . . . . . . ...6-33
Inspection . . . . . . . . 6-33
Repair, . . . . . . . ...6-33
Reassembly . . . . . .. 6-33
Installation . . . . . . . .6-33
400 Hertz Convenience Receptacle
Assembly . . . . . . .. 6-35
Removal . . . . . . . ...6-35
Disassembly . . . . . . .6-35
Cleaning . . . . . . . ...6-35
Inspection. . . . . . . . . 6-35
Repair . . . . . . . . ...6-35
Reassembly . . . . . .. 6-39
Installation . . . . . ...6-39
EXCITER-REGULATOR . . .. 6-39
6-74.
6-75.
6-76.
6-77.
6-78.
6-79.
6-80.
6-81.
6-82.
6-83.
6-84.
General . . . . . . . ...6-39
Test and
Removal . . . . . . . ..6-40
Test . . . . . . . . . . ...6-42
Disassembly . . . . . , .6-42
Cleaning . . . . . . . ...6-49
Inspection. . . . . . . . .6-49
Repair . . . . . . . . ...6-49
Rebuild . . . . . . . ...6-49
Reassembly . . . . . . .6-49
Installation . . . . . . .. 6-51
Adjustment . . . . . . . .6-51
Change 3
iii
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
TABLE OF CONTENTS (Continued)
Page
Section
VI MODE I RELAY BOX
ASSEMBLY . . . . . . . 6-59
6-85.
6-86.
6-87,
6-88.
6-89.
6-90.
6-91.
6-92.
6-93.
6-94.
6-95.
6-96.
6-97.
6-98.
6-99.
6-100.
6-101.
6-102.
6-103.
General . . . . . . . . 6-59
DC Relay Assembly
(A5) . . . . . . . ...6-59
On Equipment Test . . 6-59
Test . . . . . . . . . . . .6-6l
Disassembly . . . . . . 6-61
Cleaning . . . . . 6-61
Inspection . . . . . . . . 6-62
Repair
. . . . . 6-62
Reassembly . . . . . . . 6-62
Installation . . . . ...6-66
Mode I Relay Box
Assembly . . . . . . . 6-66
On Equipment Test . . 6-66
Bench Test . . . . . . . 6-67
Disassembly . . . . . .6-67
Cleaning . . . . . . . . . 6-75
Inspection and
Bench Test . . . . ...6-75
Repair . . . . . . . . . . 6-75
Reassembly . . . . . . . 6-75
Installation . . . . . . . 6-77
VII MODE II RELAY BOX
ASSEMBLY .. . . . . . . 6-82
6-104. General . . . . . . ...6-82
6-105. DC Relay Assembly
(A5) . . . . . . . . . . 6-83
6-106. 400 Hertz Under
Frequency Relay . . . 6-83
6-107. On Equipment
Test . . . . . . . ...6-83
6-108. Bench Test . . . . ...6-84
6-109. Installation . . . . ...6-85
6-110. 400 Hertz Undervoltage Relay
(K1l) . . . . . . . . . . . . . . 6-85
6-111. On Equipment Test . . 6-85
6-112. Bench Test . . . . ...6-85
6-113. Installation . . . . ...6-86
6-114. Permissive Parallel
Relay (K16),
400 Hertz . . . . ...6-86
6-115. On Equipment Test . . 6-86
iv
Change 3
Section
6-116.
6-117.
6-118.
6-119.
6-120.
6-121.
6-122.
6-123.
6-124.
6-125.
6-126.
6-127.
6-128.
6-129.
6-130,
6-131.
6-132.
6-133.
6-134.
6-135.
Page
Bench Test . . . . . . . 6-87
Installation . . . . . . 6-87
400 Hertz Electronic
Components
Assembly (A6) . . . . 6-87
On Equipment Test . . 6-87
Bench Test . . . . ...6-87
Disassembly . . . . . . 6-88
Cleaning . . . . . . ...6-88
Inspection . . . . . . . . 6-88
Repair . . . . . . . ...6-89
Reassembly . . . . . . . 6-89
Installation l . . . . . . 6-89
Mode 11 Relay Box
Assembly (A27),
400 Hertz . . . . ...6-90
On Equipment Test . . 6-90
Bench Test . . . . . . . 6-91
Disassembly . . . ...6-91
Cleaning . . . . . . . . 6-98
Inspection . . . . . . . . 6-98
Repair . . . . . . . . . .6-l02
Reassembly . . . . . . . 6-102
Installation . . . . ...6-10.
VIII RECONNECTION BOARD ASSEMBLY
LOAD CONTACTOR, MOTOR
OPERATED CIRCUIT BREAKER,
LOAD BOARD ASSEMBLY, AND
TRANSFORMER ASSEMBLY. 6-108
6-136. General . . . . . . . . .6-108
6-137. Reconnection Board
Assembly . . . . . . . 6-l08
6-138. Removal . . . . . . . . .6-l08
6-139. Disassembly . . . . . . . . . 6-108
6-140. Cleaning . . . . . . . . . 6-109
6-141. Inspection . . . . . . . . 6-109
6-142. Reassembly . . . . . . .6-109
6-143. Installation . . . . . . . 6-109
6-144. Load Contactor . . . . 6-109
6-145. On Equipment Test . . 6-109
6-145A. Removal . . . . . . ...6-117
6-146. Bench Test . . . . ...6-117
6-146A. Disassembly . . . ...6-117
6-146B. Cleaning . . . . . . . . .6-117
6-146C. Inspection . . . . . . . . 6-118
6-146D. Repair . . . . . . . ...6-118
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
TABLE OF CONTENTS (Continued)
Page
Section
6-146E .
6-146F.
6-147.
6-147A.
6-147B.
6-147C.
6-147D.
6-147E.
6-147F.
6-147G.
6-147H.
6-1471.
6-148.
6-149.
6-150.
6-151.
6-152.
6-153.
6-154.
6-155.
6-156.
6-157.
6-158.
6-159.
6-160.
Reassembly . . . . . .
Adjustment . . . . . .
Installation . . . . . .
Circuit Breaker
Assembly . . . . . .
Test on Equipment . .
Test . . . . . . . . . .
Disassembly . . . . .
Cleaning. . . . . . . .
Inspection . . . . . . .
Repair . . . . . . . . .
Reassembly . . . . . .
Installation . . . . . .
Load Board Assembly
Removal and
Disassembly . . . . .
Cleaning. . . . . . . .
Inspection . . . . . . .
Reassembly and
Installation . . . . .
Transformer
Assembly . . . . , .
Removal . . . . . . .
Disassembly . . . . .
Cleaning . . . . . . .
Inspection . . . . . . .
Repair . . . . . . . . .
Reassembly . . . . . .
Installation . . . . . .
6-118
6-119
6-120
6-167.
6-168.
6-169.
6-170.
General . . . . . . . .
Overvoltage Relay (K2)
On Equipment Test . .
Bench Test , . . . . .
Installation . . . . . .
Reverse Power
Relay (K15) . . . . .
On Equipment Test . .
Bench Test . . . . . .
Installation . . . . . .
Short Circuit
Relay (K13) . . . . .
6-171.
6-172.
6-173.
6-174.
6-175.
6-176.
6-177.
6-178.
6-120
6-120
6-120A
6-120A
6-120I
6-120I
6-120I
6-120I
6-120M
6-121
6-179.
6-180.
6-181.
6-182.
6-183.
6-184.
6-185.
6-186.
6-121
6-121
6-121
X
On Equipment Test . . .
Bench Test . . . . . . .
Installation . . . , . . .
Overload Relay (K14) .
On Equipment Test . . .
Bench Test . . . . . . .
Installation . . . . . . .
Tactical Relay
B OX (A29) . . . . . . .
On Equipment Test . . .
Bench Test . . . . . . .
Disassembly . . . . . .
Cleaning . , . . . . . .
Inspection and Test . .
Repair . . . . . . . . .
Reassembly . . . . . .
Installation . . . . . . .
6-131
6-132
6-132
6-132
6-132
6-133
6-133
6-134
6-134
6-135
6-135
6-143
6-143
6-l43
6-143
6-146
PRECISE RELAY BOX . . . . . 6-146
6-121
6-121
6-121
6-123
6-123
6-123
6-123
6-123
6-123
IX TACTICAL RELAY BOX . . . . 6-126
6-161.
6-162.
6-163.
6-164.
6-165.
6-166.
Page
Section
6-126
6-126
6-126
6-127
6-129
6-129
6-129
6-130
6-131
6-131
6-187.
6-188.
6-189.
6-190.
6-191.
6-192.
6-193.
6-194.
6-195.
6-196.
6-197.
6-198.
6-199.
6-200.
General . . . . . . . . .
50/60 Hertz Underfrequency Relay (K12)
On Equipment Test . . .
Bench Test . . . . . . .
Installation . . . . . . .
Precise Relay
B OX (A25) . . . . . . .
Test and Removal . . .
Bench Test . . . . . . .
Disassembly . . . . . .
Cleaning. . . . . . . . .
Inspection and Test . .
Repair . . . . . . . .
Reassembly . . . . . .
Installation . . . . . .
6-146
6-147
6-147
6-149
6-150
6-150
6-150
6-150
6-150
6-153
6-157
6-l57
6-157
6-161
XI PRECISE GOVERNOR CONTROL
CONTROL UNIT . . . . . . . 6-161
6-201.
6-202.
6-203.
6-204.
General . . . . . . . .
On Equipment Test . .
Bench Test . . . . . .
Disassembly . . . . .
Change 3
.
.
.
.
6-161
6-162
6-164
6-164
v
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
TABLE OF CONTENTS (Continued)
Page
Section
6-205.
6-206.
6-207.
6-208.
6-209.
6-210.
6-211.
6-211A.
Cleaning . . . . . . .
Inspection . . . . . .
Repair . . . . . . . .
Rebuild . . . . . . .
Reassembly . . . . .
Installation . . . . .
Alignment . . . . . .
Alignment Procedures
Peculiar to Operation of 400 Hertz
Generator Sets in
Support of E3A
Aircraft . . . . . .
XII LOAD MEASUREMENT UNIT .
6-212.
6-213.
6-214.
6-215.
6-216.
6-217.
6-218.
6-219.
6-220.
General . . . . . . .
On Equipment Test .
Test and Adjustment
Disassembly. . . . .
Cleaning . . . . . . .
Inspection . . . . . .
Repair . . . . . . . .
Reassembly . . . . .
Installation . . . . .
6-173
6-173
6-173
6-173
6-173
6-175
6-175
vi
General . . . . . .
On Equipment Test
Disassembly . . .
Cleaning . . . . . .
Inspection . . . . .
Repair or Rebuild .
Reassembly . . . .
High Potential Test
Installation . . . .
Change 3
.
.
.
.
.
.
.
.
.
Page
CHAPTER 8- ENGINE GROUP
REPAIR INSTRUCTIONS
I
ENGINE COMPONENTS . . . . . 8-1
8-1.
8-2.
8-3.
8-4.
8-5.
General . . . . . .
Removal . . . . .
Disassembly . . . .
Reassembly . . . .
Installation . . . . .
.
.
.
.
.
.
.
.
.
.
.8-l
.8-l
8-1
8-1
8-2
II ENGINE HARNESS GROUP . . . 8-2
6-182
6-182A
6-182A
6-183
6-183
6-183
6-183
6-184
6-184
6-184
6-187
CHAPTER 7- GENERATOR ASSEMBLY
REPAIR INSTRUCTIONS
7-1.
7-2.
7-3.
7-4.
7-5.
7-6.
7-7.
7-8.
7-9.
Section
7-1
7-1
7-4
7-7
7-7
7-8
7-8
7-24
7-25
8-6.
8-7.
8-8.
8-9.
8-10.
8-11.
General . . . . . ...8-2
Removal . . . . . ...8-2
Cleaning . . . . . ...8-2
Inspection . . . . . . . 8-2
Rebuild . . . . . . ...8-3
Installation . . . . . . 8-3
III ALTERNATOR. . . . . . . . . . 8-6
8-12.
8-13.
8-14.
8-15.
8-16.
8-17.
8-18.
8-19.
8-20.
General . . . . . ...8-6
Removal........8Disassembly . . . . . . 8-6
Cleaning . . . . . ...8-6
Inspection . . . . . . . 8-7
Repair . . . . . . ...8-9
Reassembly . . . . . . 8-10
Test and Adjustment . . 8-10
Installation . . . . . . . 8-13
IV STARTING MOTOR . . . . . . . 8-14
8-21.
8-22.
8-23.
8-24.
8-25,
8-26.
8-27.
8-28.
8-29.
General . . . . . . . .8-l4
Removal . . . . . . . . 8-14
Disassembly . . . . . . 8-14
Cleaning . . . . . . . .8-l4
Inspection . . . . . . . 8-14
Repair . . . . . . . . .8-l5
Reassembly . . . . . . 8-15
Testing . . . . . . ...8-18
Installation . . . . . . 8-20
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-O7464A-35
TM 5-6115-457-34
TABLE OF CONTENTS (Continued)
Section
V
Page
FAN MOUNTING GROUP. , . ..8-22
8-30.
8-31.
8-32.
8-33.
8-34.
8-35.
8-36.
8-37.
General . . . .
Removal . . . . . ..
Disassembly . . . . .
Cleaning. . . . . .
Inspection. . . . .
Repair . . . . .
Reassembly .
Installation . .
......
.......
......
. . . .
. . . . .
. . . . .
......
. . . . .
Section
Page
IX FUEL PUMP GROUP . . . . . . . 8-33
8-61.
8-62.
8-63.
8-64.
8-65.
8-66.
8-67.
8-68.
8-22
8-22
8-22
8-22
8-22
8-22
8-22
8-24
General . . . . . . . ...8-33
Removal . . . . . . ...8-33
Disassembly . . . . . .. 8-33
Cleaning. . . . . . . . .. 8-33
Inspection. . . . . . . . . 8-33
Repair . . . . . . . . ...8-35
Reassembly . . . . . .. 8-35
Installation . . . . . . .. 8-35
X TURBOCHARGER GROUP . . . 8-36
VI DAY TANK ASSEMBLY . . . . . 8-25
8-38.
8-39.
8-40.
8-41.
8-42.
8-43.
General . . . . . . . . .
Removal and
Disassembly . . . . .
Cleaning. . . . . . . . . .
Inspection . . . . . . . . ..
Repair . . . . . . . . .
Reassembly and
Installation . . . . .
8-25
8-25
8-25
8-25
8-25
8-25
VII OVERSPEED SWITCH. . . . . . . 8-26
8-44.
8-45.
8-46.
8-47.
8-48.
8-49.
8-50.
8-51.
8-52.
General . . .
Removal . .
Disassembly
Cleaning. . .
Inspection. .
Repair . . , .
Reassembly
Adjustment .
Installation .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
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..
.
.
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.
.
.
.
..
..
..
..
. .
. .
..
...
...
8-26
8-26
8-26
8-26
8-26
8-27
8-27
8-27
8-30
VIII TACHOMETER DRIVE
GROUP . . . . . . . .. 8-31
8-53.
8-54.
8-55.
8-56.
8-57.
8-58.
8-59.
8-60.
8-69.
8-70.
8-71.
8-72.
8-73.
8-74.
8-75.
8-76.
General . . . . . . . . 8-31
Removal. . . . . . . . . . 8-31
Disassembly . . . . . . . 8-31
Cleaning. . . . . . . . . . 8-31
Inspection . . . . . . . 8-31
Repair . . . . . . . . . . .8-31
Reassembly . . . . .8-31
Installation . . . . . . .8-33
XI
General . . .
Removal. . .
Disassembly
Cleaning. . .
Inspection .
Repair . . . .
Reassembly
Installation .
.
.
.
.
.
.
.
.
.
.
.
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.
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.
.
8-36
8-36
8-36
8-37
8-37
8-39
8-40
8-40
OIL COOLER GROUT . . . . . . . 8-41
8-77.
8-78.
8-79.
8-80.
8-81.
8-82.
8-83.
8-84.
General . . .
Removal . .
Disassembly
Cleaning . .
Inspection. .
Repair . . . .
Reassembly
Installation .
.
.
.
.
.
.
.
.
.
.
.
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.
.
8-41
8-41
8-41
8-41
8-43
8-43
8-43
8-43
XII HYDRAULIC TANK (PRECI5E
SETS ONLY) . . . . ...8-45
8-85.
General . . . . . . . ...8-45
8-86.
Removal . . . . . . . ...8-45
8-87.
Disassembly . . . . . ..8-45
8-88.
Cleaning . . . . . . . ...8-47
8-89.
Inspection . . . . . ...8-47
Repair . . . . . . . . ...8-47
8-90.
Reassembly . . . . . .. 8-47
8-91.
Installation . . . . . . . .8-47
8-92.
XIII HYDRAULIC PUMP (PRECISE
SETS ONLY) . . . . . .8-48
General . . . . . . . ...8-48
8-93.
Removal . . . . . . . ...8-48
8-94.
vii
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
TABLE OF CONTENTS (Continued)
Page
Section
8-95.
8-96.
8-97.
8-98.
8-99.
Cleaning . . . . . . . .
Inspection . . . . . . .
Repair . . . . . . . . . .
Hydraulic Pump Test
and Adjustment (On
Precise Generator
Sets Only) . . . . . .
Installation . . . . . .
XIV HYDRAULIC PUMP DRIVE
GROUP . . . . . . . . .
8-100.
8-101.
8-102.
8-103.
8-104.
8-105.
8-106.
8-107.
General . . . . . . . .
Removal . . . . . . . .
Disassembly . . . . .
Cleaning. . . . . . . .
Inspection . . . . . .
Repair . . . . . . . . .
Reassembly . . . . .
Installation . . . . .
.
.
.
.
.
.
.
.
XV GOVERNOR ACTUATOR
UNIT (PRECISE
SETS ONLY) . . . . .
8-108.
8-109.
8-110.
8-111.
8-112.
8-113.
8-114.
8-115.
8-116.
8-48
8-48
8-48
8-49
8-49
8-50
8-50
8-50
8-50
8-50
8-50
8-51
8-51
8-51
8-53
General . . . . . . . . .
Removal . . . . . . . .
Disassembly . . . . . .
Cleaning . . . . . . . . .
Inspection . . . . . . .
Repair . . . . . . . . . .
Reassembly . . . . . .
Test and Adjustment.
Installation . . . . . . .
8-53
8-53
8-54
8-55
8-55
8-57
8-57
8-59
8-60
XVI WATER PUMP GROUP . . . .
8-62
8-117.
8-118.
8-119.
8-120.
8-121.
viii
General . . . . . .
Removal . . . . .
Disassembly . . .
Cleaning . . . . .
Inspection . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
8-62
8-62
8-62
8-62
8-62
Section
8-122.
8-123.
8-124.
Page
Repair . . . . . . . . . .
Reassembly . . . . . .
Installation . . . . . .
8-63
8-63
8-63
XVII CRANKSHAFT PULLEY,
DAMPER AND
TIMING GEAR
COVER GROUP . . .
8-65
8-125.
8-126.
8-127.
8-128.
8-129.
8-130.
8-131.
8-132.
.
.
.
.
.
.
.
.
8-65
8-65
8-65
8-67
8-68
8-68
8-68
8-69
XVIII UTILITY GOVERNOR
GROUP . . . . . . . . .
8-69
8-133.
8-134.
8-135.
8-136.
8-137.
8-138.
8-139.
8-140.
General . . . . . . .
Removal . . . . . .
Disassembly . . . .
Cleaning . . . . . .
Inspection . . . . .
Repair . . . . . . .
Reassembly . . . .
Installation . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
8-69
8-70
8-70
8-75
8-75
8-80
8-80
8-81
XIX FUEL INJECTION GROUP . .
8-86
8-141.
8-142.
8-143.
8-144.
8-145.
8-146.
8-147.
8-148.
8-149.
General . . . . . . . .
Removal . . . . . . .
Disassembly . . . . .
Cleaning . . . . . . . .
Inspection . . . . . .
Repair . . . . . . . . .
Reassembly . . . . .
Installation . . . . .
General . . . . . . . .
Removal . . . . . . .
Disassembly . . . . .
Cleaning . . . . . . .
Inspection . . . . . .
Repair . . . . . . . . .
Reassembly . . . . .
Installation . . . . .
Testing . . . . . . . .
.
.
.
.
.
.
.
.
.
8-86
8-86
8-89
8-90
8-90
8-91
8-91
8-92
8-92
P-9-TM-457-35
TM-07464A-35
T. O. 35C2-3-442-2
TM 5-6115-457-34
TABLE OF CONTENTS (Continued)
Section
XX
Page
ACCESSORY DRIVE GROUP. . .8-96
8-150.
8-151.
8-152.
8-153.
8-154.
8-155.
8-156.
8-157.
General . . .
Removal . .
Disassembly
Cleaning . .
Inspection .
Repair . . . .
Reassembly
Installation
.
.
.
.
.
.
.
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.
.
8-96
8-96
8-97
8-97
8-97
8-99
8-99
8-100
XXI EXHAUST MANIFOLD
GROUP . . . . . . . . . . 8-101
8-158.
8-159.
8-160.
8-161.
8-162.
8-163.
General . . . . . . . . . . 8-101
Removal and Disassembly . . . . . . . .8-101
Cleaning . . . . . . . . .8-101
Inspection . . . . . . . 8-101
Repair . . . . . . . ...8-101
Reassembly and
Installation . . . . . .8-101
XXII OIL PAN GROUP AND
RELATED PARTS
8-164.
8-165.
8-166.
8-167.
8-168.
8-169.
8-170.
8-171.
General . . . . . .
Removal . . . . . .
Disassembly . . . .
Cleaning . . . . . .
Inspection . . . . .
Repair . . . . . . .
Reassembly . . . .
Installation . . . .
. .8-103
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.8-103
.8-103
.8-103
.8-103
.8-103
..8-l05
.8-105
.8-105
XXIII OIL PUMP GROUP. . . . . . . . .8-106
8-172.
8-173.
8-174.
8-175.
8-176.
General . . . . . . . . .8-l06
Removal . . . . . . . .8-106
Disassembly . . . . . .8-l06
Cleaning . . . . . . . .8-106
Inspection . . . . . . . .8-106
Section
8-177.
8-178.
8-179.
Page
Repair . . . . . . . . .
Reassembly . . . . . .
Installation . . . . . .
8-107
9-109
8-109
XXIV VALVE COVER AND VALVE
MECHANISM GROUP
8-110
8-180.
8-181.
8-182.
8-183.
8-184.
8-185.
8-186.
8-187.
General . . . . . . . .
Removal . . . . . . .
Disassembly . . . . .
Cleaning . . . . . . . .
Inspection . . . . . .
Repair . . . . . . . . .
Reassembly . . . . .
Installation . . . . .
.
.
.
.
.
.
.
.
8-110
8-110
8-110
8-110
8-112
8-112
8-112
8-113
XXV CYLINDER HEAD GROUP . . 8-113
8-188.
8-189.
8-190.
8-191.
8-192.
8-193.
8-194.
8-195.
General . . . . . . . .
Removal . . . . . . .
Disassembly . . . .
Cleaning . . . . . . .
Inspection . . . . . .
Repair . . . . . . . . .
Reassembly . . . . .
Installation . . . . .
.
.
.
.
.
.
.
.
8-113
8-113
8-113
8-114
8-114
8-115
8-115
8-119
XXVI FLYWHEEL AND FLYWHEEL
HOUS1NG GROUP . . 8-120
8-196.
8-197.
8-198.
8-199.
8-200.
8-201.
8-202.
8-203.
General . . . . . . . .
Removal . . . . . . .
Disassembly . . . .
Cleaning . . . . . . .
Inspection . . . . . .
Repair . . . . . . . . .
Reassembly . . . . .
Installation . . . . .
.
.
.
.
.
.
.
.
8-120
8-120
8-120
8-120
8-121
8-121
8-121
8-126
XXVII CAMSHAFT GROUP . . . . . . 8-126
8-204.
8-205.
General . . . . . . . . . 8-126
Removal . . . . . . . . 8-126
ix
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
TABLE OF CONTENTS (Continued)
Section
8-206.
8-207.
8-208.
8-209.
8-210.
8-211.
Disassembly . . . . .
Cleaning . . . . . . .
Inspection . . . . . .
Repair . . . . . . . . .
Reassembly . . . . .
Installation . . . . .
.
.
.
.
.
.
Page
Section
8-127
8-127
8-127
8-129
8-129
8-129
XXXI ENGINE TEST AFTER OVERHAUL . . . . . . . . ...8-146
8-236.
8-237.
XXVIII CONNECTING RODS AND
PISTONS GROUP . . 8-129
8-212.
8-213.
8-214.
8-215.
8-216.
8-217.
8-218.
8-219.
General . . . . . . .
Removal . . . . . .
Disassembly . . . .
Cleaning . . . . . .
Inspection . . . . .
Repair . . . . . . .
Reassembly . . . .
Installation . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
8-129
8-130
8-130
8-130
8-131
8-131
8-131
8-133
General . . . . . . . .
Removal . . . . . . .
Disassembly . . . . .
Cleaning . . . . . . .
Inspection . . . . . .
Repair . . . . . . . . .
Reassembly . . . . .
Installation . . . . .
.
.
.
.
.
.
.
.
8-134
8-134
8-135
8-137
8-137
8-138
8-138
8-139
I
General . . . . . .
Removal . . . . . .
Disassembly . . . .
Cleaning . . . . . .
Inspection . . . . .
Repair . . . . . . . .
Reassembly . . . .
Installation . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
8-139
8-140
8-141
8-141
8-141
8-141
8-141
8-145
BASE ASSEMBLY . . . . . . ...9-1
9-1.
9-2.
9-3.
9-4.
9-5.
9-6.
9-7.
9-8.
II
III
General . . . . . . . . . .9-l
Removal . . . . . . ...9-1
Disassembly . . . . . . . 9-1
Cleaning . . . . . . . . .9-l
Inspection . . . . . . . . 9-3
Repair . . . . . . . . ...9-3
Reassembly . . . . . . . 9-3
Installation . . . . . . .9-4
STOWAGE TOOL BOX . . . . ..9-4
9-9.
9-10.
9-11.
9-12.
9-13.
9-14.
9-15.
9-16.
XXX CYLINDER BLOCK AND
COVERS GROUP . . . 8-139
8-228.
8-229.
8-230.
8-231.
8-232.
8-233.
8-234.
8-235.
General . . . . . . . ...8-146
Engine Assembly
Run-in and
Adjustments . . . , . . 8-146
CHAPTER 9- BASE ASSEMBLY,
STOWAGE TOOL BOX, AND FUEL
TANK REPAIR . . , . . 9-1
XXIX CRANKSHAFT GROUP AND
MAIN BEARINGS . . 8-134
8-220.
8-221.
8-222.
8-223.
8-224.
8-225.
8-226.
8-227.
Page
General . . . . . . . ...9-4
Removal . . . . . . ...9-4
Disassembly . . . . . . . 9-4
Cleaning . . . . . . ...9-4
Inspection . . . . . . . . 9-5
Repair . . . . . . . . ...9-5
Reassembly . . . . . . .9-5
Installation . . . . ...9-5
FUEL TANK ASSEMBLY . . . . 9-6
9-17.
9-18.
9-19.
9-20.
9-21.
9-22.
General . . . . . . . ...9-6
Removal . . . . . . ...9-6
Disassembly . . . . . .. 9-6
Cleaning . . . . . . ...9-6
Inspection . . . . . . . . 9-6
Repair . . . . . . . . . . .9-8
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
TABLE OF CONTENTS (Continued)
Section
9-23.
9-24.
Reassembly . . . . . .
Installation. . . . . .
CHAPTER 9A - PAINT AND MARKING
REQUIREMENTS AFTER OVERHAUL
General . . . . . . . . . .
9A-1.
Noise Level Warning Sign.
9A-2.
CHAPTER 10 - TEST AFTER OVERHAUL
I
PRETEST CHECKS AND
ADJUSTMENTS . . . . . . . . . .
General . . . . . . . . . .
10-1.
Pretest Checks and
10-2.
Adjustments. . . . .
TEST AFTER OVERHAUL . . . . . . .
II
10-3.
10-4.
10-5.
10-6.
10-7.
10-8.
10-9.
10-10.
10-11.
10-12.
10-13.
10-14.
10-15.
General . . . . . . . . .
Start and Stoutest. .
Instrument Check . .
Low Oil Pressure
Trip Test. . . . . .
High Coolant Temperature Trip
Test . . . . . . . . . .
Low Fuel Level
Trip Test . . . . . . .
Short Circuit Trip
Test . . . . . . . . . .
Over and Under
Voltage Trip
Test . . . . . . . . . .
Under Frequency
Trip Test (Precise
Generator Sets
Only) . . . . . . . . .
Phase Sequence
Check . . . . . . . . .
Phase Balance Test .
Frequency Adjustment
Range Test . . . . .
Regulator Range
Test . . . . . . . . . .
Page
9-8
9-8
Section
10-16.
9A-1
9A-1
10-17.
10-18.
10-1
10-1
10-19.
10-1
10-1
Page
Exciter Regulator
and Governor Stability and Transient
Response Test . . .
Long Term Steady
State Stability
Test . . . . . . . . . .
Parallel Operation
and Reverse
Power Test . . . . .
Engine Efficiency
Test . . . . . . . . . .
10-6
10-7
10-7
10-8
CHAPTER 1l - FUEL BURNING
WINTERIZATION KIT REPAIR
INSTRUCTIONS
10-1
10-1
10-2
I
CONTROL BOX . . . . . . . . . 11-1
10-2
11-1.
11-2.
11-3.
11-4.
11-5.
11-6.
11-7.
11-8.
10-3
10-3
10-3
10-4
II
10-5
10-6
11-17.
10-4
10-5
11-1
11-1
11-1
11-1
11-1
11-4
11-4
11-4
HEATER . . . . . . . . . . . . . . 11-4
11-9.
11-10.
11-11.
11-12.
11-13.
11-14.
11-15.
11-16.
10-4
General . . . . . . . . .
Removal . . . . . . . .
Disassembly. . . . . .
Cleaning . . . . . . . .
Inspection . . . . . . .
Repair . . . . . . . . . .
Reassembly . . . . . .
Installation . . . . . .
General . . . . . . . .
Removal . . . . . . .
Disassembly . . . . .
Cleaning . . . . . . .
Inspection . . . . . .
Repair . . . . . . . . .
Reassembly . . . . .
Component Test and
Adjustments . . . .
Installation . . . . . .
.
.
.
.
.
.
.
11-4
11-4
11-5
11-5
11-5
11-8
11-9
11-10
. 11-11
Change 2 xi
P-9-TM-457-35 T O 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
TABLE OF CONTENTS (Continued)
Section
Page
CHAPTER 12 - ELECTRIC WINTERIZATION
KIT REPAIR INSTRUCTIONS
I
CONTROL BOX . . . . . . . . .12-1
12-1.
12-2.
12-3.
12-4.
12-5.
12-6.
12-7.
12-8.
12-9.
II
General ... . . . . . . .l2-l
Removal . . . . . . .l2-l
Test . . . . . . . . . . . .12-l
Disassembly . . . . . . 12-1
Cleaning. . . . . . . . . . 12-4
Inspection . . . . . . . 12-4
Repair . . . . . . . . . . .l2-4
Reassembly . . . . . . . 12-7
Installation . . . . . . . . 12-7
ELECTRIC HEATER . . . . . . .12-7
12-10.
12-11.
12-12.
12-13.
12-14.
12-15.
12-16.
General . . . . . . . .
Removal . . . . . . .
Disassembly . . . . .
Cleaning . . . . . . . .
Inspection. . . . . . .
Reassembly . . . . .
Installation . . . . .
. .l2-7
...12-7
. 12-7
. 12-8
. 12-8
. 12-8
. 12-8
II: COOLANT PUMP . . . . . . . ...12-8
12-17.
12-18.
12-19.
12-20.
12-21.
12-22.
12-23,
12-24,
12-25.
General . . . . . . . . .l2-8
Removal . . . . . . . . . .l2-9
Test . . . . . . . . . .l2-9
Disassembly . . . . . . . 12-9
Cleaning . . . . . . . . . 12-9
Inspection . . . . . . . . 12-9
Repair . . . . . . . . ...12-10
Reassembly . . . . . . . 12-11
Installation . . , . . . . . 12-11
Section
13-3.
13-4.
13-5.
13-6.
13-7.
13-8.
13-9.
Page
Disassembly . . . . .
Cleaning . . . . . . . .
Inspection . . . . . , .
Repair . . . . . . . . . .
Wiring Harness
Rebuild . . . . . . . .
Reassembly . . . . . .
Installation . . . . . .
H CONTROL BOX . . . . . . . . .
13-10.
13-11.
13-12.
13-13.
13-14.
13-15.
13-16.
13-17.
13-18.
13-19.
13-20.
13-21.
13-22.
13-23.
13-24.
13-25.
13-26.
13-27.
13-28.
13-29.
General . . . . . . . . .
Load Dumping
Relay (K5) . . . . . .
Removal . . . . . . . .
Test . . . . . . . . . . .
Disassembly . , . . , .
Cleaning . . . . . . . . .
Inspection , . . . . . .
Repair . . . . . . . . . .
Reassembly . . . . . .
Installation . . . . . . .
Control Box . . . . . .
Removal . . . . . . . .
Disassembly . . . . . .
Cleaning . . . . . . . . .
Inspection . . . . . . .
Test . . . . . . . . . . .
Repair . . . . . . . . . .
Wiring Harness
Rebuild . . . . . . . .
Reassembly . . . . . .
Installation . . . . . . .
13-1
13-1
13-1
13-5
13-5
13-5
13-5
13-10
13-10
13-10
13-10
13-10
13-10
13-10
13-10
13-10
13-10
13-17
13-17
13-17
13-18
13-18
13-18
13-18
13-21
13-21
13-21
13-22
CHAPTER 14- DELETED
CHAPTER 13 - DUMMY LOAD KIT
REPAIR INSTRUCTIONS
I
DUMMY LOAD KIT. . . . . .13-1
13-1.
13-2.
xii
General . . . . . . . . . .l3-l
Removal . . . . . . . . . .l3-l
Change 6
APPENDIX A
. . . . . . . . . . . . A-1
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
LIST OF ILLUSTRATIONS
Number
Title
Page
1-1. Hydraulic system schematic
Precise Generator Sets . . . . 1-61
1-2. 50/60 Hertz DC system
schematic . . . . . . . . . . . .. 1-63
1-3. 400 Hertz DC system
schematic . . . . . . . . . . . .. 1-65
1-4. 50/60 Hertz AC system
schematic . . . . . . . . . . . .. 1-67
1-5. 400 Hertz AC system
schematic . . . . . . . . . ...1-69
1-6. Control cubicle (A3)
schematic . . . . . . . . . . . . . 1-71
1-7. Control cubicle (A3) wiring
diagram . . . . . . . . . . . . .. l-73
1-8. Fault locating indicator (A9)
schematic . . . . . . . . . . . . 1-75
1-9. Fault locating indicator (A9)
wiring diagram . . . . . . . . . 1-76
1-10. Exciter regulator (A10 and
All) 50/60 Hertz
schematic . . . . . . . . . . . . 1-77
1-11. Exciter regulator (A10 and
All) 50/60 Hertz wiring
diagram (2 sheets) . . . . . .. 1-79
1-12. Exciter regulator (A10 and
All) 400 Hertz
schematic . . . . . . . . . . . .. 1-81
1-13. Exciter regulator (A10 and
All) 400 Hertz wiring
diagram (2 sheets) . . . . ...1-83
1-14. Mode I relay box (A27)
schematic diagram 50/60
Hertz generator sets. . . ...1-85
1-15. Mode I relay box (A27)
wiring diagram 50/60 Hertz
generator sets (2 sheets) . ..1-87
1-16. Mode II relay box (A27)
schematic 400 Hertz
Generator Sets . . . . . . ...1-91
1-17. Mode II relay box (A27) wiring
diagram 400 Hertz
generator sets (3 sheets). .. 1-93
Number
Title
Page
1-18. Tactical relay box (A7)
schematic diagram . . . . . . 1-99
1-19. Tactical relay box (A7)
wiring diagram . . . . . . . . 1-101
1-20. Precise relay box (A25)
schematic precise 50/60
Hertz generator sets. . . . . 1-103
1-21. Precise relay box (A25) wiring
diagram precise 50/60
Hertz generator sets. . . . . 1-105
1-22. 50/60 Hertz precise governor
system schematic, precise
generator sets . . . . . . . . . 1-107
1-23.400 Hertz precise governor
system schematic, precise
generator sets . . . . . . . . . 1-109
1-24. 50/60 Hertz precise governor
control unit (A23)
wiring diagram . . . . . . . . 1-111
1-25.400 Hertz precise governor
control unit (A23)
wiring diagram . . . . . . . . 1-112
1-26. Precise governor actuator
(A24) wiring diagram . . . . 1-113
1-27. Load measuring unit (A8)
wiring diagram . . . . . . . . 1-114
1-28. Generator assembly simplified
schematic diagram . . . . . . 1-115
1-29. Fuel burning winterization
kit (A17) schematic . . . . . 1-115
1-30. Electric winterization kit
(A18) schematic . . . . . . . 1-116
1-31. Dummy load (A28) schematic
(2 sheets) . . . . . . . . . . . .l-117
2-1. Specially Designed Tools
(Fabricated) (3 sheets) . . . 2-1
2-2. Control Cubicle, Removal
and Installation . . . . . . . . 2-4
2-3. Rear Housing and Upper Sides
Housing, Removal and
Installation . . . . . . . . ...2-5
Change 4
xiiA/(xiiB blank)
P-9-TM-457-35
T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457 -34
LIST OF ILLUSTRATIONS (Continued)
Number
2-4.
2-5.
Title
Page
Generator Controls, Removal
and Instillation (2 sheets) . 2-7
Generator, Removal and
Installation . . . . . . . . 2-8A
Number
2-6.
2-7.
Title
Page
Engine, Removal and
Installation . . . . . . . . .
Wheel Mounting Kit, Removal
and Installation . . . . . .
Change 4
2-14
2-18
xiii
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457 -34
LIST OF ILLUSTRATIONS (Continued)
Number
2-8.
2-9.
3-1.
3-2.
3-3*
4-1.
4-2.
4-3.
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
5-7.
5-8.
5-9.
xiv
Title
Page
Engine Assembly, D3306(T)
Engine (2 sheets) . . . . . 2-59
Front Lower Right Panel
Drilling Dimensions for Fuel
Bleed Line Tubing . . . . 2-66
Housing Frame, Exploded View 3-2
Lifting Frame Assembly,
Exploded View . . . . . . . 3-6
Housing, Partially Exploded
View (2 sheets) . . . . . . 3-8
Radiator Assembly . . . . . 4-3
Shutter Control Assembly,
Exploded View . . . . . . . 4-5
Shutter, Exploded View . . . 4-6
Relay Box to Control Cubicle
Wire Harness (2 sheets) .
Relay Box to Exciter Regulator Wire Harness . . . .
Tactical Relay Box to Load
Measuring Unit Wire
Harness . . . . . . . . . .
Relay Box to Precise Relay
Box Wire Harness, 50/60
Hertz Generator Sets . . .
Relay Box to Governor Control Unit Wire Harness
Precise Generator Sets . .
Governor Control Unit to
Governor Actuator Unit
Wire Harness Precise
Generator Sets. . . . . . .
Relay Box to Reconnection
Panel Wire Harness, 50/60
Hertz Generator
Sets (2 sheets) . . . . . .
Relay Box to Reconnection
Panel Wire Harness, 400 Hz
Generator Sets (2 sheets) .
Relay Box to Fault Locator
Indicator Wire Harness . .
Change 4
5-3
5-5
5-6
5-7
5-8
5-9
5-10
5-12
5-14
Number
Title
Page
5-10. Parallel receptacle wire
harness . . . . . . . . . . . . .5-l5
5-11. Relay box to tactical relay
box wire harness . . . . ...5-16
6-1. Thermal Watt converter
(Al) test setup . . . . . . ...6-3
6-2. Frequency meter (M6) and
transducer test setup . . . .6-4
6-3. Control Box relay assembly
(A4) test setup . . . . . . ...6-6
6-4. Control Box relay assembly
exploded view . . . . . . ...6-8
6-5. Plug in relay test setup. . . .. 6-9
6-6. AC current meter (M8)
test setup . . . . . . . . . ...6-11
6-7. Control cubicle exploded view .6-12
6-8. Control cubicle wire
harness (4 sheets) . . . . . , 6-14
6-9. DC circuit breaker box,
exploded view . . . . . . . . . 6-20A
6-10. Fault Locating indicator box
(A9), test setup . . . . . ...6-24
6-11. Fault locating indicator box,
exploded view . . . . . . . . . 6-28
6-12. Fault locating indicating box
wiring harness (2 sheets). . 6-31
6-13. 50/6 O Hertz convenience
receptacle assembly,
exploded view . . . . . . . . . 6-34
6-14.400 Hertz convenience
receptacle assembly,
exploded view..... . . . . 6-38
6-15. Location of Exciter
Regulator, and Mode I, Mode
II, Precise and Tactical
Relay Assemblies . . . . .. 6-41
6-16. Exciter Regulator (A10,
All) Test Setup . . . . . ...6-43
6-17. Exciter Regulator exploded
view . . . . . . . . . . . . . . .6-50
6-18. Voltage regulator exploded
view . . . . . . . . . . . . . . . 6-52
6-19. Voltage regulator subassembly. 6-54
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
LIST OF ILLUSTRATIONS (Continued)
Number
Title
Page
6-20. Exciter Regulator Wiring
Harness (2 sheets) . . . . 6-55
6-21. Voltage Regulator Wiring
Harness . . . . . . . . . . . 6-57
6-22. Mode I and Mode II Relay
Box Assembly, Cover
Removed . . . . . . . 6-60
6-23. DC Relay Assembly (A5)
Test Setup . . . . . . . . . 6-62
6-24. DC Relay Assembly Exploded
View . . . . . . . . .. 6-66
6-25. Mode I Relay Box Assembly,
(A27) Test Setup . . . . . . 6-68
6-26. Mode I Relay Box Assembly,
(A27) Exploded View . . . 6-76
6-27. Mode I Relay Box Wiring
Harness (Dwg 70-4228)
(4 sheets) . . . . . . . . . . 6-78
6-28. 400 Hertz Under Frequency
Relay (K12) Test Setup. . 6-84
6-29. Under Voltage Relay (Kll)
Test Setup . . . . . . . . . . 6-86
6-30. Permissive Paralleling Relay
(K16) Test Setup . . . . . 6-87
6-31. Electronic Components Assy.
(A6) Test Data . . . . . . . 6-88
6-32. Electronic Component
Assembly (A6),
Exploded View . . . . . . . 6-89
6-33. Mode 11 Relay Box Assembly
(A27) Test Setup . . . . . . 6-96
6-34. Mode II Relay Box Assembly
(A27) Exploded View. . . 6-97
6-35. Mode II Relay Box Assembly
(A27) Wiring Diagram
(4 sheets) . . . . . . . 6-103
6-36. Reconnection Board Assembly,
bad Contactor, and Load
Board Assembly, Removal
and Installation . . . . . . 6-110
6-36A. Main Load Contactor
(2 sheets) . . . . . . . . . .6-l13
Number
6-37.
6-37A.
6-37B.
6-37C.
6-37D.
6-37E.
6-37F.
6-38.
6-39.
6-40.
6-41.
6-42.
6-43.
6-44.
6-45.
6-46.
6-47.
6-48.
6-49.
Title
Page
Reconnection Board Assembly,
Exploded View . . . . . . 6-116
Motor Operated Circuit
Breaker Assembly (CB2),
6-120B
Removal and Installation
Circuit Breaker Assembly
(CB2), Test Setup . . . . 6-120C
Motor Operated Circuit
Breaker Assembly (CB2),
Exploded View . . . . . . 6-120F
Motor Operated Circuit
Breaker Assembly (CB2),
Wiring Diagram . . . . . 6-120J
Motor Operated Circuit
Breaker Assembly (CB2)
Schematic . . . . . . . . 6-120K
Motor Operated Circuit
Breaker Assembly (CB2)
Relay Box Wiring
Diagram . . . . . . . . . 6-120L
Transformer Assembly,
6-122
Removal and Installation
Transformer Assembly,
Exploded View . . . . . . 6-124
Transformer Inspection . . 6-125
Tactical Relay Box (A29)
Cover Removed . . . . . 6-128
Over Voltage Relay (K2)
Test Setup . . . . . . . . 6-129
Reverse Power Relay
(K15) Test Setup . . . . 6-130
Short Circuit Relay (K13)
Test Setup . . . . . . . . 6-132
Overload Relay (K14)
Test Setup . . . . . . . . 6-134
Tactical Relay Box (A29)
Test Setup . . . . . . . . 6-137
Tactical Relay Box (A29)
Exploded View . . . . . 6-142
Tactical Relay Box (A29)
Wiring Harness (2 sheets) 6-144
Precise Relay Box (A25) 50/60
Hz Precise Generator Sets
Cover Removed . . . . . 6-148
Change 3
xv
P-9-TM-457-35
TM-07464A-35
T. O. 35C2-3-442-2
TM 5-6115-457-34
LIST OF ILLUSTRATIONS (Continued)
Number
6-50.
6-51.
6-52.
6-53.
6-54.
6-55.
6-56.
6-57.
6-58.
6-59.
6-60.
6-61.
7-1.
7-2.
7-3.
7-4.
7-5.
xvi
Title
Page
50/60 Hertz, Under Frequency
Relay (K12), Test Setup . 6-149
Precise Relay Box (A25)
Test Setup . . . . . . . . 6-151
Precise Relay Box (A25),
Exploded View . . . . . . 6-156
Precise Relay Box (A 25) Wire
Harness (2 sheets) . . . 6-158
Precise Governor Control
Unit (A23) Adjustment
and Test Points . . . . . 6-164
Precise Governor Control Unit
(A23) Test Setup . . . . 6-172
Precise Governor Control Unit
(A23) Exploded View . . 6-174
Precise Governor Control
Unit (A23) Printed Wiring
Board Assembly . . . . . 6-177
Precise Governor Control
Unit (A 23) Wiring Harness
Diagram (2 sheets) . . . 6-178
Load Measurement Unit, ‘
Removal and Installation 6-185
Load Measurement Unit,
Test Setup . . . . . . . . 6-185
Load Measurement Unit,
Exploded View . . . . . . 6-186
Generator Assembly,
Exploded View . . . . . . 7-3
50/6 O Hertz Generator, Main
Stator Rewind Data . . . 7-9
400 Hertz Generator, Main
Stator Rewind Data . . . 7-12
50/60 Hertz Generator, Main
Rotor Rewind Data. . . . 7-14
400 Hertz Generator, Main
Rotor Rewind Data . . . 7-16
Change 3
Number
7-6.
7-7.
7-8.
7-9.
8-1.
8-2.
8-3.
8-4.
8-5.
8-6.
8-7.
8-8.
8-9.
8-10.
8-11.
8-12.
8-13.
8-14.
Title
Page
50/60 Hertz Generator, Exciter
Rotor Rewind Data . . . . 7-18
400 Hertz Generator, Exciter
Rotor Rewind Data . . . . 7-20
50/60 Hertz Generator, Exciter
Stator Rewind Data . . . 7-22
400 Hertz Generator, Exciter
Stator Rewind Data . . . 7-23
Engine Wire Harness
(sheets) . . . . . . . . .
Alternator Assembly (2 sheets)
Voltage Regulator Excitation
Circuits . . . . . . . . .
Alternator Schematic and
Wiring Diagram (2 sheets)
Voltage Regulator Setting
Test . . . . . . . . . . .
Alternator Output Test . . .
Starter Motor, Exploded
View . . . . . . . . . . .
Starting Motor, Test
Setup . . . . . . . . . . .
Starting Motor Pinion
Position, Test Setup . . .
Fan and Fan Drive Group,
Removal and Installation
Fan Drive Assembly,
Exploded View . . . . . .
Over speed Switch,
Exploded View . . . . . .
Overspeed Switch, Test
Setup . . . . . . . . . . .
Tachometer Drive Group,
Exploded View . . . . . .
8-4
8-8
8-10
8-11
8-13
8-13
8-16
8-19
8-21
8-23
8-24
8-28
8-29
8-32
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
LIST OF ILLUSTRATIONS (Continued)
Number
Title
Page
8-15 Fuel Pump Group, Exploded
View . . . . . . . . . . . . . ...8-34
8-16 Turbocharger Group,
Exploded View . . . . . . . ...8-38
8-17 Pressing Shaft and Turbine
Wheel from Compressor
Wheel. . . . . . . . . . . . 8-40
8-18 Removing Thrust Plate . . . . . 8-40
8-19 Oil Cooler Group, Removal
Installation . . . . . .. .. 8-42
8-20 Oil Cooler Group, Exploded
View . . . . . . . . . . . 8-44
8-21 Hydraulic Tank Removal and
Installation . . . . . . . . . ...8-45
8-22 Hydraulic Tank, Exploded
View . . . . . . . . . . . . . . . . . . 8-46
8-23 Hydraulic pump, Exploded
View (Precise Sets Only) . ..8-48
8-24 Hydraulic Pump Drain Group,
Exploded View.. . . . . . . . . 8-52
8-25 Governor Actuator or Nut,
Removal and Installation
(Precise Sets Only) . . . ...8-54
8-26 Governor Actuator Unit,
Exploded View (Precise
Sets Only) . . . . . . . . . . ...8-56
8-27 Governor Actuator Unit, Test
and Adjustment . . . . . . . . . 8-58
8-28 Water Pump Group,
Exploded View. . . . . . . ...8-64
8-29 Crankshaft Pulley, Damper, and
Timing Gear Cover Group,
Exploded View . . . . . . . ...8-66
8-30 Alignment of Timing Marks . .. 8-68
8-31 Utility Governor and Linkage,
Exploded View . . . . . . . ...8-72
8-32 Governor Drive Housing,
Removal and Installation . . .8-74
8-33 Utility Governor Assembly,
Exploded View. . . . . . . . . .8-76
Number
Title
Page
8-34 Governor Drive Housing,
Exploded View. . . . . . . ...8-78
8-35 Dimensions For Installing
Utility Governor Assembly
Bushings . . . . . . . . . . ...8-81
8-36 Engagement of Control Rack
To Control Lever . . . . . . . . . . . 8-82
8-37 Installing Fuel Rack Setting
Gauge . . . . . . . . . . . . . . 8-84
8-38 Utility Governor Droop Setting. .8-85
8-39 Fuel Injection Group, Exploded
View (2 sheets) . . . . . . ...8-87
8-40 Removing Fuel Regulator
Rack Bearings. . . . . . . . . .8-90
8-41 Installing Regulator Fuel Rack. .8-91
8-42 Fuel Injection Pump Alignment .8-91
8-43 Correct Position of Gear
Segment and Rack . . . . . . .8-92
8-44 Fuel Injection Timing on The
Engine . . . . . . . . . . . . ...8-93
8-45 Aligning Timing Pointer On
Flywheel . 0 . 0 . . . . . . ...8-94
8-46 Fuel Injection Timing off the
Engine . . . . . . . .. . . . . . 8-95
8-47 Accessory Drive Group,
Exploded View . . . . . . . ...8-98
8-48 Accessory Drive Shaft Timing . .8-100
8-49 Exhaust Manifold Group,
Exploded View . . . . . . ...8-102
8-50 Oil Group and Related Parts,
Exploded View . . . . . . ...8-104
8-51 Oil Pump Group, Removal and
Installation . . . . . . . . . ...8-107
8-52 Oil Pump Group, Exploded
View . . . . . . . . . . . . . ...8-108
8-53 Valve Cover and Valve
Mechanism Group, Exploded
View . . . . . . . . . . . . . . . .8-111
8-54 Cylinder Head Group, Exploded
View . . . . . . . . . . . . . . . .8-ll6
xvii
P-9-TM-457-35
TM-07464A-35
T. O. 35C2-3-442-2
TM 5-6115-457-34
LIST OF ILLUSTRATIONS (Continued)
Number
Title
Page
8-55 Valve and Valve Seat
Specifications . . . . . . . . . . 8-118
8-56 Tightening Sequence For
Cylinder Head . . . . . . . . . . 8-119
8-57 Flywheel and Flywheel Housing
Group, Exploded View . . . .8-122
8-58 Installing Crankshaft Seal . . . .8-124
8-59 Flywheel Housing Bore
Concentricity Check . . . . . .8-125
8-60 Flywheel Housing Face
Parallelism Check . . . . . . .8-125
8-61 Camshaft Group, Exploded View
View . . . . . . . . . . . . . . . .8-l27
8-62 Connecting Rods and Pistons
Group, Exploded View . . . . .8-132
8-63 Crankshaft Group and Main
Bearings, Exploded
View . . . . . . . . . . . . ...8-136
8-64 Cylinder Block and Covers
Group, Exploded View
(2 sheets) . . . . . . . . . . . . .8-l42
8-65 Securing Cylinder Liner In Its
Bore and Measuring Height
Projection . . . . . . . . . . . .8-l44
8-66 Location of Manual Fuel
Shutdown Lever . . . . . . . .8-147
9-1 Base Assembly, Exploded
View . . . . . . . . . . . . . ...9-2
9-2 Stowage Tool Box, Exploded
View . . . . . . . . . . . . . ...9-5
9-3 Fuel Tank Assembly, Exploded
View . . . . . . . . . . . . . ...9-7
9A-1 Noise Level Warning Sign . . . . 9A-1
11-1 Fuel Burning Winterization Kit
Control Box, Exploded View .... 11-2
11-2 Fuel Burning Winterization Kit
Heater, Exploded View . . . . 11-6
11-3 Coolant Pump Wear Limits . . . . 11-9
11-4 Coolant Pump Test Set-up . . .. 11-11
xviii
Change 2
Number
Title
Page
12-1 Electric Winterization Kit
Control Box, Test Setup . . . 12-1
12-2 Electric Winterization Kit
Control Box, Exploded View 12-3
12-3 Electric Winterization Kit
Control Box Wiring
Harness . . . . . . . . . . . . .l2-5
12-4 Electric Winterization Kit
Control Box Connector
Wiring Harness . . . . . . . . 12-6
12-5 Electric Winterization Kit
Electric Heater, Exploded
View . . . . . . . . . . . . . . .12-7
12-6 Electric Winterization Kit
Coolant Pump, Exploded
View . . . . . . . . . . . . ...12-10
13-1 Dummy Load Kit, Exploded
View (2 sheets) . . . . . . . . 13-2
13-2 Dummy had Kit Right Side
Wiring Harness (2 sheets) . 13-6
13-3 Dummy Load Kit (Left Side)
Wiring Harness (2 sheets) . 13-8
13-4 Dummy Load Kit Control
Box, Exploded View
(2 sheets) . . . . . . . . . . . .l3-ll
13-5 Dummy Load Kit Load
Dumping Relay (K5),
Test Setup . . . . . . . . ...13-14
13-6 Dummy Load Kits Load
Dumping Relay (K5) . . . . . 13-17
13-7 Dummy Load Kit Control Box
Harness (3 sheets) . . . . . . 13-19
14-l Deleted . . . . . . . . . . ..14-2
14-2 Deleted, . . . . . . . . . .. 14-7
P-9-TM-457-35
TM-07464A-35
LIST OF TABLES
Number
Title
Page
1-1. Repair and Replacement
Stand adds . . . . . . . . . . . . 1-30
1-2. Special Torque Data . . . . . . . 1-41
1-3. Time Standards . . . . . . . . . . 1-43
2-1. Recommended Tools and
Equipment . . . . . . . . . . 2-20
2-2. Specially Designed (Fabricated)
Tools and Equipment . . . . . 2-32
2-3. Troubleshooting . . . . . . . . . 2-33
6-1. Control Box Relay Assembly
(A4) Procedural Analysis . . 6-7
6-2. Circuit Breaker Box Hookup
Wire Data . . . . . . . . . ...6-21
6-3. Fault Locating Indicating
Box (A9) Procedural
Analysis . . . . . . . . . . ...6-25
6-4. Fault Locating Indicator (A 9)
Hookup Wire Data . . . . . . . 6-30
6-5. 50/60 Hertz Convenience
Receptacle Assembly . . . . 6-36
6-6. 400 Hertz Convenience
Receptacle Assembly . ... . 6-37
6-7. Exciter Regulator (A10,
A 11) Procedural
Analysis . . . . . . . . . . . . 6-44
6-8. Voltage Regulator Subassembly
Wire Data . . . . . . . . . ...6-58
6-9. DC Relay Assembly (A 5)
Procedural Analysis . . . . . 6-63
6-10. Mode I Relay Box Assembly
(A27) Continuity Test ., . . 6-69
6-11. Mode I Relay Assembly (A27)
Procedural Analysis . . . . . 6-73
6-12. Electronic Components
Assembly (A6) Hook-up
Wire Data . . . . . . . . ...6-90
6-13. Mode II Relay Box Assembly
(A27) Continuity Test . . ...6-91
●
Number
6-14.
6-15.
6-15A.
6-16.
6-17.
6-18.
6-19.
6-20.
6-21.
6-22.
7-1.
T.O. 35C2-3-442-2
TM 5-6115-457-34
Title
Page
Mode II Relay Box Assembly
(A27) Procedural
6-99
Analysis . . . . . . . . .
6-120
Load Contactor (CB2) Test
Circuit Breaker Assembly
(C B2), Procedural
6-120D
Analysis . . . . . . . . .
Tactical Relay Box (A29)
6-135
Continuity Test . . . . .
Tactical Relay Box (A7)
6-139
Procedural Analysis . .
Precise Relay Box (A25)
Continuity and Resistance
6-153
Test . . . . . . . . . . .
Precise Relay Box (A25)
6-154
Procedural Analysis . .
Precise Governor Control Unit
6-163
(A23) Resistance Checks
Precise Governor Control Unit
(A23) Procedural Analysis 6-165
Load Measurement Unit
6-188
Procedural Analysis . .
Generator Output Lead
Lengths . . . . . . . . .
7-11
8-1.
Timing Plate Degree Setting
8-95
11-1.
Fuel Burning Winter ization
Kit Control Box Wire
Termination Data . . . .
11-3
12-1.
13-1.
14-1.
Electric Winterization
Kit Control Box
Procedural Analysis . . .
12-2
Dummy Load Kit Load lhmping Relay (K5) Procedural
Analysis . . . . . . . . . .
13-15
Deleted . . . . . . . . .
14-3
Change 3
...
xix/(xx blank)
P-8-627-34 T . O 3 5 C 2 - 3 - 4 4 2 - 2
TM-07464A-35 TM 5-6115-457-34
SAFETY STATEMENT
DANGEROUS GASES (Cont)
All specific cautions and warnings contained in this
manual shall be strictly adherred to. Otherwise,
severe injury, death and/or damage to the equipment
may result.
HIGH VOLTAGE
is produced when this generator set is in operation.
When filling fuel tank, maintain metal to metal
contact between filler nozzle and fuel tank. Do not
smoke or use an open flame in the vicinity.
Use extreme care, should a selenium rectifier malfunction, to avoid inhalation of poisonous fumes.
DEATH
or severe burns may result if personnel fail to
observe safety precautions. Do not operate this
generator set until the ground terminal stud has
been connected to a suitable ground. Disconnect
the battery ground cable before removing and
installing components on the engine or in the
electrical control panel system.
Do not attempt to service or otherwise make any
adjustments, connections or reconnection of wires
or cables until generator set is shut-down and
completely de-energized.
CLEAN I NG SOLVENT
Compressed air used for c lean ing and dry
purposes can create airborne particIes
may enter the eyes. Pressure shall not
ceed 30 psig and use only with adequate
guards and chipping goggles.
Exhaust discharge contains noxious and deadly
fumes. Do not operate generator sets in inclosed
areas unless exhaust discharge is properly vented
to the outside.
i ng
that
exchip
Solvent, Dry Cleaning P-D-680, Type II is
flammable and moderately toxic to skin, eyes
and respiratory tract. Eye and skin protection required. Good general ventilation Is
normal Iy adequate.
DANGEROUS GASES
Batteries generate explosive gas during charging;
therefore. utilize extreme caution, do not smoke.
or use open flame in vicinity when servicing
batteries.
LIQUIDS UNDER PRESSURE
are generated as a result of operation of the
generator set. Do not expose any part of the body
to a high pressure leak in the fuel or hydraulic
system of the generator set.
Relieve pressure from radiator before removing
radiator cap.
NOISE
operating level of this generator can cause hearing
damage. Ear protectors, as recommended by the
medical or safety officer, must be worn when
working near this set.
DAMAGE
to the equipment may result if personnel fail to
observe the cautions contained in this manual.
If generator set is shutdown by the operation of
a safety device, do not attempt to operate the
unit until the cause has been determined and
eliminated.
Change 8
0-1/0-2
P-9-TM-457-35
TM-07464A-35
T.O. 35 C2-3-442-2
TM 5-6115-457-34
CHAPTER 1
INTRODUCTION
Section I. GENERAL
1-1. SCOPE.
a. This manual contains instructions for
the use of intermediate (field) (direct and
general support) and depot maintenance
personnel maintaining the 100 KW Diesel
Engine Generator Set, Models MEP007A,
ME P106A, and MEP1 16A, as allocated by
the Maintenance Allocation Chart. It provides information on the maintenance of
equipment which is beyond the scope of the
tools, equipment, personnel, or supplies
normally available to operator and organizational level of maintenance. This manual
is to be used in conjunction with the Operator
and Organizational Maintenance Manual.
b. THIS TECHNICAL MANUAL IS USED
BY THE ARMY, AIR FORCE, NAVY, AND
MARINE CORPS. THE USE OF FORMS
AND COMPLIANCE WITH DIRECTIVES AS
STATED HEREIN WILL BE ACCOMPLISHED ONLY BY PERSONNEL OF THE
SERVICE TO WHICH THEY APPLY.
will be those prescribed by TM4700-15/1,
Other service users should refer to
appropriate specifications/publications for
equipment maintenance forms and records.
b. Report of errors, omissions, and
recommendations for improvement of this
publication by the individual users is encouraged. Reports should be submitted as
follows :
1. Air Force - AFTO Form 22 in
accordance with T. O. 00-5-1 and direct to
Commander, Sacramento Air Logistics
Center, ATTN: MMEDT, McClellan AFB,
California 95652.
2. Army - DA Form 2028 direct to:
Commanding General, U.S. Army Troop
Support and Aviation Material Readiness
Command, ATTN: DRSTS-MTP, 4300
Goodfellow Blvd., St. Louis, Missouri 63120.
3. Marine Corps - by letter direct
to: Commandant, U.S. Marine Corps,
ATTN: Code LME, Washington, D. C. 20380.
1-2. FORMS AND RECORDS.
a. Forms and Records used by the
Army will be only those prescribed by
TM38-750. Those used by the Marine Corps
4. Navy - by letter direct to:
Commanding Officer, U.S. Navy Ships
Parts Control Center, ATTN: Code 783,
Mechanicsburg, Pennsylvania 17055.
Change 4
1-1
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-35
1-2A. RECORD OF APPLICABLE TIME COMPLIANCE TECHNICAL ORDERS.
Date
T.O. No.
35C2-3-442-503
1-2
15 July 77
Change 3
Title
Modification of Generator
Set, DED, 100 KW, 400 Hz,
DOD Model ME P116A, for
comparability with E3AAWACS Program,
(ECP 76CE2122).
Changes/Revisions/Supplement
Date
15 July 77
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Section II. DESCRIPTION AND DATA
Operating temperature range:
1-3. DESCRIPTION.
A general description of the generator sets and information pertaining to the
identification plates are contained in the
Operator and Organizational Maintenance
Manual. A more detailed description of
specific components and assemblies is contained in the applicable section(s) of this
manual. Detailed descriptions of the
components of the generator set are provided in the applicable maintenance paragraphs
of this manual.
1-4. TABULATED DATA.
Voltage Output
120/208 volts and
240/416 volts, 3
phase 4 wire, WYE
connected at reconnection terminals.
Power Factor
0.8
Capacities:
This paragraph contains all
maintenance data pertinent to intermediate
(field) (direct and general support) and
depot maintenance personnel.
a. GENERATOR
SET
MANUFACTURER
without external heat + 125 °F to -25° F
with external heat + 125° F to -65° F
Consolidated Diesel
Electric Company
Old Greenwich,
Connecticut
Model
Mode
Class
MEP 007A
ME P106A
MEP116A
50/60 Hertz
50/60 Hertz
400 Hertz
utility
Fuel System
Cooling System
Hydraulic System
(precise generator
sets only)
90 gallons
11 gallons
6.5 quarts
Dimensions and Weights:
Precise
Precise
Overall Length
Overall Width
Overall Height
Net Weight Empty
Net Weight Filled
Shipping Weight
106 inches
40 inches
65 inches
6680 pounds
7500 pounds
6680 pounds
b. SAFETY DEVICES.
1. Over speed Switch.
DOD Drawing Number
70-4058 or 70-1105
Manufacturer
Synchro-Start Products, Inc.
Skokie, Illinois
International Signal and Control Corp.
Lancaster, Pennsylvania
Change 4
1-2A
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Type
Manufacturers Part Number
Centrifugal, 3-element
50/60 Hz; SA897-3DOB (Synchro-Start)
72-2203-1 (International Signal)
400 Hz; SA1644-3DOB (Synchro-Start)
72-2203-2 (International Signal)
1-2B
Change 4
P-9-TM-457-35 T. O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Operating Temperature
Range
+ 150° F to -65° F
Functions
Disconnects starter, flashes generator field,
and energizes precise governor on precise
generator sets.
Operating speed
Switch rotates at half of engine speed.
Element 1
Starter disconnect and field flash. SPDT contact
arrangement. Contacts transfer at 290-310 RPM
rising switch speed. Automatic reset 100 RPM
maximum below trip speed. Contact rating 3
ampere inductive at 28 VDC.
Element 2
Energizes precise governor on precise generator
sets. Not utilized on utility generator sets. SPST
contacts close at 590-610 RPM rising switch speed
on 60 hertz sets, and 825-850 RPM rising switch
speed on 400 hertz sets. Automatic reset 100
RPM maximum below trip speed. Contact rating
10 amperes inductive at 28 VDC.
Element 3
Overspeed. Two separate SPST contact sets;
one open, one closed. Transfers at 1200-1225
RPM rising switch speed. Manual reset by
button on rear of switch. Contact rating 10
amperes inductive at 28 VDC.
Weight
1.50 pounds (approx.)
Overall dimensions
2.60 dia. x 8.00 inches (approx.)
2. Over Voltage Relay
DOD Drawing Number
70-1138
Manufacturer
Electromagnetic Industries, Inc.
Clearwater, Florida
Manufacturer’s Part Number
11486
Nominal Voltage
120 volts, 50 to 450 hertz
Voltage Trip Point
0
Weight
Trip at 156 volts ± - volts
2
0
Trip at 151 volts ± volts
2
1 pound (approx.)
Overall dimensions
3 . 0 9 x 3 . 4 4 x 2 . 6 6 inches (approx.)
50 to 100 hertz operation
350 to 450 hertz operation
Change 7 1-3
P-9-TM-457-35
TM-07464A-35
T.O. 35 C2-3-442-2
TM 5-6115-457-34
Time Delay
0.18 to 0.8 second
Contact Rating
10 amperes, 28.5 VDC resistive
Temperature Limits
-85° F to + 185° F
Temperature Effect On
Pull-In Voltage
Changes ± 1 volt at -85°F
Changes ± 1 volt at + 185° F
3. Under Voltage Relay
DOD Drawing Number
70-1120
Manufacturer
Electromagnetic Industries, Inc.
Clearwater, Florida
Manufacturer’s Part Number
11636
Nominal Input
120 volts, 50 to 400 Hz, 100 milliamperes
maximum
Dropout Voltage
99 volts
Dropout Voltage Tolerance
± 1 volt at 60 hertz and 75° F, ± 4 volts at
any combination of frequency and temperature within specified limits.
Frequency Range
50 to 400 hertz.
±1.5 volt
Temperature Limits
-65°F to + 170° F. Temperature trip effect
±1.5 volt
Time Delay
6 ± 2 seconds above 72 volts, instantaneous
below 48 volts
Pull In Voltage
112 volts
Contact Arrangement
DPDT. Terminals 3, 4 and 5 isolated from
terminals 6, 7 and 8. Normally closed contacts
are terminals 3 to 4 and terminals 6 to 7.
Contact Rating
10 ampere resistive or 5 ampere
inductive, 28 VDC.
Service Life
5, 000 hours minimum
Weight
1 pound (approx. )
Overall dimensions
4.28 x 3.375 x 3.53 inches (approx.)
1-4 Change 7
Frequency trip effect
P-9-TM-457-35
TM-07464A-35
4.
TO 35 C2-3-442-2
TM 5-6115-457-34
Under Frequency Relays
(a) 400 hertz generator sets
DOD Drawing Number
70-1141
Manufacturer
Electromagnetic Industries Inc.
Clearwater, Florida
Wilmar Electronics Inc.
Torrance, California
Manufacturer’s Part Number 23370 (Electromagnetic Ind.) 20-350-1 (Wilmar
Electronics
Nominal Input
120 volt, 400 hertz, 200 milliamperes, maximum
Trip Frequency
370 ± 0.5 hertz at 120 volt and 75%
Temperature Range
-65° F to +170° F
Service Life
5000 hours minimum
Contact Arrangement
Contacts 3 and 4 normally closed.
Contacts 5 and 6 normally open.
Contact Rating
10 ampere resistive or 5 ampere inductive, 28 VDC.
Weight
1 pound (approx.)
Overall dimensions
3.09 x 3.44 x 2.66 inches (approx.)
(b) 50/60 hertz generator sets
DOD Drawing Number
70-1119
Manufacturer
Electromagnetic Industries, Inc.
Clearwater, Florida
Wilrnar Electronics, Inc.
Torrance, Cal ifornia
Manufacturer’s Part Number 11638 (Electromagnetic Ind.) 20-050-5 (Wilrnar
Electronics)
Nominal Input
120 volt, 50 or 60 hertz, 200 milliamperes, max.
Trip Frequency
46 hertz for 50 hertz operation or 55 hertz
for 60 hertz operation at 120 volts and 75° F
Trip Frequency Selections
Switching between terminals 7 and 8. Switch
closed for 50 hertz operation and open for 60
hertz operation.
Voltage Input Limits
± 10 percent of nominal
Change 10
1-5
P-9-TM-457-35 T.O. 35C2-3-442-2
TM 5-6115-457-34
TM-07464A-35
5.
Voltage Trip Effect
± 0. 2 hertz
Temperature Range
-65° F to + 170° F
Temperature Trip Effect
±0.2 hertz
Service Life
5000 hours minimum
Contact Arrangement
Contact 3 and 4 normally closed.
Contact 5 and 6 normally open.
Contact Rating
10 ampere resistive or 5 ampere inductive, 28 VDC
Weight
1 pound (approx.)
Overall dimensions
3.09 x 3.44 x 2.66 inches (approx.)
Short Circuit Relay
(a) 50/60 hertz generator sets
DOD Drawing Number
70-1137
Manufacturer
Electromagnetic
Industries, Inc.
Clearwater, Florida
Manufacturer’s Part Number
21380C 1 (Electromagnetic Ind.) 800 (Wilmar
Electronics)
Function
Trips if generator set output current exceeds
425 ± 25 percent of generator set rated current.
Trip Voltage
24 volts at 60 hertz and 75° F on any phase to neutral
Trip Voltage Tolerance
±0.3 volt at 60 hertz and 75° F, ±1.5 volt at any
Wilmar Electronics, Inc.
Torrance, California
combination of frequency and temperature
deviation within specified limits.
1-6 Change 7
Frequency Range
50 to 400 hertz. Frequency trip effect ±0.6 volt
Temperature Limits
-65° F to + 170°F. Temp. trip effect ±0.6 volt
Operating Time
Instantaneous
Contact Arrangement
Contacts 5 and 6 normally closed.
Contacts 7 and 8 normally open.
Contact Rating
10 amperes resistive, 28 VDC
Service Life
5000 hour minimum
Weight
1 pound (approx.)
Overall dimensions
3.09 x 3.44 x 2.66 inches (approx.)
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
(b) 400 hertz generator sets
DOD Drawing Number
76-4181
Manufacturer
Electromagnetic Industries, Inc.
Clearwater, Florida
Manufacturer’s Part Number
63030-230-50
Function
Trips if generator set output current exceeds
180 ±25 percent of generator set rated current.
Trip Voltage
10 volts at 60 hertz and 75° F on any phase to
neutral
Trip Voltage Tolerance
±0.3 volt at 60 hertz and 75°F, ±1.5 volt at any
combination of frequency and temperature deviation within specified limits.
Frequency Range
50 to 400 hertz. Frequency trip effect ±0.6 volt.
Temperature Limits
-65° F to +170°F. Temperature trip effect
±0.6 volt.
operating Time
Instantaneous.
Contact Arrangement
Contact 5 and 6 normally closed.
Contacts 7 and 8 normally open.
Contact Rating
10 amperes resistive, 28 VDC.
Service Life
5000 hour minimum.
Weight
1 pound (approx.).
Overall Dimensions
3.09 x 3.44 x 2.66 inches (approx.).
Change 3
1-6A
P-9-TM-457-35
TM-07464A-35
6.
T.O. 35 C2-3-442-2
TM 5-6115-457-34
Reverse Power Relay
(a) 50/60 hertz generator sets
DOD Drawing Number
70-1136
Manufacturer
Electromagnetic
Industries, Inc.
Clearwater, Florida
Manufacturer’s Part Number
21690-1 (Elect. Ind. ) 700-2 (Wilmar Elect. )
Function
Trips when reverse power into generator set
Wilmar Electronics, Inc.
Torrance, California
exceeds 20 percent of rated output.
DC Input Voltage
0-10 VDC with AC signal superimposed on DC
input, 20 volts maximum.
External Power
24 VDC across terminals 3 and 4, terminal 3
is positive.
Trip Voltage
2 VDC across terminals 1 and 2, terminal 1 is
positive. (Corresponds to approximately 20
percent reverse power. )
Trip Voltage Tolerance
±0.1 VDC under standard conditions. ±1 VDC
with any combination of superimposed AC frequency and temperature within specified limits.
Frequency Range
50 to 400 hertz. Frequency trip effect
±.4 VDC.
Temperature Limits
-65° F to +170°F. Temperature trip effect
±0.5 volt.
Contact Arrangement
Contacts 5 and 6 normally open.
Contacts 7 and 8 normally closed.
Contact Rating
10 amperes resistive, 28 VDC.
Service Life
5000 hour minimum.
Weight
1 pound (approx. )
Overall Dimensions
3.09
1-6B Change 7
x
3.44
x
2.66 inches (approx. )
P-9-TM-457-35 T.O. 35 C2-3-442-2
TM-07464A-35 TM 5-6115 -457-34
6.
Reverse Power Relay
(b) 400 hertz generator sets
76-4194
DOD Drawing Number
Manufacturer
Electromagnetic
Industries, Inc.
Clearwater, Florida
Manufacturer’s Part Number
63030-240-50 (El. Ind.)
Function
Trips when reverse power into generator
set exceeds 50 percent of rated output.
DC Input Voltage
0-10 VDC with AC signal superimposed on
DC input, 50 volts maximum.
External Power
24 VDC across terminals 3 and 4, terminal
3 is positive.
Trip Voltage
5 VDC across terminals 1 and 2, terminal
1 is positive. (Corresponds to approximately
50 percent reverse power.)
Trip Voltage Tolerance
±0.1 VDC under standard conditions. ±1
VDC with any combination of superimposed
AC frequency and temperature within
specified limits.
Frequency Range
50 to 400 hertz.
±.4 VDC.
Temperature Limits
-65° F to +170°F. Temperature trip effect
±0.5 volt.
Contact Arrangement
Contacts 5 and 6 normally open.
Contacts 7 and 8 normally closed.
Contact Rating
10 amperes resistive, 28 VDC
Service Life
5,000 hour minimum.
Weight
1 pound (approx.)
Overall dimensions
3.09 x 3.44 x 2.66 inches (approx.)
Frequency trip effect
7. Overload Relay
DOD Drawing Number
70-1135
Manufacturer
Consolidated Diesel Electric Co.
Old Greenwich, Corm.
Change 7 1-7
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Manufacturer’s Part Number 00000-4857
Function
Trips if current in anyplace exceeds 110
percent of rated current on an inverse time
principle.
AC Input (Signal)
3 wire, 3 phase 50/60 and 400 Hz 0.75
ampere per phase (at 100 percent rated load)
DC Input
28 VDC 0.1 ampere maximum.
Time Delay
Operates in a minimum of 8 minutes ±2
minutes after the current in any phase
remains at 130 percent of rated current.
Temperature Limits
-65° F to +140°F
Contact Arrangement
Two contacts, 1 normally open, 1
normally closed
Contact Rating
10 ampere resistive or 5 ampere inductive,
28 VDC
Service Life
5,000 hour minimum
Weight
1 pound (approx.)
Overall dimensions
3.87 x 2.68 x 3.62 inches (approx.)
8. Permissive Paralleling Relay
DOD Drawing Number
70-1118
Manufacturer
Electromagnetic Industries Inc.
Clearwater, Florida
Manufacturer’s Part Number
23390
External Power Required
24 VDC, 200 milliamperes maximum.
Input Signal AC Burden
0-20 VAC, 60 to 400 hertz. At 300 VAC,
40 milliamperes maximum.
Contact Operation
5 and 6 normally closed with AC signal
above 10 volts. 7 and 8 normally open
with AC signal above 8 ± 1 volt.
Contact Rating
28 VDC, 10 amperes resistive, 5 amperes
inductive.
Life Expectancy
5,000 hours minimum
Weight
1 pound (approx.)
Overall dimensions
2.56 x 3.38 x 3,00 inches (approx.)
1-8 Change 7
P-9-TM-457-35
TM-07464A-35
T.O. 35 C2-3-442-2
TM 5-6115-457-34
c. RADIATOR
DOD Drawing Number
70-4088
Manufacturer
G & O Manufacturing Company,
New Haven Corm.
Manufacturer’s Part Number
X-1817
Coolant Capacity
21.3 quarts
Heat Rejection:
Water GPM
flow
Engine RPM
speed
62
70
80
1500
1800
2000
Heat BTU/rein.
rejection
35
34
37
Air Test Pressure
15 PSI
Operating Pressure
7 PSI
Weight
115 pounds (approx.)
Overall dimensions
28.25 x 39.0 x 10.00 inches (approx.)
d. RADIATOR SHUTTER AND CONTROL ASSEMBLY.
DOD Drawing Number
70-4092
Manufacturer
Evans Products Company
Coldwater, Michigan
Manufacturer’s Part Number
1 G 409
Type
16 vanes with left hand manual control
handle, thermostat operated
Control Element Setting
Nominal 170” F (158° F crack open, 173° F
full open)
Weight
10 pounds (approx.)
Overall dimensions
30.56 x 32.25 x 2.5 inches (approx.)
e. GENERATOR CONTROL ASSEMBLY
1. DC Circuit Breaker
DOD Drawing Number
MS25244-7. 5
Rating
24 VDC 7.5 amperes
Change 7 1-9
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Circuit Breaker Reset
Manual
Contact Arrangement
SPST
Weight
0.25 pounds (approx.)
Overall dimensions
2.00 x 1.80 x 0.75 inches (approx.)
2. Convenience Receptacle Box Assembly
(a) 50/60 hertz generator sets
DOD Drawing Number
70-4101
Number of Receptacles
1 duplex
Voltage
120 VAC
Current
15 amperes
Circuit Breaker Reset
Manual
Weight
5 pounds (approx.)
Overall dimensions
9.62 x 3.0 x 5.50 inches (approx.)
(b) 400 hertz generator sets
DOD Drawing Number
70-4107
Number of Receptacles
2
Receptacle 1 rating
125/250 VAC, 30 amperes
Receptacle 2 rating
125 VAC, 15 amperes
Circuit breaker Reset
Manual
Weight
5 pounds (approx.)
Overall dimensions
9.62 x 3.0 x 5.50 inches (approx.)
3. Exciter Regulator (Voltage)
DOD Drawing Number
70-4145 (50/60 Hertz generator sets)
70-4235 (400 Hertz generator sets)
Manufacturer
Consolidated Diesel Electric Co.
Old Greenwich, Connecticut
Solid state, with capability to automatically
flash field of generator.
Voltage Regulation:
Precise Sets
Utility Sets
1-10
1 percent of rated voltage
3 percent of rated voltage
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Voltage Stability:
Short Term (30 seconds)
Precise Sets
within bandwidth equal to 1 percent of
rated voltage.
Utility Sets
within bandwidth equal to 2 percent of
rated voltage.
Long Term (4 hours)
Precise Sets
within bandwidth equal to 2 percent of
rated voltage.
Utility Sets
within bandwidth equal to 4 percent of
rated voltage.
Voltage Drift (8 hours)
1 percent
Transient performance
(application or rejection
of load).
Resumption of steady
state condition :
Precise Sets
within 0.5 seconds
Utility Sets
within 3 seconds
Overshoot and Undershoot:
Precise Sets (50/60 Hertz) 15 percent of rated voltage
4.
Precise Sets (400 Hertz)
12 percent of rated voltage
Utility Sets
20 percent of rated voltage
Weight
40 pounds (approx.)
Overall dimensions
20.0 x 6.50 x 9.88 inches (approx.)
Load Contactor (CB2) (50/60 hertz generator sets)
DOD Drawing Number
70-501
Manufacturer
Hartman Electric Manufacturing
Mansfield, Ohio
HB Electrical Mfg. Co.
Mansfield, Ohio
Manufacturer’s Part Number
B-301E (Hartman Electric)
HB200A (HB Electrical)
Change 4
1-11
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
KVA Rating
125 KVA
Mechanism
Electrically held
Main Contacts
3 PST double break
AC Voltage
Frequency
Continuous Current
Second Current
Interrupting Capacity
Auxiliary Contacts
DC Voltage
Current
AC Voltage
Current
Lamp Current
DC
50/60 Hertz
400 Hertz
Auxiliary Contacts Trip
Time
120/208-240/416 Volts
50/60 and 400 Hertz
50/60 and 400 Hertz
350 amperes at 120/208
50/60 and 400 hertz
750 amperes at 120/208
50/60 and 400 hertz
5000 amperes at 120/208
50/60 and 400 hertz
2500 amperes at 240/416
50/60 and 400 hertz
volts
volts
volts
volts
4 SPST normally open, 2 SPST normally closed
and 1 SPDT.
32 Volts
2.5 amperes maximum resistive or
inductive
120 Volts
2.0 amperes maximum
4.0 amperes maximum
1.5 amperes maximum
3.0 amperes maximum
Within 0.004 seconds of main contacts
activation.
Coil Data
Operating Voltage
32 VDC Maximum
16 VDC Minimum (without external series
resistance)
Main Contacts Maximum
Operating Time
1-12
Close
0.050 Seconds at 24 to 32 VDC with 0.25 ohms
resistance in series with coil.
Open
0.035 Seconds at 24 to 32 VDC with 0.25 ohms
resistance in series with coil.
Change 1
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Duty Cycle
Continous
Maximum Holding Current
0.75 amperes at 32 VDC after 30
minutes warmup.
Pulling Current
Contactor shall close with 24 VDC applied
across the operating coil and a 5.0 ohm
resistor in series.
Electrical Life
10,000 cycles at a duty cycle of not less than 325
make and break operations per hour. With the ON
portion of the cycle not less than 1.0 seconds and
the OFF portion of the cycle not more than
10.0 seconds.
Mechanical Life
100,000 cycles
Weight
4 pounds (approx.)
Overall dimensions
4.80 x 6.06 x 4.80 inches (approx.)
4A. Circuit Breaker Assembly (CB2) (400 hertz generator sets)
DOD Drawing Number
76-4191
Manufacturer
Consolidated Diesel Electric Co.
Old Greenwich, Connecticut
Main Contacts
3 pole normally open, 400 ampere
Current Rating (minimum)
350 amperes continuous at 208 volts and
175 amperes at 416 volts
1600 amperes for 4 seconds
Interrupting Capability
42,000 amperes
30,000 amperes at 416 volts
Auxiliary Contacts
SPST normally open contacts,
3 rated 10 amperes; 1 rated 5 amperes
Temperature Range
-65°F to +135° F
Weight
25 pounds (approx.)
Overall Dimensions
7.75 x 8.50 x 16.00 inches (approx.)
Change 3
1-13
P-9-TM-457-35
TM-07464A-35
5.
T.O. 35C2-3-442-2
TM 5-6115-457-34
Current Transformer Assembly
(a) Current transformer (CT1, CT2, and CT3)
DOD Drawing Number
70-4084
Manufacturer
Electromagnetic Industries, Inc.
Clearwater, Florida
Manufacturing Part Number
51
Primary Current
464 amperes
Secondary Current
1 ampere
Turns Ratio
1 primary to 464 secondar
Frequency
50/60 and 400 hertz
Burden
12. 5VA minimum at 1 ampere secondary current.
Temperature Range
-65° F to +155° F
Weight
3 pounds (approx.)
Overall Dimensions
3.75 x 3.75 x 2,19 inches (approx.)
(b) Current Transformer Exciter CT 4 (400 Hertz Generator Sets)
1-14
DOD Drawing Number
71-4891
Manufacturer
Consolidated Diesel Electric Co.
Old Greenwich, Connecticut
Change 3
P-9-TM-457-35
TM-07464A-35
T. O. 35C2-3-442-2
TM 5-6115-457-34
Manufacturing Part Number
00000-4928
Total Turns
94
Rated Voltage
40VAC
Rated Current
3.7 amperes
Resistance
0.15 ohms ± 20 percent
Frequency
400 hertz
Excitation Current
With 40 volts RMS applied exciting current
is 0.5 amperes RMS maximum
High Potential Rating
2,000 volts between winding and core.
Temperature Range
-65° F to + 155° F
Weight
3 pounds (approx.)
Overall dimensions
5.00 x 4.20 x 2.75 inches (approx.)
(c) Current Transformer CT 4 (50/60 Hertz Generator Sets)
DOD Drawing Number
70-4067
Manufacturer
Consolidated Diesel Electric Co.
Old Greenwich, Connecticut
Manufacturing Part Number
00000-4921
Total Turns
260
Rated Voltage
60 VAC
Rated Current
2.7 amperes
Resistance
0.83 ohms
Frequency
60 hertz
Excitation Current
With 60 volts RMS applied, exciting current
is 0.30 amperes maximum
Temperature Range
-65° F to +155° F
Weight
3 pounds (approx.)
Overall dimensions
5.38 x 5.38 x 3.50 inches (approx.)
(d) Current Transformer Exciter CT5 and CT6 (400 Hertz Generator Sets)
DOD Drawing Number
71-4892
Manufacturer
Consolidated Diesel Electric Co.
Old Greenwich, Connecticut
Change 3
1-14A/( 1-14B blank)
P-9-TM-457-35 T. O. 35C2-3-442-2
TM-07464A-35
TM 5-6115-457-34
Manufacturing Part Number
00000-4929
Total Turns
47
Rated Voltage
35 VAC
Rated Current
7.4 amperes
Resistance
0.05 ohms ± 20 percent
Frequency
400 hertz
Excitation Current
With 35 volts RMS applied exciting current
is 1.0 amperes RMS maximum
High Potential Rating
2000 volts between winding and core
Temperature Range
-65° F to +155° F
Weight
2 pounds (approx.)
Overall dimensions
5.00 x 4.12 x 3.25 inches (approx.)
(e) Current transformer CT5 and CT6 (50/60 Hertz Generator Sets)
DOD Drawing Number
70-4086
Manufacturer
Consolidated Diesel Electric Company
Old Greenwich, Connecticut
No Load Voltage
60 volts
Current
8.0 amperes
Resistance
0.22 ohms
Frequency
50/60 Hertz
Excitation Current
0.90 amperes m aximum
Total Turns
87
Temperature Range
-65° F to + 155° F
Weight
3 pounds (approx.)
Overall dimensions
5.38 x 5.63 x 6.0 inches (approx.)
(f) Current transformer CT7
DOD Drawing Number
70-4085
Manufacturer
Electromagnetic Industries Inc.
Clearwater, Florida
1-15
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-0746 4A-35 TM 5-6115-457-34
Manufacturing Part Number
6 (400/1 ratio)
Primary Current
600 amperes
Secondary Current
1.5 amperes
Turns Ratio
1 primary to 400 secondary
Frequency
50/60 and 400 hertz
Burden
25VA minimum
Temperature Range
-65° F to + 155° F
Weight
3 pounds (approx.)
Overall dimensions
3.94 x 1.25 inches (approx.)
6. Precise Governor System (LEH GOVERNOR)
Type
Closed loop feedback system
(a) Governor control unit
Type
Solid state
DOD Drawing Number
400 Hertz Generator Sets 69-800
50/60 Hertz Generator Sets 69-700
Manufacturer
Electromagnetic Industries, Inc.
Clearwater, Florida
Manufacturer Part Number
400 Hertz Generator Sets 22910
50/60 Hertz Generator Sets 22810
Input Voltage
24 VDC and single phase
120 VAC from generator output
Weight
7 pounds (approx.)
Overall dimensions
10.41 x 10 x 4.06 inches (approx.)
(b) Governor actuator unit
DOD Drawing Number
69-790-3
Manufacturer
Electromagnetic Industries, Inc.
Clearwater, Florida
Type
Hydraulic, differential pressure operated
Manufacturer Part Number
23600-3
Piston Position
Transducer
Variable reluctance type
1-16 Change 7
P-9-TM-457-35
TM-07464A-35
Input Pressure
Hydraulic Fluid Type
Input Voltage
Frequency
Weight
Overall dimensions
T.O. 35 C2-3-442-2
TM 5-6115-457-34
300 to 320 PSI
MIL-H-5606
120 volts
50/60 or 400 hertz
3 pounds (approx)
6.00 x 2.91 x 4.90 inches (approx.)
(c) Hydraulic Pump
DOD Drawing Number
70-4038
Manufacturer
John S. Barnes Corp.
Rockford, Illinois
Type
Gear driven, positive displacement
Manufacturer’s Part Number
GC5100 - A-82-A
Rating
2 GPM
Drive Type
Tang with drive coupling
Relief Valve Type
Pressure
Drive Speeds
Rotation
Weight
Overall dimensions
Adjustable plunger
320 ± 10 PSI
1500 to 2116 RPM
Clockwise (viewed from drive end)
10 pounds (approx.)
3.56 x 3.56 x 2.81 inches (approx.)
(d) Hydraulic Tank Assembly
DOD Drawing Number
71-4476
Type
Welded with filler cap level gauge.
Capacity
6 quarts
Type Fluid
MIL-H-5606
Weight
12 pounds (approx.)
Overall dimensions
3.75 x 16 x 8.50 inches (approx.)
7. Load Measuring Unit
DOD Drawing Number
69-785
Manufacturer
Electromagnetic Industries, Inc.
Clearwater, Florida
Type
Electrical, three phase load sensing
Manufacturer’s Part
Number
69-500
1-17
P-9-TM-457-35 T.O. 35 C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Frequency Regulation
Isochronous ±1/4 of 1 percent.
Frequency Stability:
Short Term
(30 Seconds)
Within bandwidth equal to 1/2 of 1 percent
of rated frequency.
Long Term
(4 Hours)
within bandwidth equal to 1 percent of
rated frequency.
Frequency Drift
(8 Hours)
1/2 of 1 percent.
Transient performance
(application or rejection
of load).
Stable Operation
within 2 seconds.
Overshoot or
Undershoot
4 percent of rated frquency
Weight
3 pounds (approx.)
Overall dimensions
6.00 x 3.80 x 4.38 inches (approx.)
f. GENERATOR
DOD Drawing Number
50/60 Hertz Generator Sets 70-4001
400 Hertz Generator Sets 70-4002
Manufacturer
Lima Electric Motor Company
Type
2 Types: 50/60 Hertz or 400 Hertz.
Both are synchronous, brushless,
with integral exciter.
Operating Speed:
50 Hertz
60 Hertz
400 Hertz
1500 RPM
1800 RPM
2000 RPM
Kilowatt Rating (KW):
(At 0.8 P. F.)
50 Hertz
60 and 400 Hertz
1-18
83.3
100
P-9-TM-457-35 T.O. 35C2-3-443-2
TM-07464A-35
TM 5-6115-457-34
Kilovolt Ampere
Rating (KVA):
50 Hertz
60 and 400 Hertz
104
125
Current rating for 3 phase
balanced rated load with
generator coils connected in
WYE at reconnection terminals.
50 Hertz:
120/208 Volts
240/416 Volts
288
144
60 and 400 Hertz:
120/208 Volts
240/416 Volts
346
173
Weight
1,500 pounds (approx.)
Overall dimensions
34 x 36 x 30 inches (approx.)
g. ENGINE
DOD Drawing Number
Manufacturer
*70-4013
Caterpillar Tractor Company
Peoria, Illinois
Four stroke cycle, liquid cooled, turbo
charged, compression ignition, diesel.
Model
*D333C(T)
Number of Cylinders
six
Piston Displacement
638 cubic inches
Rotation
Counterclockwise from flywheel end.
Lubricating Oil
Capacity
30 quarts
Weight
2,200 pounds (approx.)
Overall dimensions
53. 19 x 40,00 x 35.50 Inches (approx.)
*At time of engine replacement, the D333C(T) engine is to be used until stock of these
engines is exhausted; at which point the D3306(T), (76-4106) engine will be used. Refer to paragraph 2-10 for engine change instructions. Refer to Generator Set “B”
Model Manual for maintenance of the D3306(T) engine.
h.
ENGINE ACCESSORIES
1.
Battery Charging Alternator
Change 4
1-19
P-9-TM-457-35 T.O. 3SC2-3-442-2
TM-07464A-35
TM 5-6115-467-34
DOD Drawing Number
69-780-2
Manufacturer
Motorola, Inc.
Franklin Park, Ill.
Type
Alternator with integral voltage regulator
and transient voltage suppressor
Manufacturers Part Number
70 D44672B02
Rating
0-35 amperes at any speed from 1900 to
4000 RPM within temperature limits
Temperature limits
-65° F to + 175° F
Drive
V-belt, 0.500 nominal width
Maximum voltage under
load removal or other
condition
32 volt average, 50 volt spikes or
transients
Fuse rating
Style 4AG, 32 volts, 40 amperes
Field (rotor) current
1.25 to 1.75 amperes at 24.0 volts
Brush Spring Tension
4 to 6 ounces.
Rotor Assembly Resistance
11 to 14 ohms.
Weight
13.5 pounds (approx.)
Overall dimensions
8.34 x 7.40 x 5.50 inches (approx.)
2. Starter Motor
DOD Drawing Number
70-4046
Manufacturer
The Prestolite Company
Toledo, Ohio
Heavy Duty
1-20
Manufacturer Part Number
MFY-6501E UT
Operating voltage
24 VDC
Brushes
8 brushes in 4 brush holders
Rotation
Clockwise, drive end
Engagement
Indexing type
P-9-TM-457-35 T. O. 35 C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Actuation
Shifting solenoid, mounted on motor
No load readings
20.0 volts, 65 maximum amperes 5000 minimum
RPM
Stall readings
4.0 volts, 400 maximum amperes 22 minimum
foot pounds.
Solenoid shunt
winding draw (70° F)
4.1 to 4.8 amperes at 12.0 volts
Solenoid series
winding draw (70° F)
23.2 to 26.6 amperes at 12.0 volts
Weight
6.5 pounds (approx.)
Overall dimensions
19.32 x 9.00 inches (approx.)
3. Day Tank Fuel Level Switch
DOD Drawing Number
70-4082
Manufacturer
Rucker Precision
Santa Ana, California 92705
Manufacturer Part Number
1145-0055.
Contact Rating
6 to 32 VDC, 50 watts maximum, 3.0 amperes
maximum.
Operating Pressure
0 to 150 PSI
Temperature Limits
-65° F to + 200” F
Fuel Type
JP4 or W-F-800
Switch Arrangement
2 switches upper and lower NO
Switch Operation
At full level switches are NO. At low level
switches are NC. At middle level upper switch
NC and lower switch open..
Weight
1 pound (approx.)
Overall dimensions
2.00 x 10.00 inches (approx.)
4. Tachometer Drive
Manufacturer
Caterpillar
Peoria, Illinois
Manufacturer Part Number
5R 1944
Operating Speed
One half engine RPM
Drive Connection
S.A. E. Heavy duty 3/16 pin and tang.
Weight
1 pound (approx.)
Overall dimensions
3.00 x 2.00 x 2. 50 inches (approx.)
1-21
P-9-TM-457-35
TM-07464A-35
T. O. 35C2-3-442-2
TM 5-6115-457-34
5, Fuel Transfer Pump
Manufacturer
Caterpillar
Manufacturer Part Number
7L543
RPM
One half engine RPM
Flow Rate
50 GPM
Discharge
20 PSI
Weight
1.5 pounds (approx.)
Overall dimensions
2.75 x 3.40 x 2.75 inches (approx.)
6. Turbocharger
Manufacturer
Air Research Manufacturing Corporation
Los Angeles, California
Part Number
407640-3
RPM at Rated Load
52,000 RPM at 1800 RPM
Method of Lubrication
Engine oil system 1 to 2 GPM
Intake Manifold Pressures
at Rated Load
8 to 10 inches mercury at 1800 RPM
Weight
60 pounds (approx.)
Overall dimensions
16.00 x 12.00 x 11.81 inches (approx.)
7. Oil Cooler
Manufacturer
Caterpillar
Peoria, Illinois
Part Number
7L7749
Coolant Flow
Engine jacket water through tubes
Oil Flow
Baffled flow around outside diameter of tubes.
Weight
75 pounds (approx.)
Overall dimensions
7.50 x 7.00 x 7.00 inches (approx.)
8. Water Pump
1-22
Manufacturer
Caterpillar
Part Number
5R1612
Type
Centrifugal
P-9-TM-457-35 T. O. 35 C2-3-442-2
TM 5-6115-457-34
TM-07464A-35
Type of Drive
Gear driven
Water Flow Rate
70 GPM at one half engine RPM engine speed.
Weight
15 pounds (approx.)
Overall dimensions
5.40 x 7.75 x 4.00 inches (approx.)
9. Utility Governor
Manufacturer
Woodward Governor Company
Rockford, Illinois
Type
Hydraulic speed droop.
Frequency Regulation
Adjustable from 1-1/2 to 3 percent of rated
frequency.
Part Number
8510-212
Frequency Stability:
Short Term
(30 Seconds)
within bandwidth equal to 2 percent of
rated frequency.
Long Term
(4 Hours)
within bandwidth equal to 3 percent of
rated frequency.
Frequency Drift
(8 Hours)
1 percent.
Transient Performance:
(application or rejection of
load).
Stable Operation
Overshoot
Undershoot
Weight
Overall dimensions
within 2 seconds
4 percent of rated frequency.
3 percent of rated frequency.
7.00 pounds (approx.)
5.30 x 7.50 x 6.25 inches (approx.)
10. Fuel Injection Pump
Manufacturer
Caterpillar
Peoria, Illinois
Part Number
5R1739
Firing Order
1-5-3-6-2-4.
Injection Timing
13 degrees, 30 minutes before top
dead center
1-23
P-9-TM-457-35
TM-07464A-35
T.O. 35 C2-3-442-2
TM 5-6115-457-34
Number of Individual Pumps 6
Type of Drive
Gear driven.
Speed
One half engine RPM
Weight
20 pounds (approx.)
Overall dimensions
9.50 x 7.00 x 5.00 inches (approx.)
i. FUEL BURNING WINTERIZATION KIT (Optional)
DOD Drawing Number
71-4410
Manufacturer
Consolidated Diesel Electric Company
Old Greenwich, Connecticut
1. Engine Heater
DOD Drawing Number
69-775
Manufacturer
Test Institute Corporation
Benmar Heater Division
Cleveland, Ohio
Manufacturer Part Number
CP 3050-24
Fuel
JP 4 Arctic diesel fuel
Fuel Rate
21 to 23 cc per minute
Fuel Pressure
3 to 15 PSI
Relief valve setting
30 to 35 PSI
Voltage
24 VDC
Radio Interference
Suppression
0.15 to 1000 mega-cycles
Coolant Circulation
80-100 GPH at 10 PSI
output
Transfer to Coolant
Usable Exhaust Heat
1-24
30,000 BTU per hour maximum
10,000 BTU per hour maximum
P-9-TM-457-35 T.O. 35C2-3-442-2
TM 5-6115-457-34
TM-07464A-35
Operating Power Requirements
Above + 30°F
Start
Run
14.5 amperes
5.0 amperes
Below + 30°F
Start
Run
17.0 amperes
7.5 amperes
Weight
20 pounds (approx.)
Overall dimensions
19.82 x 10.12 x 6.32 inches (approx.)
2. Coolant Thermostat Switch
DOD Drawing Number
70-4044
Manufacturer
NASON Company
Clarkston, Michigan.
Mfr. Part Number
TC-125B-50M-2AN.
Contacts Rating
28 VDC, 15 amperes resistive, 10 amperes
inductive.
Contacts Arrangement
2 contacts normally closed
Contacts Operation
contacts open at + 125 ± 5° F, contacts close at
+ 50 ±5° F
Temperature Limits
-65° F to + 230° F.
Life Expectancy
1 year or 5,000 operating hours.
Weight
1 pound (approx.)
Overall dimensions
2.43 x 4.75 inches (approx.)
3. Control Box
j.
DOD Drawing Number
69-650
Circuit Breaker Type
Manual reset.
Circuit Breaker Current
15 amperes
Switch Arrangement
2 PST normally open
Control Box Function
Protects heater circuitry against overload, in OFF
position heater will continue to operate for
4 1/2 minutes.
Weight
1 pound (approx.)
Overall dimensions
5.75 x 4.50 x 3.00 inches (approx.)
ELECTRIC WINTERIZATION KIT (Optional)
DOD Drawing Number
71-4430
1-25
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Manufacturer
Consolidated Diesel Electric Company
1. Electric coolant heater 2500 Watts
DOD Drawing Number
70-4073
Manufacturer
Kim Hotstart Manufacturing Co.
Spokane Washington.
Mfg. Part Number
BC 220
Rating
2500 watts at 230 volts (nominal,
50/60 and 400 hertz
Operating Voltage
205 to 240 volts.
Flow Rate
30 to 40 gallons per hour maximum
Type
Gravity flow, and must have head pressure.
Operating Life
1500 hours minimum at -65° F ambient.
Coolant
Arctic anti-freeze per MIL-A-11755.
Duty Cycle
Continuous
Weight
1.5 pounds (approx.)
Overall dimensions
3.50 x 18.00 x 4.50 inches (approx.)
2. Pump motor assembly
DOD Drawing Number
70-4048
Manufacturer
Welton Tool Company
Cleveland, Ohio
Manufacturer Part Number
P400-E (Rev B)
Rating
80 GPH Minimum at 2 PSI
Voltage
24 VDC
Duty classification
Continuous
Motor
Voltage
Amperes
RPM
1-26
20-32V DC
3.3 maximum at 80° F
7500
Coolant
Mil-A-11755
Relief Valve
Opens at 30 to 35 PSI
Weight
2.5 pounds (approx.)
Overall dimensions
3.62 x 3.69 x 7.5 inches (approx.)
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457 -34
3. Control Box
DOD Drawing Number
70-4196
Voltage
205 to 240 VAC
Frequency
50/60 or 400 Hz
Phase
Single
Current
30 amperes
Operation
Manual
Weight
1 pound (approx.)
Overall dimensions
9.50 x 3.25 x 5.56
4. Electric heater coolant thermostat
DOD Drawing Number
70-4074
Manufacturer
Kim Hotstart Manufacturing Co.
Spokane, Washington.
Manufacturer Part Number
KS 1012
Switch Type
SPST
Switch Rating
25 amperes at 240 volts, 50/60 and 400 hz.
Cycling Operation
At -65° F ambient contact to open at 120° F
(increasing temperature) and close at 100° F
(decreasing temperature)
Weight
1 pound (approx.)
Overall dimensions
2.00 x 2.38 x 3.90 inches (approx.)
k. DUMMY LOAD KIT
DOD Drawing Number
71-4636
Manufacturer
Consolidated Diesel Electric Company
Old Greenwich, Connecticut
Type
Resistive, 3 phase, 4 wire
Voltage
120/208 and 240/416
Kilowatt Rating (KW)
48
Increments of change
12 KW
Weight
300 pounds (approx)
Overall dimensions
96,00 x 23.5 x 19.12 inches (approx.)
Change 1
1-27
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
1. Power Transformer
DOD Drawing Number
71-4837
Manufacturer
Consolidated Diesel Electric Company
Old Greenwich, Connecticut
Manufacturer Part Number
00000-4842
No Load Voltage
230 volts .
Frequency
50, 60, and 400 hertz
Rating
Primary terminals
1 and 2, 3 and 4
Secondary terminals
5 and 6
230 volts and 6.5 ohms
35 volts, 0.06 ohms, and 6.0 amperes
Total Turns
primary terminals 1 and 2
3 and 4
460
460
secondary terminals
5 and 6
70
Temperature limits
-65° F to + 155° F.
Weight
2 pounds (approx.)
Overall dimensions
4.50 x 3.81 x 4.56 inches (approx.)
2. Load Dump Relay Assembly
1-28
DOD Drawing Number
71-4716
Manufacturer
Consolidated Diesel Electric Company
Old Greenwich, Connecticut
Manufacturer Part Number
00000-4938
External Power Required
20 to 32 VDC.
Input Signal
0 to 10 VDC.
Trip Voltage
5.28 VDC ± 5 percent
Contact Rating
26 VDC, 10 amperes resistive, 5 amperes
inductive
Weight
0.50 pounds (approx.)
Overall dimensions
3.25 x 2.62 x 3.00 inches (approx.)
P-9-TM-457-35 T. O. 35C2-3-442-2
TM-07464A-35
TM5-6115-457-34
3. Electrical Heating Element
DOD Drawing Number
70-4047
Manufacturer
General Electric Company
Shelbyville, Indiana
Manufacturer Part Number
2A838B101
Voltage Rating
120 volts
Power Rating
1000 watts
Watts per Square Inch
7.8 watts
Life Expectancy
10,000 hours
Skin Temperature
1, 000° F
Weight
2 pounds (approx.)
Overall dimensions
38.50 x 1.50 x 1.00 inches (approx.)
4. Load Contactor
DOD Drawing Number
71-4828
Manufacturer
Rowan Controller Co.
Westminster, Maryland
Manufacturer Part Number
2200-EBH 330JA-11
Contact Arrangement
3 pole normally open
Contact Rating at 50/60
and 400 Hz.
42 amperes resistive at 208 volts and 21
amperes at 416 volts
Coil Data
Voltage Rating
Input Current
Holding Current
24 to 32 VDC
4.5 amperes
0.9 amperes
Temperature Range
-65° F to + 125° F
Mounting Position
Vertical only.
Weight
1 pound (approx.)
Overall dimensions
3.15 x 2.50 x 3.75 inches (approx.)
1. REPAIR AND REPLACEMENT
STANDARDS. Table 1-1 list manufacturer’s dimensions, tolerances, desired
clearances, and maximum allowable wear
and clearances.
m. TORQUE DATA. Components
not listed in table 1-2 should be tightened to
standard torque values. Table 1-2
lists components that require special
torques.
1-29
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
n. TIME STANDARDS. Table 1-3
lists the number of man-hours required
under normal conditions to perform the
indicated maintenance and repair for the
generator sets. Components are listed
under the appropriate functional index. The
conditions with highly skilled mechanics,
most of the operations can be accomplished
in considerably less time.
times listed are not intended to be rigid
standards, Under adverse conditions, the
operations will take longer, but under ideal
and wiring diagrams for the 50/60 and 400
hertz generator sets, their components and
auxiliaries.
o. SCHEMATICS AND WIRING DIAGRAMS.
Figures 1-1 through 1-31 show the schematic
Table 1-1. Repair and Replacement Standards
COMPONENT
MANUFACTURER’S
DIM ENSIONS AND
TOLERANCES
IN INCHES
MIN
MAX
DESIRED CLEARANCE
MIN
MAXIMUM
ALLOWABLE
WEAR AND
CLEARANCE
MAX
tarting Motor Assembly:
Brush length
0.7500
-
0.3750
Thrust washer thickness
(Commutator end of
armature shaft).
0.0312
0.0930
0.0250
Thrust washer thickness
(Drive end of armature
shaft).
0.0950
0.0900
Thrust washer thickness
(Intermediate bearing)
0.0312
0.0280
Maximum end play of
armature
0.0300
0.0500
Thrust washer thickness
(Outer washers)
0.0650
*
Yoke pin diameter
0.2790
0.2810
0.2740
Yoke bore for pin
0.2820
0.2830
*
Fit of pin in yoke
0.0010L
0.0040L
*
Fit of pin in cover
0.0010L
0.0050L
*
1-30
T.O. 35C2-3-442-2
P-9-TM-457-35
TM 5-6115-457-34
TM-07464A-35
Table 1-1. Repair and Replacement Standards (continued)
MANUFACTURER’ S
DIMENSIONS AND
TOLERANCES
IN INCHES
COMPONENT
DESIRED CLEARANCE
MAXIMUM
ALLOWABLE
WEAR AND
CLEARANCE
MIN
MAX
Cover bore for pin
0. 2820
0.2840
*
Commutator end head
bronze bearing I.D.
0.6260
0.6270
0.6320
Armature shaft diameter
at commutator end
0.6230
0.6250
0.6200
MIN
MAX
Starting Motor Assembly:
(continued)
Fit of shaft in bearing
0. 0010L
Commutator end head
bronze bearing O.D.
0.7540
*
*
0.7550
Fit of bearing in end head
Intermediate housing
bronze bearing I.D.
0. 0040L
0. 0020T
0. 0040T
*
0.8740
0.8760
0.8780
Armature shaft diameter 0. 8700
(Between spline and
armature).
0.8720
0.8670
Fit of armature shaft in
bronze bearing
0. 0020L
0. 0060L
Runout of shaft bearing
with end bearing
0. 0080L
0. 0050TIR
intermediate housing bore 0.9990
1.0000
*
Intermediate housing
sleeve bearing O.D.
1.0040
*
1.0030
0. 0030T
Fit of bearing in housing
Pinion housing bearing
I.D.
0.7470
0.7480
0. 0050T
*
0.7520
* - L - T - See footnotes at end of table.
1-31
P-9-TM-457-35
TM-07464A-35
T. O. 35 C2-3-442-2
TM 5-6115-457-34
Table 1-1. Repair and Replacement Standards (continued)
MANUFACTURER’S
DIMENSIONS AND
TOLERANCES
IN INCHES
COMPONENT
MIN
MAX
0.7450
0.7460
DESIRED CLEARANCE
MIN
MAXIMUM
ALLOWABLE
WEAR AND
CLEARANCE
MAX
tarting Motor Assembly:
(continued)
Armature shaft diameter
(Drive end)
Fit of shaft in bearing
(Drive end)
0.7420
0. 0010L
Pinion housing bore
0.8740
0.8750
Pinion housing bronze
bearing O.D.
0.8770
0.8780
Fit of bearing in
housing
0. 0030L
0. 0060L
*
0. 0020T
0. 0040T
*
Pinion housing bearing
I.D.
0.7500
0.7530
Fit of shaft in intermediate housing
bearing
0. 0020L
0.0060L
Commutator diameter
1.6800
1.6480
Commutator minimum
turned diameter
1.6700
1.6470
Commutator diameter
T.I. R. runout with
shaft diameters at
bearings
0.7550
0. 0080L
0.0020
* - L - T - See footnotes at end of table.
1-32
0.0030
P-9-TM-457-35
T.O. 35C2-3-442-2
TM-07464A-35
TM 5-6115-457-34
Table 1-1. Repair and Replacement Standards (continued)
COMPONENT
MANUFACTURER’S
DIMENSIONS AND
TOLERANCES
IN INCHES
MIN
MAX
Bearing bore
0.4950
0.4956
Body bore depth
0.3747
0.3753
1
DESIRED CLEARANCE
MIN
MAX
0.001
0. 003
MAXIMUM
ALLOWABLE
WEAR AND
CLEARANCE
el Pump Group:
Gear to cover total
clearance
Shaft diameter
0.4936
0.4938
Shaft bearing bore
0.4950
0.4956
Bearing bore I.D.
0.6268
0.6272
Shaft bearing journal
diameter
0.6250
0.6254
Housing bore
0.9827
0.9832
Bearing diameter O. D.
0.9780
0.9785
0.0035
0.003
Turbocharger Group:
Oil seal ring gap
0.001
0.006
Utility Governor Group:
Terminal lever I.D.
0.352
0.356
0.0005
Power piston O. D.
0.7486
0.7490
0.0005
Larger lands (3) O. D.
0.2490
0.2495
0.0005
Small land (1) O. D.
0.2485
0.2495
0. 0005
Bushing O.D.
0.5635
0.5645
0. 0005
Spline end O. D.
0.504
0.504
0.0005
Large diameter I.D.
0.281
0.281
0. 0005
Small diameter I.D.
0.2475
0.2485
0.0005
Pilot valve:-
Pilot valve bushing:-
1-33
P-9-TM-457-35
TM-07464A-35
T.O. 35 C2-3-442-2
TM 5-6115-457-34
Table 1-1. Repair and Replacement Standards (continued)
COMPONENT
MANUFACTURER’S
DIMENSIONS AND
TOLERANCES
IN INCHES
DESIRED CLEARANCE
MIN
MAXIMUM
ALLOWABLE
WEAR AND
CLEARANCE
MAX
MIN
MAX
0.5675
0.5685
0.0005
0.376
0.377
0.0005
0.3735
0.001
Utility Governor Group:
(continued)
Gearlands (3) O.D.
Bushing (2) I.D.
Speed adjusting shaft O. D. 0.373
Terminal shaft O.D.
0.373
0.374
0.001
Relief valve sleeve I.D.
0. 187
0.188
0.0005
Relief valve sleeve O.D.
0.4370
0.4373
0.0005
Idler gear stud O.D.
0.3130
0.3133
0.0005
Idler gear O.D.
1.120
1.216
0.0005
Idler gear 1. D.
(measured over 0.148
diameter pins)
0.3140
0.3150
Drive gear O. D.
1.120
1.126
0.001
Relief valve plunger O. D.
0.182
0.184
0.0005
Rack bearing bore
0.5007
0.5013
Fuel rack diameter
0.4983
0.4987
Fuel Injection Group:
Fuel rack bearing
clearance
0.005
Pump plunger length
2.5931
2.5937
Cam shaft bearing bore
1.875
1.876
Camshaft bearing
journal diameter
1.8725
1.8735
2.5881
Camshaft bearing
clearance
0.010
Accessory Drive Group:
Idler gear end clearance
Idler gear bearing bore
Idler gear shaft diameter
1-34
0.004
1.376
1.3736
1.381
1.3746
0.016
0.018
0.009
P-9-TM-457-35
T.O. 35 C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Table 1-1. Repair and Replacement Standards (continued)
COMPONENT
MANUFACTURER’S
DIM ENSIONS AND
TOLERANCES
IN INCHES
MIN
MAX
0.8745
0.8749
MAXIMUM
DESIRED CLEARANCE
ALLOWABLE
WEAR AND
CLEARANCE
MAX
Oil Pump Group:
Drive shaft diameter
Gear to cover clearance
0.005
0.002
0.004
Drive idler gear shaft
diameter
1.1220
1.1230
0.008
Idler gear shaft diameter
0. 8745
0.8749
0.008
Relief valve pressure
spring O. D.
0.770
---
Rocker arm bearing bore
0.7260
0.7266
Shaft diameter
0.7240
0.7250
Valve spring O.D.
1.386
---
Valve stem O.D.
0.3712
0.3722
Valve Mechanism Group:
0.008
Cylinder Head:
0.0010
Valve lip thickness:Exhaust valve
0.070 (rein
Inlet valve
0.057 (rein
Valve face angle
29-1/4 degree
Inlet valve head diameter
2.015
2.025
Exhaust valve head
diameter
1.891
1.901
Valve guide bore
0.3736
0.3756
0.0010
Valve spring free length
2.05
VaIve guide projection
above head (measure
from valve spring seat
to top of guide)
0.875
Valve seat insert bore
depth
0.448
0.450
1-35
P-9-TM-457-35
TM-07464A-35
T.O. 35 C2-3-442-2
TM 5-6115-457-34
Table 1-1. Repair and Replacement Standards (continued)
COMPONENT
MANUFACTURER'S
DIMENSIONS AND
TOLERANCES
IN INCHES
MIN
MAX
Inlet valve seat insert
diameter
2. 1280
2.1290
Bore in head for seat
insert
2. 1250
2.1260
Exhaust valve seat insert 2. 0030
2.0040
Bore in head for seat
ins ert
2. 0010
DESIRED CLEARANCE
MIN
MAXIMUM
ALLOWABLE
WEAR AND
CLEARANCE
MAX
Cylinder Head: (continued)
2. 0000
30 degrees
Valve seat face angle
Exhaust valve seat width
0.076
Inlet valve seat width
0.076
Maximum permissible
closed valve projection:
Inlet valve
0.134
Exhaust valve
0.154
Inlet valve seat face
diameter
1.934 (Min)
1.984 (Max
Exhaust valve seat face
diameter
1.810 (Min)
1.860 (Max
Angle to grind insert sea
face to reduce maximum
seat diameter
15 degrees
Lifter diameter
1.3100
1.3110
Lifter bore in block
1.3135
1.3155
2.3105
2.3115
0.012
Camshaft Group:
Camshaft bearing journal
diameter
Camshaft bearing to shaft
clearance
0.002
0.006
0.008
Camshaft end clearance
0.004
0.010
0.025
1-36
P-9-TM-457-35
T.0. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Table 1-1.
COMPONENT
Repair and Replacemment Standards (continued)
MANUFACTURER’S
DIMENSIONS AND
TOLERANCES
IN INCHES
MIN
MAX
Pin bearing bore
1.7009
1.7012
Center to center length
9.594
9.596
Bore in rod forbearing
3.2495
3.2505
Pin diameter
1.6997
1.7000
Crankshaft journal
bearing bore
3.002
3.006
DESIRED CLEARANCE
MIN
MAXIMUM
ALLOWABLE
WEAR AND
CLEARANCE
MAX
Connecting Rods:
0.006
0.010
Piston Group:
Top ring to groove
clearance
0.0028
0.0046
0.006
Intermediate ring to
groove clearance
0.0023
0.0041
0.006
Oil control ring to groove
clearance
0.0015
0.0033
0.006
Pin bore
1.6999
1.7001
0.006
Ring gap measured in
unworn portion of liner
bore size 4.750 in. **
Top ring
0.017
0.023
Intermediate ring
0.017
0.023
Oil control ring
0.013
0.023
‘*Increase in ring gap
for each 0.001 in
increase in liner
bore
0.003
1-37
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 1-1. Repair and Replacement Standards (continued)
COMPONENT
MANUFACTURER’S
DIMENSIONS AND
TOLERANCES
IN INCHES
MIN
MAX
2.999
3.000
MAXIMUM
ALLOWABLE
WEAR AND
DESIRED CLEARANCE
MIN
CLEARANCE
MAX
Crankshaft Group:
Connecting rod journal
diameter
0.007
Maximum out of
roundness
Main bearing journal
diameter
0.004
3.499
3.500
Bearing to crankshaft
clearance
Main bearing bore in
cylinder block
3.8155
0.008
0.0030
0.0059
0.010
0.0025
0.0145
0.025
0.002
0.006
3.8165
End play
Cylinder Block:
Liner counterbore depth
0.400
0.402
Camshaft bearing bore
2.5625
2.5635
Camshaft bearing to block
clearance
Main bearing bore
3.8155
3.8165
Cylinder liner bore
4.750
4.752
Maximum permissible
bore (worn) measured
near top of piston
ring travel
Cylinder liner flange
thickness
1-38
4.758
0.4040
0.4056
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 1-1. Repair and Replacement Standards (continued)
COMPONENT
MANUFACTURER’S
DIMENSIONS AND
TOLERANCES
IN INCHES
MIN
MAX
earing inside
diameter
2.7551
2.7559
earing outside
diameter
5.9047
5.9055
Shaft bearing
surface diameter
2.7560
2.7565
Endbell bearing
contact surface
5.9055
5.9062
ROTOR head diameter
0.904
0.906
ROTOR head length
0.246
0.248
ROTOR bore diameter
0.3033
0.3038
Rotor blade slot width
0.0935
0.0945
Rotor blade slot depth
0.263
0.268
Height
0.247
0.249
Thickness
0.091
0.093
Width
0.247
0.249
0.315
0.318
DESIRED CLEARANCE
MIN
MAXIMUM
ALLOWABLE
WEAR AND
CLEARANCE
MAX
nerator:-
el Burning Winterization
it:
eater Coolant Pump:
Blade:
Adapter bore diameter
1-39
P-9-TM-457-35 T.O. 35 C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Table 1-1. Repair and Replacement Standards (continued)
COMPONENT
MANUFACTURER’S
DIMENSIONS AND
TOLERANCES
IN INCHES
MIN
MAX
DESIRED CLEARANCE
MIN
MAXIMUM
ALLOWABLE
WEAR AND
CLEARANCE
MAX
Fuel Burning Winterization Kit:
Heater Coolant Pump
(continued):
Relief valve spring
free length
1.164
0.010
Heater Motor Endplay
Heater fuel orifice
assembly opening
0. 025
0.012
Electric Winterization
Kit Coolant Pump:
Relief valve spring
free length
1, 164
Seal spring free
length
0.470
Shaft diameter
0.3075
0.3175
Rotor head diameter
0.904
0.906
Rotor head length
0.246
0.248
Rotor bore diameter
0.3033
0.3038
Rotor blade slot width
0.0935
0.0945
Rotor blade slot depth
0.262
0.268
Height
0.247
0.249
Thickness
0.091
0.093
Width
0.247
0.249
Adapter bore diameter
0.315
0.318
Cam ringbore diameter
1.000
1.002
Cam ring width
0.249
0.255
Blade:
Motor Endplay
1-40
0.010
0.025
I
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 1-2. Special Torque Data
COMPONENT
TORQUE VALUE
GENERATOR:
Generator Mount to Skid Base Screws
600 foot pounds
Shaft Coupling to Flywheel Mounting
Screws
150 foot pounds
Generator Frame to Flywheel Housing
Mounting Screws
75 foot pounds
Main Stator Assembly Setscrews
5 foot pounds
Rectifier Assembly Setscrews
20 foot pounds
Spacer Setscrews
20 foot pounds
Shaft Coupling Screws
50 foot pounds
STARTER MOTOR
Intermediate to Pinion Housing
Screws
8 foot pounds
Mounting Screws
200 foot pounds
Valve Cover Screws
8 ± 2 foot pounds
Tachometer Drive Group Mounting
Bolts
8 ± 2 foot pounds
Exhaust Manifold Mounting Bolts
29 to 35 foot pounds
Fuel Injection Pump Bushings
140 to 160 foot pounds
Fuel Injection Pump Nozzle
Retaining Nuts
100 to 110 foot pounds
Fuel Injection Pump Fuel Line Nuts
25 to 35 foot pounds
1-41
P-9-TM-457-35
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Table 1-2. Special Torque Data (continued)
COMPONENT
TORQUE VALUE
ENGINE (continued)
Cylinder Head Plug
96 to 144 inch pounds
Cylinder Head Chamber Assemblies
140 to 160 foot pounds
*Cylinder Head Bolts:
Numerical Bolts
170 to 180 foot pounds
Alphabetical Bolts
27 to 37 foot pounds
Connecting Rod Cap Bolts
27 to 33 foot pounds (wet)
Accessory Drive Gear Retaining Nut
90 to 110 foot pounds
Timing Gear Cover Bolts
27 to 33 foot pounds
Crankshaft Pulley Bolt
210 to 250 foot pounds
Flywheel Housing Bolts
100 foot pounds
Flywheel Bolts
150 foot pounds
Water Pump Impeller Nut
25 to 35 foot pounds
Oil Pump Gear Retaining Nut
60 foot pounds
Main Bearing Cap Bolts
27 to 33 foot pounds (wet)
Turbocharger Wheel Retaining Nut
120 inch pounds (with shaft heated to
350°F) (when shaft is cooled to less than
150°F) 20 inch pounds (wet)
Turbocharger Collar Screws
30 to 40 inch pounds
Hydraulic Pump Elbow Fittings
65 to 75 inch pounds
*See figure 8-56 for cylinder head tightening sequence
1-42 Change 7
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Table 1-3. Time Standards
MAINTENANCE OPERATIONS
MAN-HOURS
03 Generator Set Housing
(to replace)
5.0
(to repair)
3.0
Doors
(to repair)
1.0
Covers
(to repair)
1.0
Panels
(to repair)
1.0
04 Radiator Assembly
(to repair)
2.0
(to overhaul)
5. 0
Shutters Assembly
(to repair)
2.0
Radiator
(to test)
2.0
(to repair)
2.0
Radiator Core
(to replace)
3.0
(to repair)
3.0
05 Engine Wiring
(to overhaul)
2.0
Wire Harness
(to rebuild)
4.0
06 Generator Control Assembly
(to test)
3,0
(to adjust)
1.0
(to replace)
5.0
1-43
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35
TM 5-6115-457-34
Table 1-3. Time Standards (continued)
MAINTENANCE OPERATIONS
MAN-HOURS
(to repair)
3.0
(to overhaul)
4.0
(to rebuild)
4.0
Generator Wire Harness
(to replace)
1.0
(to rebuild)
4.0
Control Cubicle Controls and Instrument Panel
(to replace)
0.50
AC Wattmeter
(to test)
0.5
AC Ammeter
(to test)
0.5
Frequency Meter
(to test)
1,0
Frequency Transducer
(to test)
0.5
Precise Governor Assembly
(to test)
0.5
(to adjust)
0.2
(to replace)
0.2
(to repair)
1.0
(to overhaul)
1.5
(to rebuild)
2.0
Precise Governor Electric Control Unit
1-44
(to test)
1.0
(to adjust)
0.5
(to replace)
0.2
(to repair)
1.0
(to overhaul)
3.0
(to rebuild)
5.0
P-9-TM-457-35 T.0. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Table 1-3. Time Standards (continued)
MAINTENANCE OPERATIONS
MAN-HOURS
Precise Governor Load Measurement Unit
(to test)
0.5
(to adjust)
0.2
(to replace)
0.2
(to repair)
1.0
(to overhaul)
1.0
(to rebuild)
1.0
Precise Governor Electro-Hydraulic Actuator
(to test)
0.5
(to adjust)
0.2
(to replace)
0.5
(to repair)
1.0
(to overhaul)
1.0
(to rebuild)
1.0
Exciter Regulator
(to inspect)
0.5
(to test)
1.0
(to adjust)
0.2
(to replace)
0.5
(to repair)
2.0
(to overhaul)
2.0
(to rebuild)
2.0
Fault Locating Indicator Box
(to test)
1.0
(to replace)
0.2
(to repair)
1.0
(to overhaul)
1.5
1-45
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 1-3. Time Standards (continued)
MAINTENANCE OPERATIONS
MAN-HOURS
DC Circuit Breaker Box
(to test)
0.2
(to replace)
0.1
(to repair)
0.5
(to overhaul)
0.5
Tactical Relay Box
(to replace)
0.2
(to repair)
2.0
(to overhaul)
2.0
Over Voltage Relay
(to test)
0.5
(to adjust)
0.2
(to replace)
0.2
(to repair)
1.0
(to overhaul)
1.0
Reverse Power Relay
(to test)
0.2
(to adjust)
0.2
(to replace)
0.2
(to repair)
1.0
(to overhaul)
1.0
Short Circuit Relay
1-46
(to test)
0.2
(to adjust)
0.2
(to replace)
0.2
(to repair)
1.0
(to overhaul)
1.0
P-9-TM-457-35
T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Table 1-3. Time Standards (continued)
MAINTENANCE OPERATIONS
MAN-HOURS
Precise Relay Box
(to replace)
0.5
(to repair)
2.0
(to overhaul)
2.0
Under Voltage Relay
(to test)
0.2
(to adjust)
0.2
(to replace)
0.2
(to repair)
1.0
(to overhaul)
1.0
Under Frequency Relay (50/60 Hertz)
(to test)
0.5
(to adjust)
0.2
(to replace)
0.2
(to repair)
1.0
(to overhaul)
1.0
Permissive Paralleling Relay
(to test)
0. 5
(to adjust)
0.2
(to replace)
0.2
(to repair)
1.0
(to overhaul)
1.0
Mode I Relay Box
(to test)
1.0
(to adjust)
0.2
(to replace)
0.5
(to repair)
2.0
(to overhaul)
2.0
1-47
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 1-3. Time Standards (continued)
MAINTENANCE OPERATIONS
MAN-HOURS
Mode II Relay Box (add times of Precise and Mode I
Relay Box for each category)
Under Frequency Relay (400 Hertz)
(to test)
0.2
(to adjust)
0.2
(to repair)
2.0
(to overhaul)
Load Contactor, Motor Operated Circuit Breaker, Current
Transformer, and Load and Reconnection Terminal Boards
(to test)
2.0
0.2
(to replace)
4.0
(to repair) - 50/60 Hertz units
2.0
(to repair) -400 Hertz units
2.5
(to overhaul) - 50/60 Hertz units
2.0
(to overhaul) -400 Hertz units
AC Output Receptacle Box
(to replace)
3.0
0.2
(to repair)
1.0
(to overhaul)
1.0
Convenience Receptacle Box
(to replace)
0.2
(to repair)
0.5
(to overhaul)
0.5
07 Generator Assembly
(to test)
3.0
(to replace)
4.0
(to repair)
4.0
(to overhaul)
40.0
(to rebuild)
40.0
Bearing
(to replace)
1-48
Change 3
2.0
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 1-3. Time Standards (continued)
MAINTENANCE OPERATIONS
MAN-HOURS
Rotating Rectifier
(to inspect)
1.0
(to test)
1.5
(to replace)
2.0
(to repair)
2.0
(to overhaul)
2.0
Generator Fan
(to inspect)
1.0
(to replace)
4.0
Rotor Assembly
(to inspect)
2.0
(to test)
1.0
(to replace)
4.0
(to repair)
20.0
(to overhaul)
20.0
(to rebuild)
Exciter Rotor
(to inspect)
2.0
(to test)
1.0
(to repair)
8.0
(to replace)
4.0
(to overhaul)
20.0
(to rebuild)
20.0
1-49
P-9-TM-457-35
TM-07464A-35
T. O. 35C2-3-442-2
TM 5-6115-457-34
Table 1-3. Time Standards (continued),
MAINTENANCE OPERATIONS
MAN-HOURS
Main Stator Assembly
(to inspect)
1.0
(to test)
1.0
(to replace)
4.0
(to repair)
20.0
(to overhaul)
20.0
(to rebuild)
20.0
Exciter Stator
(to inspect)
1.0
(to test)
1.0
(to replace)
4.0
(to repair)
20.0
(to overhaul)
20.0
(to rebuild)
20.0
08 Engine
Engine Assembly
1-50
(to replace)
6.0
(to repair)
15.0
(to overhaul)
30.0
(to rebuild)
106
P-9-TM-457-35
TM-07464A-35
Table 1-3.
T.O. 35C2-3-442-2
TM 5-6115-457-34
Time Standards (continued)
MAINTENANCE OPERATIONS
MAN-HOURS
Alternator Assembly
(to repair)
1.0
(to overhaul)
2.0
(to rebuild)
4.0
Diodes
(to inspect)
0.2
(to test)
0.5
(to replace)
1.0
Rotor
(to test)
0.5
(to replace)
0.5
(to overhaul)
2.0
Starter Assembly
(to repair)
2.0
(to overhaul)
8.0
(to rebuild)
10.0
Starter Solenoid
(to replace)
1.0
Starter Armature
(to test)
1.0
(to replace)
1.0
(to repair)
3.0
(to overhaul)
6.0
Starter Drive
(to replace)
1.0
(to repair)
1.0
Field Assembly
(to test)
1.0
(to replace)
1.0
(to repair)
3.0
1-51
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 1-3. Time Standards (continued)
MAINTENANCE OPERATIONS
MAN-HOURS
Fan Mounting Group
(to replace)
0.4
(to repair)
0.1
Day Tank Assembly
(to adjust)
0.5
(to repair)
1.0
Over speed Governor Switch
(to adjust)
0.5
(to repair)
1,0
(to overhaul)
2.0
(to rebuild)
2.0
Tachometer Drive
(to replace)
0.2
(to repair)
1.0
Fuel Pump Group
(to replace)
0.4
(to repair)
0.4
Turbocharger Group
(to repair)
2.4
(to overhaul)
2.5
(to rebuild)
3.3
Oil Cooler Group
(to replace)
2.0
(to repair)
4.0
Water Pump Group
(to repair)
1-52
1.2
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM5-6115-457-34
Table 1-3. Time Standards (continued)
MAINTENANCE OPERATIONS
MAN-HOURS
Hydraulic Oil Tank Assembly (used on Precise
Generator Sets only)
(to replace)
0.5
(to repair)
1.0
Hydraulic Pump (used on Precise Generator Sets only)
(to test)
1.0
(to replace)
0.5
(to repair)
0.5
(to overhaul)
1.0
(to rebuild)
2.0
(to adjust)
0.5
Hydraulic Pump Drive Group
(to replace)
0.2
(to repair)
1.0
(to overhaul)
1.2
Crankshaft Pulley
(to replace)
Damper
(to replace)
3.0
Timing Gear Cover
(to replace)
4.0
Timing Gears
(to replace)
4.5
Utility Governor Group
(to test)
0.5
(to replace)
0.5
(to repair)
1.0
(to overhaul)
3.0
(to rebuild)
4.0
(to adjust)
0.5
1-53
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 1-3. Time Standards (continued)
MAINTENANCE OPERATIONS
MAN-HOURS
Governor Linkage
(to replace)
1.0
(to repair)
1.0
(to adjust)
0.2
Fuel Injection Lines
(to replace)
0.5
Valve Assemblies
(to test)
1.0
(to replace)
4.0
(to repair)
6.0
(to overhaul)
6.0
(to adjust)
0.5
Injection Pump
(to test)
2.0
(to replace)
0.4
(to repair)
6.0
(to overhaul)
8.0
(to rebuild)
10.0
Accessory Drive Group
(to replace)
0.7
(to repair)
1.0
(to overhaul)
1.2
Exhaust Manifold Group
(to replace)
0.9
Oil Pan Group
1-54
(to replace)
0.9
(to repair)
0.1
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 1-3. Time Standards (continued)
MAINTENANCE OPERATIONS
MAN- HOURS
Oil Pump Group
(to test)
0.3
(to replace)
1.0
(to repair)
1.5
Valve Mechanism Group
(to replace)
0.5
(to repair)
0.8
Arm Assemblies
(to replace)
0.5
(to adjust)
0.6
Push Rods
(to replace)
0.5
Cylinder Head Group
(to replace)
5.0
(to repair)
2.0
(to overhaul)
4.0
(to rebuild)
4.0
Intake and Exhaust Valves
(to test)
0.5
(to replace)
1.6
(to repair)
2.0
Valve Springs
(to test)
1.0
(to replace)
1.6
Intake and Exhaust Valve Inserts
(to replace)
1.2
Valve Guides
(to replace)
2.4
Flywheel and Flywheel Housing Group
(to replace)
2.0
1-55
P-9-TM-457-35
TM-07464A-35
T.0. 35C2-3-442-2
TM 5-6115-457-34
Table 1-3. Time Standards (continued)
MAINTENANCE OPERATIONS
Flywheel
(to replace)
0.3
Flywheel Ring Gear
(to replace)
0.9
Flywheel Housing
(to replace)
1.7
Camshaft Group
(to replace)
7.0
Connecting Rods and Pistons Group
(to replace)
6.0
Connecting Rod
(to replace)
0.2
Rod Bearings
(to replace)
0.4
Piston Pins
(to replace)
0.2
Piston Rings
(to replace)
0.5
Crankshaft Group and Main Bearings
(to replace)
5.0
Cylinder. Block
(to replace)
48.0
Cylinder Sleeves
(to replace)
0.5
Fuel Burning Winterization Kit (Regular)
(to repair)
1.0
(to overhaul)
2.0
Heater Control Assembly
(to repair)
1-56
0.5
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 1-3. Time Standards (continued)
MAINTENANCE OPERATIONS
MAN-HOURS
Valve
(to inspect)
0.2
(to replace)
0.5
Nozzle
(to inspect)
0.5
(to replace)
0.5
Terminal Board
(to replace)
0.2
Switch
(to replace)
0.2
Burner Assembly
(to replace)
0.5
(to repair)
0.5
Head Assembly
(to inspect)
(to replace)
0.5
1.0
Blower Assembly
(to replace)
1.0
(to repair)
2.0
Fan Motor Assembly
(to replace)
1.0
(to repair)
1.0
(to replace)
1.0
Fan
Motor
(to replace)
0.5
Coolant Pump
(to replace)
1.0
(to repair)
2.0
1-57
P-9-TM-457-35
TM-07464A-35
T.0. 35C2-3-442-2
TM 5-6115-457-34
Table 1-3. Time Standards (continued)
MAINTENANCE OPERATIONS
MAN-HOURS
10 Sub Base Assembly
(to replace)
6.0
(to repair)
2.0
Main Fuel Tank
(to replace)
1.0
(to repair)
2.0
Fuel Transmitter
(to test)
0.5
(to replace)
1.0
Fuel Burning Winterization Kits (Auxiliary)
(to replace)
1.0
(to repair)
2.0
(to overhaul)
3.0
(to rebuild)
3.0
Fuel Pumps
(to repair)
1.0
Control Assembly
(to repair)
1.0
Terminal Board
(to replace)
0.5
Heater Relay
(to test)
0.5
(to replace)
0.2
Wire Harness
(to rebuild)
2.0
Flame Switch
(to replace)
0.5
Burner Assembly
(to replace)
1-58
1.0
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115 -457-34
Table 1-3. Time Standards (continued)
MAINTENANCE OPERATIONS
MAN-HOURS
Blower Assembly
(to replace)
1.0
(to repair)
1.0
12 Electric Winterization Kit (Regular and Auxiliary)
(to overhaul)
1.0
(to rebuild)
1.0
Heater Assembly
(to replace)
1.0
(to repair)
1.0
(to overhaul)
1.0
Coolant Pumps
(to replace)
1.0
(to repair)
1.0
Heat Exchange (Coil)
(to inspect)
0.2
(to test)
0.2
(to replace)
0.5
(to repair)
1.0
Transformer
(to test)
0.2
(to replace)
0.2
Semi-Conductors
(to inspect)
0.2
(to test)
0.1
(to replace)
0.5
1-59
P-9-TM-457-35 T. O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Table 1-3. Time Standards (continued)
MAINTENANCE OPERATIONS
MAN-HOURS
Wheel Mounting Kit
(to install)
3.5
(to replace)
3.5
Load Bank
(to test)
1.0
(to repair)
2.0
(to overall)
4.0
Wire Harness
(to rebuild)
3.0
T.O. 35C2-3-442-2
P-9-TM-457-35
TM-07464A-35 TM 5-6115-457-34
Figure 1-l. Hydraulic system schematic, precise generation sets.
1-61/(1-62 blank)
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 1-6. Control cubicle (A3) schematic
Change 3
1-71/(1-72 blank)
P-9-TM-457-35
TM-07464A-35
Figure 1-8.
T.O. 35C2-3-442-2
TM 5-6115-457-34
Fault locating indicator (A9) schematic
Change 3
1-75
P-9-TM-457-35
T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
1-76
Figure 1-9.
Figure 1-11.
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
1-79
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 1-11. Exciter regulator (Al0 and Al1) 50/60 Hertz wiring diagram (sheet 2 of 2)
1-80
Figure 1-13.
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
1-83
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 1-13. Exciter regulator (A10 and All) 400 Hertz wiring diagram (sheet 2 of 2)
1-84
P-9-TM-457-35
TM-07464A-35
Figure 1-19.
Change 1
T.O. 35C2-3-442-2
TM 5-6115-457-34
1-101/(1-102 blank)
Figure 1-21.
P-9-TM-457-35
T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
l-105/(1-106 blank)
Figure 1-24.
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
1-111
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35
TM 5-6115-457-34
1-112
Figure 1-25.
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure l-26. Precise governor actuator (A24) wiring diagram
1-113
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35
TM 5-6115-457-34
Figure 1-27. Load measuring unit (A8) wiring diagram
1-114
P-9-TM-457-35 T.O. 35C2-3-442-2
TM 5-6115-457-34
TM-07464A-35
Figure 1-28. Generator assembly simplified schematic diagram
Figure 1-29. Fuel burning winterization kit (A17) schematic
Change 3
1-115
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 1-30.
1-116
Change 1
Electric winterization kit schematic.
T.O. 35C2-3-442-2
P-9-TM-457-35
TM-07464A-35 TM 5-6115-457-34
Figure 1-31. Dummy load kit (A28) schematic (sheet 1 of 2)
1-117
P-9-TM-457-35
TM-07464A-35
1-118
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 1-31.
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35
TM 5-6115-457-34
CHAPTER 2
GENERAL MAINTENANCE INSTRUCTIONS
Section I. REPAIR PARTS, SPECIAL TOOLS, AND EQUIPMENT
2-1.
SPECIAL TOOLS AND EQUIPMENT.
There are no special tools and equipment required to perform intermediate
(field) (direct and general support) and
depot maintenance on generator sets
Models MEP007A, MEP106A, and
MEP116A. Recommended tools are listed
in table 2-1.
2-2.
ORGANIZATIONAL. INTERMEDIATE
(FIELD) (DIRECT SUPPORT AND
GENERAL SUPPORT) AND DEPOT
MAINTENANCE REPAIR PARTS.
Refer to Organizational, Intermediate (Field) (Direct Support and General
Support) and Depot Maintenance Repair
Parts and Special Tools List.
2-3.
SPECIALLY DESIGNED (FABRICATED) TOOLS AND EQUIPMENT.
The specially designed tools and
equipment illustrated in figure 2-1 and
listed in table 2-2 are for intermediate
(field) (direct and general support) and
depot maintenance personnel performing
maintenance on the generator set. The
tools and equipment listed in table 2-2
are not available for issue, but must be
fabricated by qualified maintenance
personnel.
Figure 2-1. Specially designed tools (fabricated)
(sheet 1 of 3)
Change 1
2-1
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 2-1. Specially designed tools (fabricated)
(sheet 2 of 3)
2-2
P-9-TM-457-35
T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 2-1. Specially designed tools (fabricated)
(sheet 3 of 3)
Section II. TROUBLESHOOTING
2-4.
GENERAL.
This section provides information
useful in diagnosing and correcting unsatisfactory operation or failure of the engine
generator sets and their components.
Malfunctions which may occur are listed in
table 2-3. Each malfunction stated is followed by a list of probable causes of the
trouble. The corrective action recommended is described opposite the probable
cause.
Section III. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
AND AUXILIARIES
2-5.
GENERAL.
This section contains instructions
for the removal and installation of major
components of the generator set to facili- tate repair and overhaul. Detailed maintenance procedures for these components are
contained in subsequent sections of this
technical manual.
2-6.
CONTROL CUBICLE.
a. Removal. Refer to figure 2-2 and
remove control cubicle as follows:
1. Disconnect harness from control
cubicle.
2. Disconnect control cubicle from
rear housing by removing screws and
washers. Remove control cubicle.
b. Installation. Refer to figure 2-2 and
install control cubicle as follows:
1. Install control cubicle in rear
housing and secure with screws and washers.
2. Connect electrical harness to
control cubicle connector.
2-3
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 2-2. Control cubicle, removal and installation
2-7.
GENERATOR.
a. Removal. Remove generator as
follows:
1. Refer to Operator and Organizational Maintenance Manual and perform the
following:
circuit breaker, control cubicle, convenience receptacle, exciter regulator,
mode I or mode II relay box, load measurement unit, tactical relay box, precise relay box (on 50/60 hertz precise
generator sets), and kit control boxes,
if installed.
cable.
(e) Disconnect receptacles of
parallel receptacle wiring harness from
rear housing.
(b) Remove rear housing cover
and generator compartment access doors.
control.
(a) Disconnect negative battery
(c) Remove air cleaner.
(d) Tag and disconnect wiring
harnesses from fault locator, DC control
2-4
(f) Remove manual speed
2. Refer to figure 2-3 and remove
upper side housings (5) and assembled rear
housing (14) in the-order of index numbers
assigned.
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Figure 2-3. Rear housing and upper sides housing,
removal and installation
Legend to figure 2-3:
1.
2.
3.
4.
5.
Nut (4)
Screw (4)
Nut (4)
Screw (4)
Upper side housing (2)
6. Screw (4)
7. Washer (4)
8. Nut (10)
9. Washer (10)
10. Screw (10)
11.
12.
13.
14.
Nut (2)
Washer (2)
Screw (2)
Rear housing
Change 8 2-5
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
3. Remove auxiliary fuel hose and
kit mount from skid base on left rear side of
generator by removing two screws and nuts.
to reconnection board wiring harness from
connector J61 of the generator and terminals
of TB2 located on transofrmer assembly (25).
4. Refer to figure 2-4 and remove
exciter regulator and stowage box (3), mode
I or mode II relay box (6), transformer
assembly cover (10), bracket (16), reconnection board assembly (20), transformer
assembly (25), relay box and bracket
assembly (28), and circuit breaker assembly
(33) in the sequence of index numbers assigned. Pay particular attention to the following:
(d) Remove generator leads
from transformer assembly.
(a) Remove nut (17), screw (18),
and washer (19). Move connection board
assembly (20) out to permit access to wiring.
(b) Tag and disconnect generator
leads and relay box to reconnection board
wiring harness from reconnection board and
connector J41 of load contactor. Tag and
disconnect ground cable from frame. Remove board assembly.
(c) Tag and disconnect relay box
5. Refer to figure 2-5 and disconnect screen (4) by removing nuts (1), lock
washers (2), and screws (3).
CAUTION
Rotate engine crank shaft as required to gain access to screws.
Do not attempt to rotate generator
by prying on generator fan or
flywheel ring gear.
6. Straighten corners of locking
plates (6) and remove screws (5) and locking
plates. Rotate engine using a suitable barring tool on crankshaft pulley bolt. Turn
engine clockwise (standing in front of engine
looking toward generator) as required for
access to screws (5).
Legend to figure 2-4:
1. Nut (4)
2. Screw (4)
3. Exciter regulator and
stowage box
4. Nut (4)
5. Screw (4)
*6. Relay Box
7. Screw (4)
8. Lock washers (4)
9. Washer (4)
10. Cover
11. Nut (4)
12. Washer (4)
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Screw (4)
Screw (6)
Washer (6)
Bracket
Nut (4)
Screw (4)
Washer (4)
Reconnection board
assembly
Screw (3)
Washer (3)
Stepped spacer (2)
Washer (2)
25.
Transformer
assembly
26. Screw
27. Washer
**28. Relay box and bracket
+29. Bracket
+30. Screw (4)
+31.
Lock washer (4)
+32. Washer (4)
+33. Circuit breaker
assembly
+33A. Screw (2)
+33B. Clamp (2)
*Mode I relay box on 50/60 hertz generator set, Mode II relay box on 400 hertz generator sets.
**Precise relay box is utilized on 50/60 hertz precise generator sets only.
+Used on 400 hertz generator sets only.
2-6
Change 8
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 2-4. Generator controls, removal and installation
(sheet 1 of 2)
Change 3
2-7
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 2-4. Generator controls, removal and installation
(sheet 2 of 2)
2-8
Change 3
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 2-5. Generator, removal and installation
Legend to figure 2-5:
1.
2.
3.
4.
5.
6.
Nut (2)
Lockwasher (2)
Screw (2)
Screen
Screw (8)
Locking plate (4)
7.
8.
9.
10.
11.
12.
Nut (8)
Washer (8)
Screw (12)
Lock washer (12)
Generator
Spacer
13. Spring washer
14. Spacer
15. Engine support
bolt (2)
16. Lock nut (2)
17. Mounting bolt (8)
Change 3
2-8A /(2- 8B blank)
P-8-627-34
TM-07464A-35
7. Connect a suitable overhead
lifting device to both generator lifting eyebolts and remove slack from lifting device.
NOTE
To remove generator mounting
bolts, the fuel tank must be
removed.
8. Remove nuts (7) and washer (8)
and permit mounting bolts to rest on fuel
tank.
9. Loosen engine support bolts lock
nuts. Turn engine support bolts clockwise
to contact skid base. Simultaneously turn
engine support bolts and lift generator with
overhead lifting device until generator
clears generator mounting bolt. Tighten
engine support bolt lock nuts.
10. Install two suitable wooden block,
180 degrees apart, between generator
frame and generator fan to prevent main
rotor assembly from sliding out of frame
during lifting. Remove screws (9) and
lockwashers (10).
WARNING
Stay clear of generator during
lifting operations.
T O 35C2-3-442-2
TM 5-6115-457-34
14. Install screen (4) on generator
with screws (3), lock washers (2), and
nuts (7).
15.
Install a suitable moving block
(refer figure 2-1 view H) across engine
mounting end of generator frame to support
main rotor assembly and prevent it from
sliding out of frame during movement.
16. Place tag on generator stating;
fan mounted to shaft coupling with two
screws and nuts for moving purposes only.
17. If necessary, remove spacers
(12 and 14) and spring washer (13) from
engine flywheel.
b. Installation. Install generator as
follows:
1. Move generator as close to generator set as possible. Remove shipping
blocks .
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protect ion required. Good general
ventilation is normally adequate.
CAUTION
set.
2. Make sure spacers (12 and 14)
and spring washer (13) are installed in flywheel. Clean flywheel with an approved
cleaning solvent and dry thoroughly.
Inspect flywheel for nicks and burrs.
Remove nicks and burrs using a suitable
file or stone.
12. Lower generator to floor and
block generator to prevent tipping, removing lifting device from generator.
3. Remove screen (4) from generator. If fan is bolted to shaft couplings,
remove shipping screws and nuts.
13. Remove wooden blocks installed
between generator frame and fan. Secure
fan to shaft couplings with two nuts and
screws 180 degrees apart.
4. Inspect generator shaft couplings
for ragged edges and burrs. Touch up
ragged edges and burrs with a suitable file,
exercising care to remove burrs and ragged
Do not lower generator on mounting bolts, weight of generator on
bolts may damage fuel tank.
11. Remove generator from generator
Change 8
2-9
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
edges only. Clean shaft couplings with
an approved cleaning solvent and dry
thoroughly.
5. Install two suitable wooden
blocks, 180 degrees apart, between generator frame and fan to prevent main rotor
assembly from sliding out of frame during
installation.
6. Connect a suitable overhead lifting device to both generator lifting eyebolts.
WARNING
Stay clear of generator during
lifting.
7. Position generator against flywheel housing and secure generator with
two screws (9) and washers (10), 180 degrees apart.
8. Remove wooden blocks from generator frame. Rotate engine crankshaft
using a suitable barring tool on engine
crankshaft pulley bolt to align flywheel
generator shaft coupling holes with holes in
shaft couplings. Turn engine clockwise
(standing in front of engine looking toward
generator). After holes are aligned, push
generator shaft couplings against engine
flywheel, making sure couplings are inside
of flywheel recess.
NOTE
Rotate engine crankshaft as required to gain access to screws.
9. Position generator fan on rear of
shaft couplings and install locking plates (6)
and screws (5). Tighten screws evenly in
a criss-cross pattern. Torque screws to
150 foot-pounds . Bend corners of locking
plates (6) against screws (5) to prevent
screws from turning.
2-10
Change 8
10. Install remaining screws (9,
and washers (10). Tighten screws evenly.
Torque screws to 75 foot-pounds.
CAUTION
Do not lower generator on mounting bolts; weight of generator on
bolts may damage fuel tank.
11. Simultaneously lower engine and
generator using overhead lifting device
engine support bolts until generator mounts
are just above generator mounting bolts.
12. Push generator toward radiator
until generator mount holes are in alignment with mounting bolts. Push mounting
bolts up through generator mounting holes
and install washer (8) and nuts (7). Lower
engine and generator onto skid base.
Remove overhead lifting device and tighten
engine support bolt lock nuts. Hold generator mounting bolts stationary and tighten
nuts (7) to 600 foot-pounds torque.
NOTE
Generator air gap should be 0.125
inch for 50/60 hertz generators
and 0.049 inch for 400 hertz generators.
13. Check generator air gap using
three plastic gauges approximately one foot
long. Equally space gauges and insert
gauges through opening between generator
frame and fan. Position gauges between
main stator and main rotor, making sure
gauges are positioned on high points
of stator pole splices. Hold gauges
stationary and rotate engine and generator approximately three revolutions
by turning engine crankshaft. Remove
and inspect gauges. Gauges should
not show any signs of interference. If
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
interference is indicated, generator is
defective or engine flywheel is not
concentric.
18. Refer to Operator and Organizational Maintenance Manual and perform the
following:
14. Install screen (4) and secure
with screws (3), washer (2), and nuts (1).
(a) Install and adjust manual
speed control.
15. Refer to figure 2-4 and install
relay box and bracket assembly (28),
transformer assembly (25), reconnection
board assembly (20), bracket (16), cover
(10), mode I or mode II relay box (6), and
exciter regulator and stowage box (3) in the
reverse order of index numbers assigned.
Pay particular attention to the following:
NOTE
(b) Connect receptacles of parallel receptacle wiring harness to rear
housing.
(c) Connect wiring harnesses to
fault locator, DC control circuit breaker,
control cubicle, convenience receptacle,
exciter regulator, mode I or mode II relay
box, load measurement unit, tactical relay
box, precise relay box (on 50/60 hertz
precise generator sets), and kit control
boxes, if installed.
For wire routing and termination,
refer to Operator and Organizational Maintenance Manual.
(a) Install transformer assembly (25) and route generator leads through
transformers.
(d) Install air cleaner.
(e) Install rear basing cover
and generator compartment access doors.
(f) Connect negative battery
cable.
(b) Connect relay box to reconnection
board wiring harness and generator leads to reconnection
board assembly. Secure reconnection board assembly to
skid base. Assure that generator leads are routed and
secured in a manner that no chaffing occurs.
(c) Connect relay box to reconnect on board harness to connector J41 of
the load contactor, J61 of the generator,
and terminal board TB2 located on transformer assembly.
16. Position auxiliary fuel hose and
mount on skid base at left side of generator
and secure with two screws and nuts.
17. Refer to figure 2-3 and install
upper side housings (5) and assembled rear
housing (14) in the reverse order of index
numbers assigned.
2-8.
ENGINE, D333C(T)
a. Removal. Remove the engine as
follows:
1. Refer to Operator and Organizational Maintenance Manual and perform the
following:
(a) Drain fuel filter and strainer,
secondary fuel filter, day tank, radiator,
engine lubricating oil, and hydraulic tank
on precise generator sets,
(b) Disconnect negative battery
cable. Tag and disconnect cables from
slave receptacle SR2, starter and starter
solenoid. Remove starter ground cable
from skid base.
Change 7 2-11
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
(c) Disconnect muffler clamps
from front housing cover. Remove front
and rear housing covers, engine, generator,
and battery compartment access doors.
(d) Remove muffler, exhaust
pipe, and crankcase breather tube. Remove
engine breather assembly.
(e) Remove radiator and shutter.
(f) Disconnect manual speed
control from utility governor input shaft
and lifting frame bracket.
(g) Remove air cleaner.
(h) If installed, remove winterization kit heaters and coolant lines from
oil pan heat exchanger tubes and engine
block. Disconnect kit harnesses from control boxes and coil harness on engine.
(i) Tag and disconnect engine
harness from connector J5 of mode I or
mode II relay box, connector J39 of DC
control circuit breaker, connector J33 of
the day tank float switch, connector J38 of
the ether primer and fuel tank fuel level
transmitter. Cut tiedown strap securing
engine harness to other harnesses. Coil
engine harness wires and secure wires to
engine.
(j) Disconnect ether starting aid
tube from atomizer at rear of cylinder head
inlet elbow.
(a) Remove two members from
rear housing by removing four screws and
washers.
3. Disconnect engine oil drain hose
from engine oil drain valve at left side of
engine. Plug hose and valve opening.
4. Remove engine block coolant
drain hose from right side skid base fitting.
5. Loosen clamp and remove fuel
filler hose from fuel tank. Cover fuel tank
opening. Disconnect fuel tank vent hoses
from fuel filler neck. Tag and disconnect
fuel hoses from fuel transfer valve,
auxiliary fuel inlet fitting, fuel supply outlet fitting and day tank. Remove supply
hose from electric fuel transfer pump.
Plug hoses. Disconnect two clamps securing hoses to lifting frame; one clamp is
located on each inside wall of lifting frame.
NOTE
Governor control unit is mounted
to lifting frame on the right side.
6. On precise generator sets, tag
and disconnect connectors from governor
control unit. Remove harness from connector P8 of the precise relay box, cut tiedown strap and coil harness on engine.
Disconnect governor control unit and mount
from lifting frame by removing four screws,
washers, and nuts.
(k) Tag and disconnect electrical
leads from radio suppression diode assembly mounted to day tank.
7. Remove sixteen screws, washers,
and nuts securing lifting frame to skid base.
Using a suitable lifting device, remove lifting frame from generator set.
2. Disconnect four upper side housing members from lifting frame by removing eight screws and nuts securing members
to lifting frame.
8. Tag and disconnect electrical
connectors from exciter regulator. Disconnect exciter regulator and stowage box
(3, figure 2-4) by removing nuts (1) and
2-12
P-8-627-34
TM-07464A-35
screws (2). Remove nuts (11 and 17),
screws (13 and 18), and washers (12 and
19). Move reconnection board assembly
(20) away from bracket (16).
9. Disconnect screen (4, figure 2-5)
by removing nuts (l), washers (2), and
screws (3).
10. Disconnect auxiliary fuel hose
and mount from skid base at left rear of
generator by removing screws and nuts.
CAUTION
T O 35C2-3-442-2
TM 5-6115-457-34
WARNING
Stay clear of engine during lifting.
CAUTION
During lifting operations, check
that generator mounting bolts are
not binding on generator mount.
15. Slowly raise lifting device, pivoting f rent of engine up until there is sufficient clearance for engine oil pan to clear
engine support.
16. Support f rent of engine to prevent
it from swinging forward when generator to
flywheel housing bolts are removed.
CAUTION
Rotate engine crankshaft as required to gain access to screws.
Do not attempt to rotate generator by prying on generator fan
or flywheel ring gear.
11. Straighten corners of locking
plates (6) and remove screws (5) and locking plates. Rotate engine using a suitable
barring tool on crankshaft pulley bolt.
Turn engine clockwise (standing in front of
engine looking toward generator) as
required for access to screws (5). Hold
barring tool stationary to permit loosening
screws.
12. Remove nuts (7) and washers (8)
and permit generator mounting bolts to rest
on fuel tank.
13. Connect a suitable overhead lifting device to both engine lifting eyebolts
(figure 2-6). Remove slack from lifting
device.
14. Disconnect engine trunion mount
from engine support by removing bolts
and washers.
Generator must be blocked so that
generator weight is on skid base.
17. Block generator in raised
tion with suitable blocks that contact
side of the skid base.
18. Remove screws (9, figure
and washers (10) securing generator
wheel housing.
posieach
2-5)
to fly-
WARNING
Stay clear of engine during lifting.
19. Remove support from
engine and move engine free of
Remove engine from generator
engine on stand, cradle, or crib
front of
generator.
set. Place
and block.
20. If necessary, remove spacers
(12 and 14) and spring washer (13) from
flywheel.
WARNING
Steam cleaning creates hazardous
noise levels and severe bum and
injury potential. Eye, skin and
ear protection required.
21. Plug all engine openings and
steam clean engine.
Change 8
2-13
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Figure 2-6. Engine, removal and installation
b. Installation. Install the engine as
follows:
1. Move engine as close to generator
set as possible.
2. Connect a suitable lifting device
to both engine lifting eyebolts (figure 2-6).
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
love nicks and burrs using a suitable
2-14
Change 8
3. Inspect flywheel for nicks and
burrs on generator contact surfaces.
Remove nicks and burrs using a suitable
file or stone. Clean flywheel with an
approved cleaning solvent and dry
thoroughly.
4. Insert spacers (12 and 14, figure 2-5) and spring washer (13) in flywheel.
5. Inspect generator shaft couplings
for ragged edges and burrs. Touch up
ragged edges and burrs with a suitable file,
exercising care to remove burrs and
ragged edges only, Clean shaft couplings
P-8-627-34
T O 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
with an approved cleaning solvent and dry
thoroughly.
WARNING
Stay clear of engine during lifting
operations.
6. Position engine in generator set,
aligning engine flywheel housing screw
holes with generator frame holes. Install
four screws (9, figure 2-5) and washers
(10), 90 degrees apart.
7. Raise lifting device so that block
can be removed from under generator.
Remove block and slowly lower engine in
place so that engine support bolt holes
(figure 2-6) and trunion mount holes are in
alignment. Secure trunion mount to engine
support with bolts and washers. Make sure
generator mounting bolts are in alignment
with generator mount holes and tighten
engine mount bolts to 200 foot-pounds
torque.
8. Remove four screws securing
generator to engine to permit engine to
move forward.
9. Rotate engine crankshaft using
suitable engine barring tool on crankshaft
pulley bolt to align flywheel generator shaft
coupling holes with holes in generator shaft
couplings. Turn engine crankshaft clockwise (standing in front of engine looking
toward generator). After holes are aligned,
push generator shaft couplings against
engine flywheel, making sure couplings are
inside of flywheel recess.
NOTE
Rotate engine crankshaft as required to gain access to screws.
10. Position generator fan on
rear of shaft couplings and install
locking plates (6, figre 2-5) and
screws (5). Tighten screws evenly in a
criss-cross pattern. Torque screws to
150 foot-pounds. Bend corners of locking plates (6) against screws (5) to
prevent screws from turning.
11. Install screws (9) and washers (10). Tighten screws evenly and to
75 foot-pounds torque.
12. Push mounting bolts up
throught generator mounting holes and
install washer (8) and nuts (7). Hold
generator mounting b i t s s t a t i o n a r y a n d
tighten nuts (7) to 500-550 foot-pounds
torque.
NOTE
Generator air gap should be 0.125
inch for 50/60 hertz generators
and 0.049 inch for 400 hertz generators.
13. Check generator air gap using
three plastic gauges approximately one foot
long. Equally space gauges and insert
gauges through opening between generator
frame and fan. Position gauges between
main stator and main rotor, making sure
gauges are positioned on high points of
stator pole pieces. Hold gauges stationary
and rotate engine and generator approximately three revolutions by turning engine
crankshaft. Remove and inspect gauges.
Gauges should not show any signs of
interference. If interference is indicated,
generator is defective or engine flywheel is
not concentric.
14. Install screen (4) and secure
with screws (3), washer (2), and nuts (1).
15. Secure reconnection board assembly (20) to skid base and bracket (16)
Change 9
2-15
T O 35C2-3-442-2
P-8-627-34
TM-07464A-35 TM 5-6115-457-34
with screws (13 and 18), washers (12 and
19), and nuts (11 and 17). Install exciter
regulator and stowage box and secure with
screws (2) and nuts (l). Connect electrical connectors to exciter regulator.
(a) Connect three electrical
leads to radio suppression diode assembly.
16. Using a suitable lifting device,
position lifting frame on generator set skid
base. Secure lifting frame to skid base
with sixteen screws, washers, and nuts.
(c) Connect engine harness to
connector J5 of mode I or mode II relay box,
connector J33 of day tank float valve, connector J38 of ether primer, connector J39
of DC control circuit breaker, and fuel tank
fuel level send unit. Fasten harness to
other harness with tiedown straps.
17. On precise generator sets, position governor control unit on lifting frame
and secure with four screws, washers, and
nuts. Connect electrical connectors to governor control unit and governor actuator.
Connect harness to connector P8 on precise
relay box. Secure harness to other harnesses with tie down strap.
18. Connect fuel filler hose to fuel
tank and secure with clamp. Connect fuel
tank vent hoses to fuel filler neck. Connect
fuel hoses to fuel transfer valve, auxiliary
fuel inlet fitting, fuel supply outlet fitting,
day tank, and electric fuel transfer pump.
Clamp hose to lifting frame.
19. Connect engine block coolant
drain hose to skid base fitting and secure
with clamp.
20. Connect engine oil drain hose to
engine oil drain valve.
21. Connect four upper side housing
members to lifting frame and secure eight
screws and washers. Connect two members to rear housing and secure with four
screws and washers.
22. Refer to Operator and Organizational Maintenance Manual and perform the
following:
2-16
Change 8
(b) Connect ether starting tube
to atomizer at rear of cylinder head inlet
elbow.
(d) If required, install winterization kit heaters and coolant lines. Connect kit harnesses to control boxes.
(e) Install air cleaner.
(f) Connect and adjust manual
speed control.
(g) Install radiator and shutter.
(h) Install engine crankcase
breather, crankcase breather tube, muffler,
and exhaust pipe.
(i) Install front and rear housing
covers; battery, engine, and generator
compartment access doors. Connect muffler clamps to front housing cover.
(j) Connect starter ground cable
to skid base. Connect cables to slave
receptacle SR2. Install negative battery
cable.
(k) Service radiator, engine and
on precise generator sets hydraulic tank.
(l) Start engine and bleed fuel
system and hydraulic system on precise
generator sets.
P-9-TM-457-35
TM-07464A-35
2-9.
WHEEL MOUNTING KIT.
a. Removal. Refer to figure 2-7 and
remove wheel mounting kit in the order of
index numbers assigned. Pay particular
attention to the following:
1. Using a suitable lifting device,
lift generator set off ground. Place suitable
block under skid base and lower generator
set on blocks.
2. Place suitable hydraulic jack
under front axle assembly and raise jack so
it will support axle assembly weight.
T.O. 35C2-3-442-2
TM 5-6115-457-34
1. On initial installation, assemble
kit components prior to performing steps 2.
through 6. as follows:
(a) Install two nuts (16) and
two yokes (15) on each stud (17), and attach
yokes on one end to hand brake and shaft
assembly (26).
(b) Attach brackets (20 and 25)
to hand brake and shaft assembly.
2. Using a suitable lifting device,
lift generator set off ground. Place
suitable block under skid base and lower
generator set on blocks.
3, Disconnect brake cables.
4. Remove axle assembly attaching
hardware and lower hydraulic jack, lowering wheels to ground. Remove axle assembly from under generator set.
3. Place front axle assembly under
generator set. Place suitable hydraulic
jack under axle assembly and jack axle into
position. Secure axle assembly to generator set and remove hydraulic jack.
4. Repeat step 3. for rear axle.
5. Repeat steps 2. through 4. for
rear axle.
5. Connect brake cables to each
b. Installation. Refer to figure 2-7
and install wheel mounting kit in the reverse
order of index numbers assigned. Pay particular attention to the following:
wheel.
6. Lift generator set, remove
blocks, and lower generator set.
2-17
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 2-7. Wheel mounting kit, removal and installation
2-18
P-9-TM-457-35
T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115 -457-34
Legend to figure 2-7:
14. Pin (8)
Screw (2)
15. Yoke (6)
Nut (2)
16. Nut (6)
Guide (2)
Screw (8)
17. Stud (2)
18. Screw (2)
Nut (8)
19. Nut (2)
Clamp (4)
20. Bracket
Screw (4)
21. Screw (2)
Nut (4)
22. Lock washer (2)
Plate (2)
Brake cable and conduit 23. Screw (5)
24. Nut (5)
assembly (2)
25. Bracket
11. Screw (2)
26. Hand brake and shaft
12. Lock washer (2)
assembly
13. Cotter pin (8)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
Nut (2)
Safety chain assembly (2)
Drawbar assembly
Wheel assembly (4)
Screw (4)
Nut (4)
clamp (2)
Rear axle assembly
Screw (4)
Nut (4)
clamp (2)
Front axle assembly
2-19
P-9-TM-457-35 T.O. 35C2-3-442-2
TM 5-6115-457-34
TM-07464A-35
Table 2-1. Recommended Tools and Equipment
REFERENCE
FSN OR
PART NUMBER
PARA
6625-581-2466
As applicable
Check continuity and
resistance of electric al components.
Inside micrometer
As applicable
To measure inside
diameter of engine
components.
Outside micrometer
As applicable
To measure outside
diameter of engine
components.
Wheatstone bridge
As applicable
To measure resistance of electrical
components.
Kelvin bridge
As applicable
To measure resistance of electrical
components.
Multimeter
As applicable
To test electrical
components.
Pressure gauge
0-20 PSI
4-10
To check radiator
pressure.
Radiator cap tester
4-13
To check radiator
cap.
ITEM
Ohmmeter
FIG.
USE
Vacuum tube DC
voltmeter 0-50 MV
6-1
To test thermal watt
converter.
Power source
120/208 ± 2 VAC
3 phase, 4 wire,
60 hertz
6-1
To test thermal watt
converter.
2-20
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-1. Recommended Tools and Equipment (Continued)
REFERENCE
ITEM
FSN OR
PART NUMBER
PARA
FIG.
USE
Ammeter
0-1.5 AMPERES
6-1
To test thermal watt
converter.
Auto transformer
75 VOLTAMPERES
6-1
To test thermal watt
converter.
Variable frequency
supply, 120V
45-415 Hz
6-2
To test frequency
meter and frequency
transducer.
Test frequency
meter
6-2
To test frequency
meter and frequency
transducer.
Power source
120 ± 2 VAC
50, 60 or 400 Hz
6-3
To test control box
relay assembly.
Voltmeter
120 ± 2 VAC
6-3
To test control box
relay assembly.
Power supply
24 ± 2 VDC
0.5 AMP
6-5
To test relay.
Power supply
210 ± 2 VAC, 60 Hz
6-6
To test AC current
meter.
Auto transformer
75 VA, 60 and/or
400 Hz (Quantity
of 3)
6-6
To test AC current
meter.
Ammeter
0-1.5 AMPERES
(Quantity of 3)
6-6
To test AC current
meter.
2-21
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-1. Recommended Tools and Equipment (Continued)
REFERENCE
ITEM
FSN OR
PART NUMBER
PARA
FIG.
USE
Power supply
24 ± 2 VDC
0.5 AMP
6-10
To test indicator box.
Power source
24 ± 2 VDC
3 AMP
6-16
To test exciterregulator.
Power source
0-130 ± 2 VAC
60 or 400 Hz
6-16
To test exciterregulator.
Ammeter
0-3 AMPS DC
6-16
To test exciterregulator.
Ammeter
0-10 AMPS DC
6-16
To test exciterregulator.
Ammeter
0-130 VAC
10 AMP
6-16
To test exciterregulator.
Power supply
24 ± 2 VDC
0.5 AMP
6-23
To test DC relay
assembly.
Power supply
0-400 Hz
120 ± 2 VAC
6-23
To test DC relay
assembly.
Power supply
24 ± 2 VDC
3 AMP
6-25
To test Mode I relay
box assembly.
Prover supply
120 ± 2 VAC
60 ± 0.5 HZ
5 AMP
6-25
To test Mode I relay
box assembly.
2-22
P-9-TM-457-35
TM-07464A-35
Table 2-1.
T.O. 35C2-3-442-2
TM 5-6115-457-34
Recommended Tools and Equipment (Continued)
REFERENCE
ITEM
FSN OR
PART NUMBER
PARA
FIG.
USE
Voltmeter 0-15 VAC
SCALE
6-25
To test Mode I relay
box assembly.
Ohmmeter R x 1000
SCALE
6-25
To test Mode I relay
box assembly.
Ohmmeter 0-3 AMP
SCALE
6-25
To test Mode I relay
box assembly.
Power supply
24 ± 2 VDC
0.5 AMP
6-28
To test 400 Hertz
underfrequency
relay.
6-28
To test 400 Hertz
underfrequency
relay.
Frequency meter
0-400 HZ
6-28
To test 400 Hertz underfrequency relay.
Power supply
24 ± 2 VDC
0. 5 AMP
6-31
To test under voltage relay
Variable voltage
power supply
0-130 ± 5 VAC,
400 HZ 1 AMP
6-31
To test under voltage frequency.
Power supply
24 ± 2 VDC
0.5 AMP
6-34
To test permissive
paralleling relay.
Variable frequency
power supply
0-400 hertz
120 VAC
5895-01-021-7156
Change 7 2-23
T.O. 35C2-3-442-2
TM 5-6115-457-34
P-9-TM-457-35
TM-07464A-35
Table 2-1. Recommended Tools and Equipment (Continued)
REFERENCE
FSN OR
PART NUMBER
FIG.
USE
Variable voltage
power supply
0-20 ± 1 VAC
400 hertz 1 AMP
6-34
To test permissive
paralleling relay.
Power supply
24 ± 2 VDC 3 AMP
6-39
To test Mode H relay
box assembly.
Fewer supply
0-130 VAC
360-420 HZ 5 AMP
6-39
To test Mode II relay
box assembly.
Voltmeter 0-15 VAC
6-39
To test Mode II relay
box assembly.
Voltmeter 0-20 VAC
SCALE
6-39
To test Mode II relay
box assembly,
Voltmeter
0-150 VAC SCALE
6-39
To test Mode II relay
box assembly.
Ammeter 0-3 AMP
SCALE
6-39
To test Mode II relay
box assembly.
Frequency meter
360-420 HZ SCALE
6-39
To test Mode II relay
box assembly.
ITEM
PARA
Power supply
24 ± 2 VDC 5 AMP
6-161
To test load contactor.
Resistor
5 OHM ± 1%, 1 watt
6-161
To test load contactor.
Resistor
250 OHM ± 10%,
25 watt
6-48
To test over voltage
relay (K2).
Power supply
24 ± 2 VDC
0.5 AMP
6-48
To test over voltage
relay.
2-24
P-9-TM-457-35 T O 35C2-3-442-2
TM 5-6115-457-34
TM-07464A-35
Table 2-1.
Recommended Tools and Equipment (Continued)
REFERENCE
FSN OR
PART NUMBER
FIG.
USE
Variable voltage
power supply
0-160 VAC
60 HERTZ
6-48
To test over voltage
relay,
Variable volt age
power supply
0-160 VAC
400 HERTZ
6-48
To test over voltage
relay.
Power supply
24 ± 2 VDC
0.5 AMP
6-51
To test reverse power relay.
Oscillator
6-51
To test reverse power relay.
Variable voltage
power supply
0-10 ± 1 VDC
1 AMP
6-51
To test reverse power relay.
Power supply
24 ± 2 VDC
0.5 AMP
6-54
To test short circuit
relay.
Power source
0-50 ± 5 VAC
60 hertz single
phase 1 AMP
6-54
To test short circuit
relay.
ITEM
Indicator,
Digital
Power supply
24 ± 2 VDC
0. 5 AMP
6625-00-414-6626
PARA
6-211
6-211A
SCU alignment
6-57
To test overload
relay.
Change 6
2-25
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-1. Recommended Tools and Equipment (Continued)
REFERENCE
ITEM
FSN OR
PART NUMBER
PARA
FIG.
USE
Power source
120/208 ± 2 VAC
3 phase, 4 wire
60 Hertz 3 AMP
6-57
To test overload
relay.
Resistor
35 OHM ± 1%
50 WATT
(Quantity of 3)
6-57
To test overload
relay.
Transformer
2 AMP (Quantity
of 3)
6-57
To test overload
relay.
Ammeter 0-3 AMPS
(Quantity of 3)
6-57
To test overload
relay.
Power supply
24 ± 2 VDC 2 AMP
6-58
To test tactical relay
box.
Power supply
0-10 ± 1 VDC
0.5 AMP
6-58.
To test tactical relay
box.
Power supply
0-1604 VAC
50/60-400 Hz
1 AMP
6-58.
To test tactical relay
box.
Power supply
0-50 VOLT
3/phase 50/60 or
400 HZ 4 wire
5 AMP
6-58.
To test tactical relay
box.
Ammeter 0 to 2 AMP
AC
6-58.
To test tactical relay
box.
Voltmeter 0-12 VDC
6-58.
To test tactical relay
box.
Volt meter
0-180 VAC
6-58.
To test tactical relay
box.
2-26
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-1. Recommended Tools and Equipment (Continued)
REFERENCE
ITEM
FSN OR
PART NUMBER
PARA
FIG.
USE
Resitor (100 OHM
± 10% 5 watt)
6-65
To test under frequency relay (K12).
Power supply
120/208 ± 2 VAC
3 phase, 4 wire
47-420 HZ
10 AMP
6-74
To test load measuring unit.
Ammeter 1 AMP
(Quantity of 3)
6-74
To test load measuring unit.
Voltmeter
0-5.6 ± 0.5 VAC
6-74
To test load measuring unit.
Voltmeter
0-10 VDC
6-74
To test load measuring unit.
Power supply
0-10 ± 2 VDC
15 AMP
7-2
7-5
To check generator
component.
Megger
500 VOLT
7-2
7-5
To check generator
component.
Variable speed drive
(2000 to 3000 RPM)
8-19
To check alternator
speed.
Resistor (1/2 OHM
500 WATT)
8-19
Used in alternator
voltage regulator
setting test.
DC voltmeter
0 to 50 volt scale
8-19
8-28
Used in alternator and
starter motor test.
Carbon pile
(0 to 600 ampere
load capacity)
8-19
8-28
Used in alternator
and starter motor
test.
Ammeter
0 to 50 ampere
scale
8-19
8-28
Used in alternator
and starter motor
test.
2-27
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-1. Recommended Tools and Equipment (Continued)
REFERENCE
ITEM
FSN OR
PART NUMBER
Armature test set
6625-238-1459
PARA
FIG.
USE
8-25
To test starter motor
armature for ground.
Spring scale
(0 to 100 pound
scale)
8-25
To check starter
motor brush spring
for proper tension.
Growler
8-25
To check starter
motor armature for
shorts.
8-26
To undercut mica
and starter motor
commutator.
Spring scale
(0 to 50 pound
scale)
8-28
Used in starter
motor stall torque
test.
Torque arm
(12 inch long)
8-28
Used in starter
motor stall torque
test.
Hand held tachometer (0 to 10,000
RPM)
8-28
Used in starter
motor stall torque
test.
Variable speed drive
(0 to 3000 RPM)
8-51
Used to check trip
settings on overspeed switch.
Hydraulic test stand
8-98
To test hydraulic
pump.
Variable speed drive
(0 to 2500 RPM)
8-98
To test hydraulic
pump.
Mica undercutter
2-28
4940-204-0319
T.O. 35C2-3-442-2
P-9-TM-457-35
TM-07464A-35 TM 5-6115-457-34
Table 2-1. Recommended Tools and Equipment (Continued)
REFERENCE
ITEM
FSN OR
PART NUMBER
PARA
FIG.
USE
8-98
To test hydraulic
pump.
8-99
8-151
8-222
To remove timing
gears and crankshaft
pulley.
Rack setting tool
8-140
Used to adjust governor drive housing.
Dial indicator
(0 to 1 inch)
8-140
Used to adjust governor drive housing.
Pressure gauge
0 to 400 PSI
Universal puller kit
3180-701-8046
Diesel injector tool
test set
4910-317-8265
8-149
To test fuel injection
pump.
Diesel injector pump
test stand
4910-443-0976
8-149
To test fuel injection
pump.
Fuel rack setting
gauge
8-149
Used to set fuel
injection pump
timing dimension.
Fuel injection
timing plate
8-149
Used to set fuel
injection pump
timing dimension
with pump off
engine.
Fuel injection pump
depth bore gauge
8-149
Used to time fuel
injection pump on
engine.
Precombustion
chamber wrench
5120-157-0718
8-190
To remove precombustion chamber
Valve face grinding
machine
4910-540-4679
8-185
8-193
To reface rocker arm
contact surface and
intake and exhaust
valves.
Change 1
2-29
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-1. Recommended Tools and Equipment (Continued)
REFERENCE
ITEM
FSN OR
PART NUMBER
PARA
Thickness gauge
5210-221-1999
8-187
To adjust valve lash.
8-192
To test intake and
exhaust valve
springs.
8-193
To reface intake and
exhaust valve seats.
Depth micrometer
(0 to 1 inch)
8-235
Used to measure cylinder liner height
projection.
Spring tester
11-13
To check heater
spring.
Power supply
24 ± 2 VDC
12 AMP
11-13
To check heater
component.
Dial indicator
11-13
To check heater
component.
Valve spring test
stand
Valve seat grinding
kit
4910-473-6437
FIG.
USE
Ammeter 0-10 AMP
11-4
To test coolant pump.
Voltmeter
0-30 VOLT
11-4
To test coolant pump.
Pressure gauge
0-50 PSI
11-4
To test coolant pump.
Power supply
24 ± 2 VDC
0.5 AMP
11-4
To test coolant pump.
Strobe light
2-30
11-16
11-22
To check coolant
pump.
T.O. 35C2-3-442-2
TM 5-6115-457-34
P-9-TM-457-35
TM-07464A-35
Table 2-1. Recommended Tools and Equipment (Continued)
REFERENCE
ITEM
FSN OR
PART NUMBER
PARA
FIG.
USE
Power supply
120 ± 2 VAC
50, 60, 400 hertz
13-5
To test load dumping
relay.
Ammeter
0-10 AMP AC
13-5
To test load dumping
relay.
Power supply
24 VDC 0.5 AMP
13-5
To test load dumping
relay.
Ammeter
0-5 AMP DC
13-5
To test load dumping
relay.
Ammeter
0-3 AMP AC
13-5
To test load dumping
relay.
Voltmeter 0-50 VAC
13-5
To test load dumping
relay.
Voltmeter 0-10 VDC
13-6
To test load dumping
relay.
Power supply
0-10 VDC 0.5 AMP
13-6
To test load dumping
relay.
Power supply
24 ± 2 VDC
0.5 AMP
13-6
To test load dumping
relay.
13-6
To test load dumping relay.
Load Bank
AVTRON
100 KW/100 KVAR
Change 7 2-31
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-2. Specially Designed (Fabricated) Tools and Equipment
REFERENCE
USE
ITEM
FIGURE
PARAGRAPH
Holding fixture
2-1A
.
8-71
Repair of turbocharger
Holding fixture adapter
2-1B
8-71
Repair of turbocharger
Supporting screw
2-1C
8-71
Repair of turbocharger
Wrench
2-1D
8-71
Repair of turbocharger
Wooden dowel
2-1E
8-71
Repair of turbocharger
Pilot
2-1 F
8-202
Installation of crankshaft seal
Sleeve
2-1G
8-202
Installation of crankshaft seal
Generator moving
block
2-1H
7-3
Used when moving
generator
Lifting fixture
2-1I
7-3
Used during disassembly of generator
2-32
P-9-TM-457-35
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Table 2-3. Troubleshooting
CORRECTIVE ACTION
PROBABLE CAUSE
MALFUNCTION
GENERATOR SET
1. Start-stop run
switch positioned to
START but engine
does not turn over.
a. Defective dc voltage
assembly, mode I or
mode 11 relay box.
b. Defective or improperly adjusted overspeed
switch (S9-1).
2. Start-stop-run
switch positioned to
START; engine turns
over but does not
start.
a. Test relay (paragraph 6-96 or 6-128).
Test relay box (paragraph 6-96 or 6-128).
b. Repair or adjust switch
(paragraph 8-46 or 8-51).
c. Defective starter.
c-. Repair STARTER
(paragraph 8-23).
d. Defective flywheel ring
gear.
d. Replace gear (paragraph
8-196 thru 8-203).
a. Defective governor
linkage.
a. Repair linkage
(paragraph 8-135 or 8-140)
b. Defective or improperly adjusted utility
governor.
b. Adjust or repair governor
(paragraph 8-135 or
8-140).
c. Defective fuel pump.
c. Repair pump
(paragraph 8-63).
d. Defective governor
actuator.
d. Test and repair if defective (paragraph 8-110 thru
8-115).
e. Defective or improperly adjusted over speed
switch (S9-1).
e. Repair or adjust switch
(paragraph 8-46 thru 8-51).
f.
Engine not properly
timed.
g.
Defective DC solenoid
or loose electrical
connections of the
solenoid plugs.
f.
Reset accessory drive
shaft timing (paragraph 8-156).
g. Repair or adjust (paragraph 8-137.a.10).
Change 6 2-33
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
MALFUNCTION
CORRECTIVE ACTION
PROBABLE CAUSE
GENERATOR SET (Continued)
3. Engine shuts down
after positioning
start-stop-run
switch to RUN.
4. Precise governor
fai1s to take over
after starting.
Engine speed increases and remains
at 2250 rpm (precise
generator sets).
5. During operation,
engine fuel throttle
goes to minimum
fuel position (precise
generator sets).
2-34
Change 3
b. Defective over voltage
relay K2.
a. Test and repair if defective (paragraph 6-14 thru
6-22).
b. Test relay
(paragraph 6-163).
c. Defective mode I or
mode II relay box.
c. Test relay box (paragraph 6-86 or 6-105).
a. Defective or improperly adjusted speed
switch (S9-2).
a. Repair or adjust switch
(paragraph 8-46 or 8-5 1),
b. 120 vac not supplied to
control unit receptacle
P1 pins A and B.
b. Repair or replace wiring
(paragraph 6-243).
c. Defective governor
linkage.
c. Repair linkage (paragraph 8-135 or 8-140).
d. Defective governor
actuator.
d. Test and repair if defective (paragraph 8-110 thru
8-115).
e. Defective governor control unit.
e. Test and repair if de feetive (paragraph 6-202).
f. Defective hydraulic
pump.
f. Test and replace if defective (paragraph 8-94 thru
8-98) .
a. Defective governor
actuator.
a. Test and repair if defective (paragraph 8-110 thru
8-115).
b. Defective governor control unit.
b. Test and repair if defective (paragraph 6-202).
a. Defective control box
relay assembly.
P-9-TM-457-35
TM-07464A-35
T. O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
MALFUNCTION
PROBABLE CAUSE
CORRECTIVE ACTION
GENERATOR SET (Continued)
6. Generator voltage
fails to build up.
7. Generator voltage
does not respond to
adjustment of voltage
adjusting rheostat
R2 .
8. Generator output
voltage erratic; frequency is stable.
a. Defective dc relay
assembly, A5 field
flash relay K5, in
mode I or mode II relay
box.
a. Test relay (paragraph 6-87 or 6-107).
b. Defective or improperly adjusted speed
switch (S51).
b. Repair or adjust switch
(paragraph 8-46 or 8-51).
c. Defective exciterregulator A10 and All.
c. Test and replace exciterregulator if defective
(paragraph 6-75).
d. Defective (shorted) current transformer C T4,
CT5, or CT6.
d. Test and replace if defective (paragraph 6-154).
e. Defective generator.
e. Test and repair if defective (paragraph 7-2).
a. Defective control box
relay assembly A4.
a. Test and repair if defective (paragraph 6-15).
b. Defective exciterregulator A10 and A11.
b. Test and repair if defective (paragraph 6-75).
a. Defective exciterregulator A10 and A11.
a. Test and replace if defective (paragraph 6-75).
b. Defective current
transformers CT4,
CT5, or CT6.
b. Test and replace if defective (paragraph 6-154).
c. Defective generator.
c. Test and repair if defective (paragraph 7-2).
Change 3
2-35
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
CORRECTIVE ACTION
PROBABLE CAUSE
MALFUNCTION
GENERATOR SET (Continued)
9. Generator frequency
fails to attain rated
value after start-up
(precise generator
sets).
a. Precise governor
system not properly
aligned.
a. Align system
(paragraph 6-211).
b. Defective precise or
mode II relay box.
b. Test and repair relay box
(paragraph 6-189 or 6-107).
c. Defective or improperly adjusted hydraulic
pump.
c. Test and replace if defective (paragraph 8-98).
d. Defective governor
actuator.
d. Test (paragraph 8-115).
e. Defective precise governor control unit.
e. Test and repair if defective (paragraph 6-202).
f.
10. Generator frequency
fails to attain rated
value (utility generator sets).
11. Generator frequency
erratic (NO LOAD).
2-36
Change 3
Improperly adjusted
engine fuel rack.
f.
Adjust fuel rack
(paragraph 8-147).
a. Defective or improperly adjusted utility
governor.
a. Adjust or repair if defective (paragraph 8-135).
b. Improperly adjusted
fuel rack.
b. Adjust fuel rack
(paragraph 8-148).
c. Defective governor
linkage.
c. Repair linkage
(paragraph 8-135).
a. Defective current
transformers CT1.
CT2, or CT3.
a. Test and replace if defective (paragraph 6-154).
b. Defective or improperly adjusted utility
governor.
b. Adjust or repair if defective (paragraph 8-135).
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
MALFUNCTION
PROBABLE CAUSE
CORRECTIVE ACTION
GENERATOR SET (Continued)
11. Generator frequency
erratic (NO LOAD).
(continued)
12. Frequency drifts
under steady load
(precise generator
sets).
13. Generator set frequency regulation is
not isochronous (precise generator sets).
c. Precise governor
system not properly
aligned.
c. Align system
(paragraph 6-211).
d. Defective hydraulic
pump (precise generator sets).
d. Test and replace if defective (paragraph 8-94 or
8-98).
e. Defective precise
generator actuator.
e. Test and repair if defective
(paragraph 8-110 thru
8-115).
f. Defective precise governor control unit.
f. Test and repair if defective (paragraph 6-202).
g. Defective precise or
mode H relay box (precise generator sets).
g. Test relay box (paragraph 6-189 or 6-107).
h. Defective exciter
regulater.
h. Test exciter regulator
(paragraph 6-75).
a. Defective governor
control unit.
a. Test and repair if defective (paragraph 6-202).
b. Test and repair if defective
(paragraph 8-110 thru
8-115).
b. Defective precise
governor actuator.
c. Defective hydraulic
pump.
c. Test and replace if defective
(paragraph 8-94 or 8-98).
a. Defective mode II or
precise relay box.
a. Test relay box (paragraph 6-107 or 6-189).
Change 3
2-37
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
MALFUNCTION
PROBABLE CAUSE
CORRECTIVE ACTION
GENERATOR SET (Continued)
ENGINE SHUTS DOWN AND/OR LOAD CONTACTOR
OR MOTOR OPERATED CIRCUIT BREAKER OPENS
DUE TO PROTECTIVE FUNCTION AND FAULT LOCATOR ILLUMINATES AS FOLLOWS:
14. Low oil pressure
indicator DS1.
15. Overspeed indicator
DS2.
2-38
Change 3
a. Broken oi1 line or
fitting.
a. Repair or replace.
b. Defective oil pump.
b. Repair pump
(paragraph 8-174).
c. Clogged or defective oil
cooler.
c. Clean, inspect and repair
cooler (paragraph 8-77
thru 8-84).
a. Defective or improperly adjusted utility
governor.
a. Test and repair if defective (paragraph 8-135 thru
8-140).
b. Defective governor
linkage.
b. Repair linkage
(paragraph 8-135).
c. Improperly adjusted
fuel rack.
c. Adjust rack
(paragraph 8-148).
d. Defective precise governor actuator (precise
generator sets).
d. Test and repair if defective (paragraph 8-110 thru
8-115).
e. Defective governor control unit (precise generator sets).
e. Test and repair if defective (paragraph 6-202).
f. Defective or improperly adjusted speed
switch (SS1).
f. Repair or adjust switch
(paragraph 8-46 or 8-51).
P-9-TM-457-35
T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
MALFUNCTION
PROBABLE CAUSE
CORRECTIVE ACTION
GENERATOR SET (Continued)
16. Short circuit indicater DS3.
a. Defective short circuit
relay (K13).
a. Remove and test relay
(paragraph 6-171 and 6-172).
17. Under voltage indiator DS4 (precise
generator sets).
a. Defective current
transformers CT4.
CT5, or CT6.
a. Test and replace if defective (paragraph 6-154).
b. Defective exciter
regulator.
b. Test exciter regulator
(paragraph 6-75).
c. Defective generator.
c. Test generator
(paragraph 7-2).
a. Defective or improperly adjusted utility
governor.
a. Adjust or repair if defective (paragraph 8-135 thru
8-140).
b. Defective governor
linkage.
b. Repair linkage
(paragraph 8-135).
c. Defective precise governor actuator (precise
generator sets).
c. Test and repair if defective (paragraph 8-110 thru
8-115).
d. Defective governor control unit (precise generator sets).
d. Test and repair if defective (paragraph 6-202).
a. Defective exciter
regulator.
a. Test exciter regulator
(paragraph 6-75).
18. Reverse power indiator DS5 (in parallel operation).
19. Over voltage indicater DS6.
Change 3
2-39
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
MALFUNCTION
PROBABLE CAUSE
CORRECTIVE ACTION
GENERATOR SET (Continued)
a. Clogged or defective
radiator.
a. Clean or repair radiator
(paragraph 4-10).
b. Defective water pump.
b. Repair pump
(paragraph 8-119).
c. Incorrect fuel injection
timing.
c. Reset timing
(paragraph 8-148).
d. Clogged engine coolant
passages.
d. Clean passages (paragraph
8-230 and 8-231).
e. Defective shutter.
e. Inspect and repair shutter
(paragraph 4-26 thru 4-33).
21. Overload indicator
DS9.
a. Defective relay (K14).
a. Test relay
(paragraph 6-175).
22. Under frequency
indicator DS10 (precise generator sets).
a. Defective precise governor actuator (precise
generator sets).
a. Test and repair if defective (paragraph 8-110 thru
8-115).
b. Defective governor control unit (precise generator sets).
b. Test and repair if defective (paragraph 6-202).
23. Generator set operates properly but
fault locator indicators illuminate.
a. Defective fault locator.
a. Test and repair if defective (paragraph 6-49).
24. Generator set shuts
down, low fuel indicater illuminates but
sufficient fuel is
available for
operation.
a. Defective dc relay
assembly, A5 relay K8,
in mode I or mode II
relay box.
a. Test relay (paragraph 6-96 or 6-128).
20. Coolant temperature
high indicator DS7.
2-40
Change 3
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
MALFUNCTION
PROBABLE CAUSE
CORRECTIVE ACTION
GENERATOR SET (Continued)
25. Generator set shuts
down, overspeed
indicator illuminates
but engine was operating at normal speed.
a. Defective or improperly adjusted over speed
switch.
a. Repair or adjust switch
(paragraph 8-46 or 8-51).
26. Load contactor or
motor operated circuit breaker opens
and overload indicator illuminates with
no overload fault.
a. Defective overload
relay K14.
a. Test relay
(paragraph 6-175).
b. Defective current
transformer CT1, CT2,
or CT3.
b. Test and replace if defective (paragraph 6-154).
a, Defective overload
relay K14.
a. Test relay
(paragraph 6-175).
b. Defective thermal watt
converter.
b. Test and replace if defective (paragraph 6-3).
c. Defective current
transformer CT1, CT2,
or CT3.
c. Test and replace if defective (paragraph 6-154).
a. Defective short circuit
relay K13.
a. Test relay
(paragraph 6-171).
b. Defective current
transformers CT1, CT2,
or CT3.
b. Test and replace if defective (paragraph 6-154).
c. Defective thermal watt
converter.
c. Test and replace if defective (paragraph 6-3).
d. Defective current
transformers CT4, CT5,
or CT6.
d. Test and replace if defective (paragraph 6-154).
e. Defective exciter
regulator.
e. Test exciter regulator
(paragraph 6-75).
27. Overload fault condition exists but load
contactor does not
open.
28. Short circuit fault
condition exists but
load contactor does
not open.
Change 3
2-41
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
MALFUNCTION
CORRECTIVE ACTION
PROBABLE CAUSE
GENERATOR SET (Continued)
29. Over voltage fault con- s. Defective over voltage
relay K2.
dition exists but load
contactor or motor
operated circuit breaker does not open.
a. Test relay
(paragraph 6-163).
30. Under voltage fault
condition exists but
load contactor or motor operated circuit
breaker does not open
(precise generator
sets).
a. Defective under voltage
relay K11.
a. Test and remove relay
(paragraph 6-111 and
6-112).
31. Under frequency fault
exists but load contactor or motor operated circuit breaker
does not open (precise
generator sets).
a. Defective under frequency relay (K12).
a. Test relay (paragraph
6-189 and 6-190).
32. Load contactor or mo- a. Defective load meastor operated circuit
urement unit.
breaker opens and reverse power indicator b. Defective reverse
power relay.
illuminate with no reverse power fault.
33. Generator sets do not
parallel properly
(precise generator
sets).
2-42
Change 3
a. Test unit
(paragraph 6-213).
b. Test and replace relay
(paragraph 6-167).
a. Precise governor system not properly
aligned.
a. Align system
(paragraph 6-211).
b. Defective governor control unit.
b. Test and repair if defective (paragraph 6-202).
c. Defective load measurement unit.
c. Test unit
(paragraph 6-213).
d. Defective permissive
paralleling relay.
d. Remove and test relay
(paragraph 6-193 and
6-194).
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
MALFUNCTION
PROBABLE CAUSE
CORRECTIVE ACTION
GENERATOR SET (Continued)
34. Attempting to parallel, without output
connected for
120/208 VAC, synchronizing lights are
very dim.
a. Defective mode I or
mode II relay box.
a. Test relay box (paragraph 6-96 or 6-128).
35. During parallel operation, load contactor
or motor operated
circuit breaker of set
number 2 will not
close.
a. Defective load contactor
or motor operated circuit breaker.
b. Defective permissive
paralleling relay K16
(precise generator
sets).
a. Test and replace if defective (paragraph 6-145).
36. During parallel operation, generator sets
do not share total
KVA equally.
b. Test relay (paragraph
6-115).
c. Defective dc relay assembly, A5 in mode I
or mode II relay box.
C. Test relay
(paragraph 6-96 or 6-128).
a. Defective or improperly adjusted KVA
rheostat R29.
a. Adjust or replace rheostat
(paragraph 6-104).
b. Defective parallel
receptacles.
b. Rebuild receptacles
(paragraph 5-5).
c. Defective mode I or
mode II relay box.
c. Test relay box (paragraph 6-96 or 6-128).
d. Defective exciter
regulator
d. Test exciter regulator
(paragraph 6-76).
e. Defective current
transformers CT4, CT5,
or CT6.
e.
f. Defective generator.
f. Test and repair if defective (paragraph 7-2).
Test and replace if defective (paragraph 6-154).
Change 3
2-43
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
MALFUNCTION
PROBABLE CAUSE
CORRECTIVE ACTION
GENERATOR SET (Continued)
37. During parallel operation, generator sets
do not share real
load (KW) equally
(precise generator
sets).
a. Defective or improperly adjusted real load
sharing rheostat R28.
a. Adjust or replace rheostat
(paragraph 6-128 and
6-193).
b. Precise governor
system not properly
aligned.
b. Align system
(paragraph 6-211).
c. Defective current
transformers CT1,
CT2, or CT3.
c. Test and replace if defective (paragraph 6-154).
d. Defective tactical relay
box.
d, Test relay box
(paragraph 6-161).
e. Defective exciter
regulator.
e. Test exciter regulator
(paragraph 6-76).
38. During parallel operation, generator sets
do not share real
load (KW) equally
(utility generator
sets).
a. Defective or improperly adjusted utility
governor.
a. Adjust or repair governor
(paragraph 8-140).
b. Defective governor
linkage.
b. Repair linkage
(paragraph 8-140).
39. Engine misses or
runs erratically.
a. Incorrect fuel injection
timing.
a. Reset timing
(paragraph 8- 148).
b. Sticking valves.
b. Free valves
(paragraph 8-192).
c. Broken rocker arm
assembly.
c. Replace rocker arm
(paragraph 8-182).
d. Cracked cylinder liner.
d. Replace liner
(paragraph 8-230).
2-44
Change 3
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
PROBABLE CAUSE
MALFUNCTION
CORRECTIVE ACTION
GENERATOR SET (Continued)
39. Engine misses or
runs erratically.
(continued)
40. Engine hunts (pre sise generator sets).
e. Blown head gasket.
e. Replace gasket
(paragraph 8-189).
f. Broken valve spring.
f. Replace spring
(paragraph 8-182).
g. Defective fuel injection
nozzle.
g. Replace nozzle
(paragraph 8-143).
h. Defective fuel injection
pump.
h. Repair pump
(paragraph 8-143).
i.
Bend or broken push
rod.
i.
Replace push rod
(paragraph 8-182).
j.
Defective piston or
rings.
j.
Replace piston or rings
(paragraph 8-214).
a. Defective exciter
regulator
a. Remove, test and replace
if defective (paragraph
6-75 and 6-76).
b. Defective or imp operly adjusted governor
actuator feedback
transducer.
b. Test and adjust transducer (paragraph 6-202).
c. Defective electronic
component assembly,
A26 in precise or
mode II relay box.
c. Replace assembly (paragraph 6-194 or 6-128).
d. Defective governor
actuator.
d. Test and repair if defective (paragraph 8-109).
e. Defective control unit.
e. Test and repair if defective (paragraph 6-202).
Change 3
2-45
P-9-TM-457-35
TM-07464A-35
T. O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
MALFUNCTION
CORRECTIVE ACTION
PROBABLE CAUSE
GENERATOR SET (Continued)
40. Engine hunts (precise generator sets).
(continued)
f. Defective hydraulic
pump.
f. Test and replace if defective (paragraph 8-94
and 8-98).
41. Sluggish governor
actuator operation
(precise generator
sets).
a “ Low hydraulic pressure
to actuator.
a. Test pump
(paragraph 8-98).
b. Defective governor
linkage.
b. Repair linkage
(paragraph 8-109).
c. Defective precise
governor actuator.
c. Test and repair if defective
(paragraph 8-94 or 8-98).
Defective governor
d. control unit.
12. Engine lacks power.
2-46
Change 3
d. Test and repair if defective (paragraph 6-202).
e. Defective hydraulic
pump.
e. Test and replace if defective
(paragraph 8-94 or 8-98).
a. Defective fuel nozzle.
a. Replace fuel nozzle
(paragraph 8-143).
b. Incorrect fuel injection
timing.
b. Reset timing
(paragraph 8-148).
c. Blown head gasket.
c. Replace gasket
(paragraph 8-190).
d. Defective valves or
valve springs.
d. Repair or replace valves
or springs
(paragraph 8-182).
e. Defective piston, rings,
or connecting rods.
e. Replace piston, rings, or
connecting rods
(paragraph 8-214).
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
PROBABLE CAUSE
MALFUNCTION
CORRECTIVE ACTION
GENERATOR SET (Continued)
42. Engine lacks power.
(continued)
43. Engine knocks, develops excessive
noise, or vibration.
44. Engine exhaust
excessively black
or gray.
f. Defective cylinder
liner,
f. Replace liner
(paragraph 8-230).
g. Turbocharger carboned
or dragging.
g. Repair turbocharger
(paragraph 8-71).
h. Defective governor
linkage.
h. Repair linkage
(paragraph 8-135).
a. Loose or defective
crankshaft pulley or
vibration damper.
a. Tighten or replace pulley
or damper
(paragraph 8-127).
b. Defective or loose fan.
b. Tighten or replace fan
(paragraph 8-31).
c.
c. Tighten or replace mount
(paragraph 8-127).
Loose or defective
engine mounts.
d. Defective crankshaft or
bearings.
d. Replace crankshaft or
bearings
(paragraph 8-222).
e. Defective connecting
rod or bearings.
e. Replace rod or bearings
(paragraph 8-214).
f. Defective piston or pin.
f. Replace piston or pin
(paragraph 8-214).
g. Damaged timing gear
train components.
g. Replace defective components (paragraph 8-127).
a. Defective fuel nozzle.
a. Replace nozzle
(paragraph 8-143).
b. Incorrect fuel injection
timing.
b. Reset timing
(paragraph 8-148).
2-47
P-9-TM-457-35
TM-07464A-35
T. O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
MALFUNCTION
CORRECTIVE ACTION
PROBABLE CAUSE
GENERATOR SET (Continued)
45. Engine exhaust
excessively white
or blue.
46. Excessive engine oil
consumption.
47. Heavy engine combustion knock.
48. Engine valve train
clicking noise.
2-48
a. Defective valve guides.
a. Repair cylinder head
(paragraph 8-143).
b. Defective piston rings.
b. Replace rings
(paragraph 8-214).
c. Incorrect fuel injection
timing.
c. Reset timing
(paragraph 8-148).
a. Excessive valve guide
wear.
a. Repair cylinder head
(paragraph 8-190).
b. High oil temperature
due to defective oil
cooler.
b. Repair cooler
(paragraph 8-79).
c. Worn piston rings
and/or cylinder liners.
c. Replace piston rings
(paragraph 8-214) and/or
cylinder liners (paragraph 8-236).
a. Defective fuel injection
pump plunger and
barrel assembly.
a. Replace plunger and barrel assembly
(paragraph 8-143).
b. Defective or leaking
fuel injection valve.
b. Replace fuel injection
valve (paragraph 8-143).
a. Defective valve spring.
a. Replace spring
(paragraph 8-143).
b. Insufficient lubrication
in valve compartment.
b. Clean oil passages leading to the cylinder head
(paragraph 8-191).
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
MALFUNCTION
PROBABLE CAUSE
CORRECTIVE ACTION
GENERATOR SET (Continued)
49. Engine lubricating
oil in coolant.
50. Engine stalls at low
speed.
51. Loud valve train
noise in engine.
52. Little rocker arm
movement and
excessive valve lash.
a. Defective cylinder
head gasket.
a. Replace gasket
(paragraph 8-190).
b. Defective oil cooler
core.
b. Repair or replace cooler
(paragraph 8-82).
a. Idle speed too low.
a. Adjust governor low idle
setting (paragraph 8-237).
b. Defective fuel injection
valve.
b. Repair valve
(paragraph 8-143).
a. Defective camshaft.
a. Replace camshaft
(paragraph 8-206).
b. Defective valve lifters.
b. Replace valve lifters
(paragraph 8-182).
a. Defective camshaft
and/or followers.
a. Replace camshaft and/or
followers
(paragraph 8-206).
b. Defective valve lifters.
b. Replace lifters
(paragraph 8-182).
c. Defective push rod.
c. Replace rod
(paragraph 8-182).
d. Insufficient lubrication
in valve compartment.
d. Clean oil passages
(paragraph 8-185).
Change 1
2-49
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
MALFUNCTION
PROBABLE CAUSE
CORRECTIVE ACTION
GENERATOR SET (Continued)
53. Engine valve rotocoil or spring
retainer free.
54. Excessive engine
blow-by.
55. Coolant in engine
lubricating oil.
2-50
a. Broken valve keepers.
a. Replace keepers
(paragraph 8-182).
b. Broken valve spring.
b. Replace valve spring
(paragraph 8-182).
c. Defective valve.
c. Replace valve
(paragraph 8-182).
a. Excessive valve guide
wear.
a. Repair cylinder head
(paragraph 8-190).
b. Excessive lubricating
oil in valve compartment.
b. Check rocker arm shaft
end plugs for proper
installation
(paragraph 8-186).
c. Worn piston rings
and/or liners.
c. Replace piston rings
(paragraph 8-214) and/or
liners (paragraph 8-230).
a. Defective cylinder
head gasket.
a. Replace gasket
(paragraph 8-190).
b. Defective cylinder
head.
b. Replace head
(paragraph 8-190).
c. Defective combustion
chamber.
c. Replace chamber
(paragraph 8-190).
d. Defective cylinder
block.
d. Replace block
(paragraph 8-230).
e. Defective oil cooler.
e. Repair or replace oil
cooler (paragraph 8-79).
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
PROBABLE CAUSE
MALFUNCTION
CORRECTIVE ACTION
GENERATOR SET (Continued)
56. Alternator charging
rate low or unsteady.
a. Intermittent or high
resistance in charging
or ground return circuits or battery connections.
a. Clean, retighten, or replace defective parts.
b. Defective regulator.
b. Replace if defective
(paragraph 8-16).
c. Alternator rectifier
diodes shorted or open.
c. Replace diodes
(paragraph 8-16).
d. Alternator rotor (field
coil) turns grounded or
shorted.
d. Replace rotor
(paragraph 8-16).
e.
57. Noisy alternator.
Loose connections on
alternator and/or
regulator.
e. Tighten connections.
f. Defective brushes.
f. Replace brushes
(paragraph 8-16).
a. Misaligned belt or
pulley.
a. Align drive pulley and
alternator pulley and
belts.
b. Loose pulley.
b. Tighten pulley nut, if keyway is worn, replace
pulley (paragraph 8-16).
c. Worn bearings.
c. Replace bearings
(paragraph 8-18).
d. Shorted rectifier
diodes.
d. Replace diode assembly
(paragraph 8-18).
2-51
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
PROBABLE CAUSE
MALFUNCTION
CORRECTIVE ACTION
GENERATOR SET (Continued)
58. Noisy turbocharger.
a. Worn bearings.
a. Replace bearings
(paragraph 8-71).
b. Insufficient lubrication.
b. Clean oil passages
(paragraph 8-71).
c. Excessive end play.
c. Repair turbocharger
(paragraph 8-71).
d. Defective shaft and
wheel assembly.
d. Repair turbocharger
(paragraph 8-71).
FUEL BURNING WINTERIZATION KIT
Limit switch detective.
59. Heater switch ON,
nothing happens,
press to test indicater energizes when
depressed.
a.
b. Heater switch
defective.
b. Check continuity of switch.
Replace if defective
(paragraph 11-5).
60. Switch on, heater
will not ignite.
Blower operates.
a. Heater orifice clogged.
a. Clean orifice. Replace if
defective
(paragraph 11-13).
b. Fuel regulator valve
solenoid closed.
b. Test and adjust fuel regulater valve
(paragraph 11-13).
2-52
a. Test and replace defective limit switch
(paragraph 11-11).
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
PROBABLE CAUSE
MALFUNCTION
CORRECTIVE ACTION
FUEL BURNING WINTERIZATION KIT (Continued)
a. Broken quartz rod.
a. Replace quartz rod
(paragraph 11-11).
b. Flame switch out of
adjustment.
b. Readjust
(paragraph 11-16).
c. Wiring defective.
c. Check continuity of wiring.
Replace if defective
(figure 1-29).
a. Defective micro switch.
a. Test and replace micro
switch if defective
(paragraph 11-16).
b. Heater overheats,
causing limit switch
to trip.
b. Check and adjust fuel flow
rate by adjusting and testing regulator valve
(paragraph 11-13).
63. Circuit breaker trips
open.
a. Short circuit.
a. Disconnect basic components one at a time, to
isolate short, then check
wiring (figure 1-29).
64. Heater will not shut
off .
a. Fuel regulator valve
stuck open.
a. Test fuel regulator valve
and replace if defective
(paragraph 11-13).
b. Flame switch stuck in
RUN position.
b. Adjust flame switch and
replace if defective
(paragraph 11-16).
61. Fan runs continuously
with switch off.
62. Heater starts, then
shuts off .
2-53
T.O. 35C2-3-442-2
P-9-TM-457-35
TM-07464A-35 TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
PROBABLE CAUSE
MALFUNCTION
CORRECTIVE ACTION
FUEL BURNING WINTERIZATION KIT (Continued)
a. Fuel regulator opersting irradically.
a. Test fuel regulator valve
(paragraph 11-13).
b. Defective sintered
filter.
b. Clean filter.
66. Coolant pump fails
to recirculate liquid.
a. Defective coolant pump.
a. Test coolant pump
(paragraph 11-16).
67. Coolant pump turns
over but fails to
deliver liquid.
a. Pump passages or
blade slots plugged with
foreign matter.
a. Remove pump and disassemble and clean
(paragraph 11-11).
68. Heater has erratic
operation or reduced
output.
a. Air leaks in tubing.
a. Check tubing connections
for leaks and repair as
necessary
(paragraph 11-11).
b. Reduced voltage.
b. Check voltage input to
motor. It should be above
24 vdc (figure 1-29).
c. Motor lags, low rpm.
c. Inspect motor brushes for
wear (paragraph 11-11).
d. Scored cam ring bore.
d. Replace cam ring
(paragraph 11-11).
e.
e. Remove pump, disassemble and clean
(paragraph 11-11).
65. Heater has surging
combustion.
69. Heater leaks.
2-54
Foreign matter in pump
blade slot.
a. Face of seal cage
stored or seal is
damaged.
a. Disassemble pump and refinish or replace seal
cage (paragraph 11-11).
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
MALFUNCTION
CORRECTIVE ACTION
PROBABLE CAUSE
ELECTRIC WINTERIZATION KIT
70. Switch on control box
positioned to ON;
heater ON indicator
energized, coolant
pump operating but
coolant temperature
not rising.
a. Defective electric
heater.
a. Test electric heater and
replace if defective
(paragraph 12-14).
71. Switch on control box
positioned to ON;
indicator energized
but coolant not being
circulated and coolant temperature not
rising.
a. Defective thermo switch
S2.
a. Check continuity of switch
at room temperature. It
should have continuity.
Immerse its temperature
sensing element in a water
bath at a temperature of
120 + °F. There should be
no continuity now. Allow
water to cool below 100°F.
There should be continuity
again.
b. Defective control box.
b. Test control box
(paragraph 12-3).
c. Defective heater.
c. Repair heater
(paragraph 12-14).
d. Defective coolant pump.
d. Test pump
(paragraph 12-19).
a. No power to input receptacle J49, terminals
A and B, figure 1-30.
a. Remove cable and measure
voltage to these two terminals. It should be between 205 to 240 VAC,
50/60 or 400 hertz.
b. Defective control box.
b. Test control box
(paragraph 12-3).
72. Switch on control box
positioned to ON and
indicator does not
energize.
2-55
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 506115-457-34
Table 2-3. Troubleshooting (Continued)
MALFUNCTION
PROBABLE CAUSE
CORRECTIVE ACTION
DUMMY LOAD KIT
a. Defective load measuring unit.
a. Test and repair if defective (paragraph 6-248).
b. Defective load dumping
relay (K5).
b. Test and repair if defective (paragraph 13-11).
c. Defective wiring
harness.
c. Rebuild harness (par agraph 13-7 or 13-26).
74. Dummy load kit trips
off the line below
automatic removal
point.
a. Defective load dumping
relay (K5).
a. Test and repair if defective (paragraph 13-11).
b. Defective load measuring unit.
b. Test and repair if defective (paragraph 6-248).
75. Dummy load kit does
not disconnect at
automatic removal
point.
a. Defective load dumping
relay (K5).
a. Test and repair if defective (paragraph 13-11).
b. Defective load measuring unit.
b. Test and repair if defective (paragraph 6-248).
76. Dummy load set does
not apply load when
automatic load switch
is in either position.
a. Defective transformer
(T1).
a. Test and replace if defective (paragraph 13-24).
b. Defective bridge rectifier assembly CR1,
CR2, CR3, or CR4.
b. Test and replace if defective (paragraph 13-24).
c. Defective wiring
harness.
c. Rebuild harness (paragraph 13-7 or 13-26).
73. Dummy load kit will
not apply load when
automatic load switch
is in the ON position,
but does apply load
when switch is in
BYPASS RESET
position.
2-56
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Table 2-3. Troubleshooting (Continued)
MALFUNCTION
PROBABLE CAUSE
CORRECTIVE ACTION
DUMMY LOAD KIT (Continued)
77. Dummy load kit
Load does not change
when load selector
switch is rotated.
78. Dummy load is
unbalanced.
a. Defective contactor K1,
K2, K3, or K4.
a. Test and replace if defective (paragraph 13-24)
a. Defective contactor K1,
K2, K3, or K4.
a. Test and replace if defective (paragraph 13-24).
b. Defective heater
elements.
b. Test and replace if defective (paragraph 13-5).
c. Defective wiring
harness.
c. Test and repair if defective (paragraph 13-7 or
13-26).
Change 8
2-57
P-8-627-34
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TM 5-6115-457-34
Section IV. ENGINE CHANGE INSTRUCTIONS, D3306(T) ENGINE
2-10.
GENERAL.
This section contains instructions
for the replacement of the existing D333C(T)
engine, which is no longer manufactured,
with the new D3306(T) engine.
2-11. ENGINE REMOVAL, D333C(T)
ENGINE.
Refer to paragraph 2-8 and remove
the existing D333C(T) engine.
2-12. REMOVAL OF SALVAGABLE
COMPONENTS FROM THE
D333C(T) ENGINE.
The following components are to be
removed from the D333T engine and salvaged for installation on the D3306(T) engine.
a. Refer to Operation and Organizational Maintenance Manual and remove the
oil pressure transmitter, low oil pressure
switch, coolant temperature transmitter,
high coolant temperature switch, alternator,
air cleaner, fuel filter and pump assembly,
coolant drain valve, hydraulic tank and
hydraulic filter assembly (MEP 116A only),
starter motor, oil sump shut-off valve with
hose assembly, elbow and nipple, and the
turbocharger exhaust elbow.
b. Refer to paragraph 8-86 and remove the hydraulic tank. Refer to figure 810 and remove the fan (3) in the sequence of
index number assigned. Refer to figure 864 and remove the lube oil filler neck (30) in
the sequence of index numbers assigned.
2-13. INSTALLATION OF COMPONENTS,
D3306(T) ENGINE.
a . Installation of Salvaged and New
Components.
The following salvaged components
from the D333C(T) engine are to be installed
on the D3306(T) engine. Before installation
of these components, completely remove all
engine preservative packaging and proceed as
follows:
2-58
Change 8
(1) Over speed Switch Magnetic
Pickup. Before installing the D3306(T) engine into the generator set, refer to figure
2-8 and install the magnetic pickup (85B) into
the engine flywheel housing. Pay particular
attention to the following:
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protect ion required. Good general
ventilation is normally adequate.
(a) Inspect flywheel for nicks
and burrs on generator contact surfaces. Remove nicks and burrs using a suitable file or
stone. Clean flywheel with an approved
cleaning solvent and dry thoroughly.
(b) Run the locknut on the
pickup (85B) to the electrical connector end
of the pickup and thread the magnetic pickup
into the flywheel housing.
(c) Center one flywheel tooth
directly below the pickup head. Using a suitable feeler gage, adjust the pickup to tooth
clearance to 0.015 to 0.020 inch gap. Pickup
can also be positioned by bottoming lightly on
gear tooth and backing off 95° to 130° to obtain correct gap.
(d) Secure pickup and tighten
locknut. Recheck clearance.
(2) Engine. Refer to paragraph
2-8 and install the D3306(T) engine into the
generator set.
(3) Turbocharger Exhaust Elbow.
Refer to figure 2-8 and install the salvaged
turbocharger exhaust elbow (85E). Pay particular attention to the following:
Figure 2-8.
P-9-TM-457-35
TM-07464A-35
2-59
T.O. 35C2-3-442-2
TM 5-6115-457-34
Change 4
Change 4
P-9-TM-457-35
TM-07464A-35
2-60
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 2-8.
P-9-TM-457-35
TM-07464A-35
T. O. 35C2-3-442-2
TM 5-6115-457-34
Legend to figure 2-8:
1.
2.
3.
4.
5.
6.
6A.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
Hose assembly
Hose assembly
Elbow
Screw (2)
Nut (2)
Bracket, hydraulic filter
Hydraulic filter assy. (salvaged)
Screw
Nut
Washer
Screw
Nut
Washer
Nut
Rod end
Threaded rod
Screw
Nut
Washer
Roller stop
Screw
Nut
Washer
Throttle override plate
Screw
Nut
Washer
Spring pin
Throttle extension arm
Screw
Nut
Washer
Link spacer
Throttle link assembly
Screw
Nut
Washer
Screw
Nut
Washer
Governor throw extender link
Hydraulic actuator clevis
Hose assembly
Elbow
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
66A.
66B.
66C.
67.
68.
69.
69A.
70.
71.
72.
73.
74•
75.
76.
77.
78.
78A.
78B.
79.
80.
81.
Reducer
Elbow
Screw
Washer
Screw
Washer
Clamp
Governor actuator
Elbow (2)
Screw (4)
Washer (4)
Screw (2)
Nut (2)
Washer (2)
Fuel filter mounting bracket
Nut
Washer
Stud
Nut
Washer
Stud
Actuator mounting brace
Governor support bracket
Rod end bearing
Nut
Threaded rod
Screw
Washer
Washer
Speed control lever
Setscrew
Shaft extender
Plastic tubing
Plastic tubing
Plastic tubing
Clamp
Plastic tubing
Plastic fitting
Elbow (2)
Screw
Washer
Screw (2)
Nut (2)
Washer (2)
Change 4
2-61
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Legend to figure 2-8 (continued):
82.
83.
84.
84A. .
85.
85A.
85B.
85C.
85D.
85E.
85F.
85G.
85H.
85J.
85K.
86.
87.
88.
89.
90.
910
92.
93.
94.
95.
96.
97.
97A.
98.
99.
99A. .
100.
101.
2-62
Fuel filter mounting bracket
Nut
Washer
Stud
Fuel filter support bracket
Cable assembly
Magnetic pickup
Elbow
Clamp
Turbocharger exhaust elbow
(salvaged)
Hose assembly (salvaged)
Elbow (salvaged)
Oil sump shut-off valve (salvaged)
Long nipple (salvaged)
Starter motor (salvaged)
Hose assembly
Elbow
Elbow
Reducer bushing
Regualting valve
Pipe tee
Hose assembly
Elbow
Tee
Reducer bushing
Reducer bushing
Hydraulic tank mounting bracket
Hydraulic tank (salvaged)
Hydraulic pump assembly
A Iternator fan guard
Alternator
Upper radiator hose
Lower radiator hose
Change 4
10 IA. Oil pressure transmitter (salvaged)
101B. Low oil pressure switch (salvaged)
101C. Coolant temperature transmitter
(salvaged)
101D. High coolant temperature switch
(salvaged)
102.
Elbow
102A. Fuel filter and pump assembly
(salvaged)
103.
Plug
103A . Clamp (salvaged)
103B. Hose (salvaged)
103C. Drain valve (salvaged)
104.
Tee
105.
Elbow
106.
Reducer bushing
106A. . Bolt (3)
106B. Lock washer (3)
106C. . Washer (3)
106D. Lube oil filler neck (salvaged)
106E. Gasket
Speed switch assembly
107.
107A. . Screw (4)
107B. Washer (4)
107C. Screw (4)
107D. Washer (4)
107E. Nut (4)
Bracket
108.
108A. . Engine wiring harness
109.
Hose assembly
110.
Hose assembly
Hose assembly
111.
112.
Grommet
113.
Engine, D3306(T)
P-9-TM-457-35
TM-07464A-35
(a) Remove the existing
D3306(T) turbocharger exhaust elbow from
the engine by removing the existing retaining clamp (85D).
(b) Install the salvaged
turbocharger exhaust elbow (85E) onto the
engine and secure with existing retaining
clamp (85D). Make certain that water drain
plug points directly downward.
(4)
Oil Sump Shut-Off Valve.
Refer to figure 2-8 and install the salvaged
oil sump shut-off valve (85H), long nipple
(85J), elbow (85G) and hose assembly (85F).
(5)
Starter Motor. Refer to
figure 2-8 and install the salvaged starter
motor (85K) and attaching hardware in the
engine. Pay particular attention to the
following:
(a) Reconnect tagged electrical leads to the starter motor and
solenoid.
(6)
Hydraulic Filter Assembly
(MEP116A only). Refer to figure 2-8 and
install the salvaged hydraulic filter assembly (6A) ) as shown. Pay particular attention
to the following:
(a) Assemble the hydraulic
filter bracket (6) to the salvaged filter
assembly (6A) using screws (4) and selflocking nuts (5).
(b) Remove existing hardware as shown and mount the hydraulic
filter assembly to the engine.
(c) Connect elbows and
hose assemblies as shown.
Lube Oil Filler Neck
(7)
Assembly. Refer to figure 2-8 and install
the saIvaged lube oil filler neck assembly
(106D). Pay particular attention to the
following :
T.O. 35C2-3-442-2
TM 5-6115-457-34
(a) Remove the existing
D3306(T) lube oil filler neck assembly from
the engine by removing three bolts (106A),
three lockwashers (106B) and three washers
(106C). Make certain not to damage existing
gasket (106E).
(b) Install the salvaged lube
oil filler neck assembly (106D) to the engine
using the existing three bolts ( 106A), three
lockwashers (106 B), three washers (106C)
and gasket (106 E).
(8)
Coolant Drain Valve. Refer
to figure 2-8 and install the salvaged coolant
drain valve (103C) as shown. Pay particular
attention to the following:
(a) Apply thread sealing
compound conforming to Military Specification
MIL-S-45180, type III to pipe threads prior to
installation.
(b) Thread new reducer
bushing (106) into engine block.
(c) Assemble tee (104), plug
(103) and elbow (105). Thread assembly into
reducer bushing (106). Thread salvaged
coolant drain valve (103C) into tee (105) as
shown.
Fuel Filter and Pump Assem(9)
bly. Refer to figure 2-8 and install the salvaged fuel filter and pump assembly (102A) as
shown. Pay particular attention to the
following:
(a) Connect tagged electrical
leads and hoses.
(10) Alternator. Refer to figure
2-8 and install the salvaged alternator (99A)
as shown. Pay particular attention to the
following:
(a) Install new alternator fan
guard (99) using salvaged hardware.
Change 4
2-63
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
(11) Fan. Refer to figure 8-10
and install the salvaged fan in the reverse
sequence of index numbers assigned.
(12) Hydraulic Tank and
Hydraulic Pump (ME P116A only).
(a) Refer to figure 2-8 and
remove the hydraulic tank mounting bracket
from the salvaged hydraulic tank (97A).
(b) Install new mounting
bracket (97) onto the hydraulic tank (97A).
(c) Refer to figure 2-8 and
assemble the modified hydraulic tank (97A)
and the new hydraulic pump (98) onto the
engine as follows:
NOTE
Be sure hydraulic pump
gears mesh properly and
there is no binding.
1. Apply thread sealing compound conforming to Military Specification MIL-S-45180, type III to pipe
threads prior to installation.
2. Place hydraulic
pump (98) into pump receptacle, making
certain that gear teeth mesh properly and do
not bind.
3. Place hydraulic
tank (97A) onto pump and secure both
assemblies with existing hardware.
4. Attach fittings and
hoses.
(13) Alternator Belt and Fan
Belts. Refer to Operator and Organizational
Maintenance Manual and install and adjust
the alternator belt and fan belts.
2-64
Change 4
(14) High Coolant Temperature
Switch. Refer to figure 2-8 and install the
salvaged high coolant temperature switch
(101D) as shown. Apply thread sealing compound conforming to Military Specification
MIL-S-45180, type III to pipe threads prior to
installation.
(15) Coolant Temperature Transmitter. Refer to figure 2-8 and install the
salvaged coolant temperature transmitter
(101C) as shown. Apply thread sealing compound conforming to Military Specification
MIL-S-45180, type III, to pipe threads prior
to installation.
(16) Low Oil Pressure Switch. Refer to figure 2-8 and install the salvaged low
oil pressure switch (101B) as shown. Apply
thread sealing compound conforming to Military Specification MIL-S-45180, type III to
pipe threads prior to installation.
(17) Oil Pressure Transmitter.
Refer to figure 2-8 and install the salvaged oil
pressure transmitter (101A) ) as shown. Apply
thread sealing compound conforming to Military Specification MIL-S-45180, type III to
pipe threads prior to installation.
(18) Over speed Switch. Refer to
figure 2-8 and install the overspeed switch
(107). Pay particular attention to the following:
(a) Remove existing screws
(107A) and washers (107B).
(b) Assemble the over speed
switch (107) to the over speed switch bracket
(108) using screws (107C), washers (107D)
and nuts (107E).
(c) Install the overspeed
shutdown switch onto the generator as shown.
P-8-627-34
TM-07464A-35
(d) Overspend switch cable
assembly. Install connector P62 on the
cable assembly (85A) to J62 on the overspeed switch (107). Connect loose end of
cable assembly (85A) to magnetic pickup
(85B).
(19) Governor Actuator and
Linkage (ME P116A only). Refer to figure
2-8, sheet 1 and install the governor actuatore (51) and the associated linkage as shown.
Pay particular attention to the following:
(a) Install the final fuel
filter supplied with the 3306(T) engine to fuel
filter bracket (58) using screws (53) and
washers (54).
(20) Lifting Frame Assembly.
Refer to paragraph 3-14 and install the
lifting frame assembly onto the generator
skid base.
(21) Day Tank. Refer to Operator and Organizational Maintenance Manual
and install the day tank in the reverse sequence of index numbers assigned.
(22) Engine Wiring Harness.
Refer to figure 2-8 and Operator and Organizational Maintenance Manual and install the
engine wiring harriess (108A). Pay particular attention to the following:
(a) Install connector P37
to J37 on overspeed switch (107).
(b) Connect harness connectors and wires.
(c) Secure harnesses with
clamps.
T O 35C2-3-442-2
TM 5-6115-457-34
(23) Air Cleaner. Refer to Operator and Organizational Maintenance Manual
and install the air cleaner as shown.
(24) Manual Speed Control. Refer
to figure 2-8 and Operator and Organizational
Maintenance Manual and connect the manual
speed control in the reverse sequence of index numbers assigned.
(25) Radiator and Housing Frame
Assembly. Refer to Operator and Organizational Maintenance Manual and install the
radiator and housing frame assembly in the
reverse sequence of index numbers assigned.
Pay particular attention to the following:
(a) Install new radiator hoses;
upper hose (figure 2-8, 100) and lower hose
(101).
(26) Doors and Covers. Refer to
Operator and Organizational Maintenance
Manual and install the doors and covers in the
reverse sequence of index numbers assigned.
(27) Crankcase Breather Tube and
Hose. Refer to Operator and Organizational
Maintenance Manual and install crankcase
breather tube and hose in reverse sequence
illustrated.
(28) Muffler and Exhaust Pipe.
Refer to Operator and Organizational Maintenance Manual and install muffler and exhaust pipe.
(29) Engine Fuel Bleed Line
Installation. Refer to figures 2-8 and 2-9
and install the engine fuel bleed line (72) as
follows:
WARNING
Drilling operations create metal
chips which may enter the eye.
Eye protection is required.
(a) Refer to figure 2-9 and
drill a 0.438 inch hole as illustrated.
(d) Join harnesses in com(b) Refer to figure 2-8 and inmon run from one side of engine to opposite
stall grommet (112). Install the engine fuel
side at six inch intervals with tiedown straps. bleed line (72) as illustrated.
Change 8
2-65
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Figure 2-9.
Front lower right panel drilling dimensions
for fuel bleed line tubing
(30) Battery Cables. Refer to
Operator and Organizational Maintenance
Manual and connect the battery cables as
illustrated.
(31). Winterization Kits. If the
generator set contains a winterization kit,
2-66
Change 8
refer to the Operator and Organizational Maintenance Manual for modification instructions.
(32) Generator Set Test After Engine Change. Refer to Chapter 10 and perform
generator set test after engine change.
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
CHAPTER 3
HOUSING AND LIFTING FRAME ASSEMBLY REPAIR INSTRUCTIONS
Section I. HOUSING FRAME
3-1.
GENERAL.
a. HOUSING FRAME. The housing
frame reinforces the housing panels and
doors. It provides interconnection between
the lifting frame and front and rear housings.
b. FRONT HOUSING. The front housing is the mounting frame for the generator
set radiator and shutter assembly. It also
provides a connection point for the engine
crankcase breather tube and slave receptacle SR2.
c. REAR HOUSING. The rear housing
provides a mount for the control cubicle,
fault locator panel, DC control cubicle,
convenience receptacle, sleeve and plate
assembly, parallel harness receptacles,
manual speed control, and mounting openings for the controls of the generator set
optional kits which are covered by plates if
the kits are not installed. It also contains
the air intake panel.
3-2.
REMOVAL AND DISASSEMBLY.
Refer to figure 3-1 and remove and
disassemble the housing frame in the order
of index numbers assigned. Pay particular
attention to the following:
a. Refer to Operator and Organizational
Maintenance Manual and perform the following:
1. Disconnect negative battery cable.
2. Remove housing panels and doors.
3. Remove DC control circuit
breaker.
4. Disconnect parallel receptacle
harness from rear housing.
5. Remove manual speed control.
6. Remove kit control panels from
rear housing, if installed.
7. Remove slave receptacles from
front housing and receptacle mounting
panel.
8. Remove radiator and shutter
assembly.
b. Remove control cubicle, as specified
in paragraph 2-6.
c. Remove fault locator panel from rear
housing by disconnecting harness from rear
of locator panel and removing four screws
attaching panel to rear housing.
d. Remove convenience receptacle
assembly from rear housing by disconnecting harness from rear of assembly and removing six screws and washer securing
assembly to rear housing.
3-1
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 3-1. Housing frame, exploded view
3-2
T O 35C2-3-442-2
P-8-627-34
TM-07464A-35 TM 5-6115-457-34
Legend to figure 3-1:
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Screw assembly (2)
Nut assembly (2)
Connector cover
Screw assembly (2)
Nut assembly (2)
Washer (2)
External power
receptacle
Screw (4)
Nut (4)
Lock washer (4)
Washer (4)
Bracket
Screw (16)
Nut (16)
Upper side panel (4)
Screw (3)
Lock washer (3)
Washer (4)
Screw (4)
Nut (4)
Washer (8)
Front housing
Screw (4)
Nut (4)
Connector and lead
Screw (4)
Nut (4)
Washer (8)
Receptacle mounting
panel
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
Screw (4)
Nut (4)
Washer (8)
Left side panel
Screw (5)
Nut (5)
Washer (5)
Bracket
Screw (5)
Nut (5)
Washer (5)
Bracket
Screw (5)
Nut (5)
Washer (5)
Bracket
Screw (5)
Nut (5)
Washer (5)
Bracket
Screw (12)
Lock washer (12)
Washer (12)
Air Intake panel
Screw (4)
Lock washer (4)
Plate
Screw (2)
Lock washer (2)
Plate
Screw (6)
61. Lock washer (6)
62. Plate and sleeve
assembly
63. Screw (4)
64. Nut and washer
assembly (4)
65. Bushing
66. Plate
67. Sleeve
68. Plate
69. Screw (6)
70. Lock washer (6)
71. Plate
72. Screw (6)
73. Lock washer (6)
74. Washer (6)
75. Screw (20)
76. Lock washer (20)
77. Washer (20)
78. Screw (2)
79. Lock washer
80. Washer (2)
81. Support
82. Screw (2)
83. Lock washer (2)
84. Washer (2)
85. Support
86. Screw (2)
87. Lock washer (2)
88. Rear housing
Change 8
3-3
P-8-627-34
T O 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
CLEANING.
3-3.
a. Clean electrical components with a
cloth moistened with an approved cleaning
solvent, and dry thoroughly.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
b. Clean metal components with an approved cleaning solvent, and dry thoroughly.
3-4.
INSPECTION.
order of index numbers assigned. Pay particular attention to the following:
NOTE
Wiring harness interconnecting diagram is contained in Operator and
Organizational Maintenance Manual
a. Install convenience receptacle assembly in rear housing and secure with six
screws and washers. Connect harness to
assembly.
b. Install fault locater panel in rear
housing and secure with four screws. Connect harness to locator panel.
a. Inspect slave receptacles and leads
for continuity and for shorts to casing.
c. Install control cubicle, as specified
in paragraph 2-6.
b. Inspect terminal lugs for security
and condition.
d. Refer to Operator and Organizational
Maintenance Manual and perform the following:
c. Inspect air intake panel screen for
holes and tears.
d. Inspect components for dents,
cracks, distortion.
1. Install radiator and shutter
assembly.
2. Install slave receptacles and in
f rent housing and receptacle mounting panel.
e. Inspect threads for damage.
f. Inspector damage paint.
3-5.
REPAIR.
a . Straighten dented and distorted
sheet metal parts using suitable tools.
b. Remove damaged paint. Blend in
edges, prime, and paint damaged areas.
3-6.
REASSEMBLY AND INSTALLATION.
Refer to figure 3-1 and reassemble
and install housing frame in the reverse
3-4
Change 8
3. If necessary, install kit control
panels.
4. Install manual speed control.
5. Connect parallel receptacle harness in rear housing.
6. Install DC control circuit breaker.
7. Install housing panels and doors.
8. Connect negative battery cable.
P-8-627-34 T O 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Section II. LIFTING FRAME ASSEMBLY
3-7.
GENERAL.
The lifting frame assembly is bolted
skid
base and provides the means of
to the
lifting the generator set. Two clevis are
located at the top of the lifting frame to permit attachment of a suitable lifting device.
The lifting frame is the center support for
the housing assembly. Bolted to the lifting
frame are the day tank, fuel transfer valve,
fuel tank filler neck and tube, and manual
speed control bracket.
3-8.
REMOVAL.
Refer to figure 3-2 and remove lifting frame as follows:
e. Remove nuts (2 and 6), screws (4 and
8), and washers (3, 5, 7, and 9). Connect
an overhead lifting device to clevis (31) and
remove lifting frame (10) from skid base.
Guide lifting frame during lifting operation
to prevent damage to components.
3-9.
DISASSEMBLY.
Refer to figure 3-2 and disassemble
lifting frame as follows:
a. Loosen clamp (11) and remove hose
(12).
b. Remove fuel filler cap (13), pull cap
chain and remove filler tube (14) and cap
from filler neck (17).
a. Remove housing frame as specified in
paragraph 3-2.
c. Remove nuts (15), screws, (16),
filler neck (17) and gasket (18) from lifting
frame.
b. Refer to Operator and Organizational
Maintenance Manual and perform the following:
d. Remove nuts (19, 22, and 25),
screws (20, 23, and 26), and plates (21, 24,
and 27).
1. Remove fuel transfer valve, fuel
inlet fitting, and fuel supply outlet fitting.
e. Remove cotter pins (28), nuts (29),
screws (30), and clevis (31).
2. Remove day tank.
3. Disconnect manual speed control
bracket from lifting frame.
4. Removal air cleaner.
c. Loosen clamp (1) securing hose (12)
to fuel tank and remove hose from tank.
Plug tank opening. Remove fuel lines
connected to filler neck.
d. Disconnect electrical connectors from
governor control unit (34) and lift governor
control unit (34) from retainer (41). Remove guard (33) by removing screws (32).
f. Remove retainer (41) and bracket (44)
from lifting frame by removing screws (38
and 42) nuts (39 and 43) and washers (40).
Remove bracket (44) from retainer (41) by
removing screws (35), nuts (36) and washer
(37).
3-10. CLEANING.
a. Clean old gasket from lifting frame
and filler neck using a suitable scraper.
b. Clean parts with an approved cleaning solvent, and dry thoroughly.
3-11. INSPECTION.
a. Inspect for damaged threads.
Change
8
3-5
P-8-627-34
T O 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
b. Inspect parts for cracks, breaks,
and defective welds.
c. Inspect hose for cuts, tears, and
deterioration.
d. Inspect filler tube screen for holes,
cuts, and other damage.
e. Inspect lifting frame mounting screw
holes for elongation.
f. Inspect plates for legibility.
g. Inspect paint for damage.
3-12. REPAIR.
WARNING
Welding operations produce heat,
highly toxic fumes, injurious
radiation, metal slag and airborne particles. Welding goggles, with proper tinted lenses,
apron or jacket and welder’s
boots are required.
a. Repair cracks by welding.
b. Remove damaged paint. Blend in
edges, prime, and paint damaged areas.
Figure 3-2. Lifting frame assembly, exploded view
3-6
Change 8
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115 -457-34
Legend to figure 3-2:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Clamp
Nut (8)
Washer (8)
Screw (8)
Washer (8)
Nut (8)
Washer (8)
Screw (8)
Washer (8)
Lifting frame
Clamp
Hose
13. Fuel filler cap
and chain
14. Filler tube and
screen
15. Nut (6)
16. Screw (6)
17. Filler neck
18. Gasket
19. Nut (2)
20. Screw (2)
21. Fuel inlet plate
22. Nut (2)
3-13. REASSEMBLY.
Refer figure 3-2 and reassemble
lifting frame as follows:
a. Assemble bracket (44) to retainer
(41) and secure with screws (35), nuts (36)
and washers (37). Position retainer (41)
and bracket (44) to lifting frame and secure
with screws (28 and 42), nuts (39 and 43)
and washers (40).
b. Install clevis (31), screws (30), and
nuts (29). Tighten nuts (29) so that clevis
are just free to move and cotter pin holes
in nuts and screws are aligned. Install
cotter pins (28).
c. Position plates (21, 24, and 27) on
lifting frame (10) and secure with screws
(20, 23, and 26) and nuts (19, 22, and 25).
d. Position gasket (18) and filler neck
(17) in lifting frame (10) and secure with
screws (16) and nuts (15). Install filler
tube (14) and cap (13).
e. Position hose (12) on filler neck and
secure with clamp (11).
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
Screw (2)
Fuel outlet plate
Nut (2)
Screw (2)
Fuel selector plate
Cotter pin (2)
Nut (2)
Screw (2)
Clevis (2)
Screw (2)
Guard
Governor control unit
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
Screw (2)
Nut (2)
Washer (2)
Screw (2)
Nut (2)
Washer (2)
Ret airier
Screw (2)
Nut (2)
Bracket
a. Connect an overhead lifting device to
clevis (31) and carefully position lifting
frame (10) on skid base. Secure lifting
frame to skid base with screws (4 and 8),
washers (3, 5, 7, and 9), and nuts (2 and
6).
b. Position hose (12) on fuel tank and
secure hose with clamp (l).
c. Secure guard (33) to governor control
unit with screws (32). Place governor control
unit into retainer (41) and connect electrical
connector.
d. Refer to Operator and Organizational
Maintenance Manual and perform the following:
1. Connect and adjust manual speed
control bracket on lifting frame.
2. Install fuel transfer valve, fuel
inlet fitting, and fuel supply outlet fitting.
3. Install day tank.
3-14. INSTALLATION.
e. Secure fuel hoses to lifting frame
with clamps, screws, and washers; one on
each inside wall of lifting frame.
Refer to figure 3-2 and install lifting
frame as follows:
f. Install housing frame as specified in
paragraph 3-6.
Change 3
3-7
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Legend to figure 3-3:
1. Seal
2. Rod (8)
3. Rivet (32)
4. Clip (8)
5. Screw (28)
6. Nut (28)
7. Access door (4)
8. Door holder (4)
9. Screw (5)
10. Nut (5)
11. Access door
11A. Seal
12. Screw (5)
13. Nut (5)
13A. Seal
14. Access door
15. Screw (8)
16. Nut (8)
16A. Seal
17. Access door
18. Screw (8)
19. Nut (8)
19A. Seal
20. Access door
21. Door holder
22. Screw (21)
23. Nut (21)
24. Washer (21)
25. Access cover
26. Battery access frame
27. Washer (21)
28. Nut (2)
29. Screw (2)
30.
* 31.
* 32.
* 33.
* 34.
* 35.
* 36.
* 37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52,
53.
54.
55.
56.
57.
58.
59.
60.
Slave receptacle
access door
Washer
Cotter pin
Rain cap
Screw (2)
Lock washer (2)
Washer (2)
support
Stud
Deleted
Nut (3)
Screw (3)
Radiator cap
access door
Rivet (2)
Receptacle
Screw (18)
Lock washer (18)
Washer (18)
Nut (4)
Screw (4)
Washer (4)
Nut (4)
Screw (4)
Washer (8)
Screw (4)
Lock washer (4)
Washer (4)
Front cover
Nut (4)
Screw (4)
*Used only on 50/60 Hertz Generator Sets.
3-8
Change 3
61.
62.
63.
64.
65.
66.
67.
68.
69.
70•
71.
72.
73.
74.
75.
76.
77.
78.
79
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
Washer (8)
Nut (5)
Washer (5)
screw (5)
Washer (5)
Screw (14)
Lock washer (14)
Washer (14)
Nut (4)
Screw (4)
Washer (8)
Screw (4)
Lock washer (4)
Washer (4)
Screw (5)
Lock washer (5)
Washer (5)
Rear cover
Nut (6)
Screw (6)
Parallel cable
stowage box
Parallel cable
Nut (12)
Washer (12)
screw (12)
Air intake
panel
Cotter pin (2)
Nut (2)
Screw (2)
Lifting clevis (2)
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 3-3. Housing, partially exploded view
(sheet 1 of 2)
Change 3
3-9
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 3-3. Housing, partially exploded view
(sheet 2 of 2)
3-10 Change 3
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
CHAPTER 4
RADIATOR AND SHUTTER ASSEMBLY REPAIR INSTRUCTIONS
Section I. RADIATOR ASSEMBLY
4-1.
GENERAL.
The radiator assembly consists of
top and bottom tanks, core assembly, vent
tube, mounting brackets, upper and lower
shrouds, and shroud plate. The shrouds
and shroud plate are bolted to the radiator
and insure that air drawn by the fan is
forced through the radiator when exiting the
generator set. The upper tanks and mounting brackets are soldered to the core
assembly, the brackets provide a means of
mounting’ the radiator and the tanks provide
area for storage of coolant. The vent tube
permits overflowing coolant to leave the
radiator. Refer to Appendix A for applicable technical manual for additional information pertaining to radiator.
4-2.
UPPER AND LOWER SHROUD AND
SHROUD PLATE .
4-3. REMOVAL. Refer to Operator and
Organizational Maintenance Manual and
remove upper and lower shrouds and shroud
plate.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
4-4. CLEANING. Clean parts with an
approved cleaning solvent and dry thoroughly.
4-5. INSPECTION. Inspect upper and
lower shrouds and shroud plate for cracks
and distortion.
Welding operations produce heat,
highly toxic fumes, injurious
radiation, metal slag and airborne particles. Welding goggles, with proper tinted lenses,
apron or jacket and welder’s
boots are required.
4-6. REPAIR. Repair cracks by welding
and straighten distorted parts using proper
tools .
4-7. INSTALLATION. Refer to Operator
and Organizational Maintenance Manual and
ins tall upper and lower shrouds and shroud
plate.
4-8. RADIATOR.
4-9. REMOVAL. Refer to Operator and
Organizational Maintenance Manual and
remove the radiator.
4-10. TEST,
a. Differential Pressure Test.
1. Plug shutter power element port
on bottom radiator tank. Check that vent
tube is free of obstructions by forcing compressed air through tube. Install radiator
cap.
2. Connect a suitable water supply
to lower radiator hose cube and reverse
flush radiator until water flowing from
upper radiator hose tube is clear.
3. Connect water supply to upper
radiator hose tube and flush radiator until
water flowing from lower tube is clear.
NOTE
All test equipment must have a
minimum inside diameter of
2.5 inches.
Change 8
4-1
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
4. Connect 0 to 20 PSI pressure
gauges to radiator hose tubes. Connect
manual shut off valve and then an 80 GPM
water supply to upper radiator hose tube.
Connect return line from gauge at lower
radiator hose tube to water supply reservoir. Close manual shut off valve.
CAUTION
Stop test immediately if pressure
gauge at top hose port reaches
15 PSI.
5. Start water supply. Slowly open
manual shutoff valve while observing gauge
at top hose tube. Stop test if pressure
reaches 15 PSI. Fully open shutoff valve
and record pressure on both gauges. If
pressure differential between upper and
lower gauges exceeds 1.8 PSI, the radiator
is restricted.
b. Pressure Test.
1. Plug radiator filler neck, hose
tubes, and shutter power element port.
Connect a regulated pressure air supply
manual shutoff valve, and 0-20 PSI pressure
gauge, to radiator vent tube.
2. Place radiator in suitable tank
filled with water.
3. Slowly apply 15 PSI to radiator
and check for air bubbles that would indicate leaks. Mark leaks if any.
4. Remove radiator from tank.
Relieve all air pressure and remove test
equipment. Repair leaks.
4-11. DISASSEMBLY. Refer to figure 4-1
and disassemble radiator as follows:
NOTE
6. Shut down water supply, relieve
pressure, and remove test equipment from
radiator. If pressure differential exceeded
1.8 PSI, remove radiator cap and perform
the following procedures.
CAUTION
Do not immerse cold radiator in
boiling solution.
7. Mix a solution of one pound baking
soda to each gallon. of water. Fill a
suitable boiling tank with solution and place
radiator in tank. Bring solution to a boil
and boil radiator for a minimum of 30 minutes. Remove radiator and perform steps 2.
through 6.
8. If pressure differential still
exceeds 1.8 PSI, the radiator must be disassembled and cleaned.
4-2
Change 8
Prior to disassembly of radiator,
its condition should be analyzed by
performing test specified in paragraph 4-10.
a. Mark mounting brackets, top tank,
and bottom tank in relation to core assembly to insure proper reassembly.
b. Remove oxide film on all soldered
joints.
c. Using suitable soldering tools,
unsolder vent tube, mounting brackets, top
tank, and bottom tank.
WARNING
Avoid breathing fumes generated by
unsoldering/soldering. Eye protection is required.
4-12. CLEANING.
a. Remove excessive solder using a
suitable torch and rag.
P-8-627-34
TM-07464A-35
Figure 4-1. Radiator assembly
WARNING
Compressed air used for cleaning and
drying purposes can create airborne
particles that may enter the eyes.
Pressure shall not exceed 30 psig.
Eye protection is required.
b. Remove obstruction from radiator
core fins using compressed air.
c. If core assembly tubes are clogged,
boil core assembly in a solution of one
pound of baking soda to each gallon of water
for a minimum of 30 minutes or until clog
is loosened.
d. Clean core assembly tubes using a
suitable bristle brush or cleaning rod.
Remove loosened particles using compressed
air.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
T O 35C2-3-442-2
TM 5-6115-457-34
e. Clean parts with an approved cleaning
solvent and dry thoroughly.
4-13. INSPECTION.
a. Test radiator cap using suitable cap
tester. Cap setting should be approximately
7 PSI. Check locking taps for condition.
b. Inspect mounting brackets for cracks,
distortion, missing captive nuts. Inspect
captive nuts for damaged threads.
c. Inspect tanks for cracks, holes, or
dents. Check hose connection tubes for
out-of-roundness, security, and damage.
Check filler neck for damage and security.
Check bottom tank flange for security, damaged threads, and damage to gasket contact
surface.
d. Inspect core assembly for loose
tubes, bent or damaged cooling fins, and
damage to tank contact surfaces.
e. Inspect paint for damage.
4-14. REPAIR.
WARNING
Welding operations produce heat,
highly toxic fumes, injurious
radiation, metal slag and airborne particles. Welding goggles, with proper tinted lenses,
apron or jacket and welder’s
boots are required.
a. Repair cracks in mounting brackets
by welding. Straighten distorted parts
using proper tools.
b. Replace defective mounting bracket
captive nuts.
c. Solder cracks and holes in tanks.
Large holes or cracks may be repaired by
soldering as suitable patch over defect.
Resolder loose hose connection tubes,
filler neck, or bottom tank flange. Remove
burrs from flange using suitable file or
stone.
d. Solder loose core assembly tubes.
To repair damaged tubes, remove cooling
fins in area of leak and solder leak. Solder
Change 8
4-3
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
cooling fin back into position. To replace
a defective tube, unsolder tube from core
assembly and remove tube. Insert a
suitable replacement tube in core assembly
and solder in position. Straighten bent
cooling fins.
e. Remove damaged paint using a
suitable scraper. Blend in edges, prime,
and paint damaged areas.
4-15. REASSEMBLY. Refer to figure 4-1
and reassemble radiator as follows:
WARNING
Avoid breathing fumes generated by
unsoldering/soldering. Eye protection is required.
a. Using suitable soldering equipment,
fill core assembly tank contact surface
grooves with solder.
b. Place upper tank on core assembly,
making sure relationship marks are in
alignment. Solder upper tank to core
assembly. Repeat procedure for lower
tank.
c. Solder mounting brackets and vent
tube in position.
d. Test radiator as specified in paragraph 4-10. Perform necessary procedures if radiator does not meet required
test results.
4-16. INSTALLATION. Refer to Operator
and Organizational Maintenance Manual and
install radiator.
Section II. SHUTTER AND CONTROL ASSEMBLY
4-17.
GENERAL.
The shutter consists of movable
vanes mounted in nylon bearings which are
actuated by a control rod connected to the
control assembly. When engine coolant
temperature reaches 158°F, the control
assembly power element starts to extend
which moves the control rod opening the
shutter vanes. If coolant temperature
decreases, the control assembly integral
return spring moves the control rod closing
the shutter vanes. This modulated control
automatically opens and closes the shutter
vanes the amount necessary to maintain the
engine at normal operating temperature.
Opening and closing of the shutter vanes
regulates cooling air flow through the
radiator. The shutter assembly is equipped
with a manual control handle to permit
manual opening of the shutter vanes. The
handle should be in the full up position during normal operation.
4-18.
4-4
CONTROL ASSEMBLY.
Change 8
4-19. REMOVAL. Refer to Operator and
Organizational Maintenance Manual and
remove the control assembly.
4-20. DISASSEMBLY. Refer to figure 4-2
and disassemble the control assembly in
the order of index numbers assigned. Pay
particular attention to the following:
a. When removing retaining ring (14),
press in on large seat (15) to relieve spring
tension on ring. Remove retaining ring and
slowly remove large seat until spring
tension is relieved.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
4-21. CLEANING. Clean parts in an
approved cleaning solvent and dry
thoroughly.
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
4-22. INSPECTION.
a. Inspect threads for damage and parts
for cracks.
b. Inspect shaft for nicks, burrs, and
scoring in flange bushing area.
c. Inspect flange bushing for nicks,
scores, and out of roundness.
d. Inspect springs for distortion and
broken ends.
e. Test power element for proper
operation, refer to Operator and Organizational Maintenance Manual.
f. Inspect manual control handle for
distortion.
4-23. REPAIR.
a. Remove nicks and burrs using a file
or stone.
Figure 4-2. Shutter control
exploded view
Legend to figure 4-2:
1.
1A.
1B.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Nut
Lock washer
Screw
Lever
Retainer
Shaft
Yoke assembly
Nut
Friction spring
Screw
Washer
Manual control
handle
11.
12.
13,
14.
15.
16.
17.
18.
19.
20.
Power
element
Preformed
packing
Nut
Retaining ring
Large seat
Felt washer
Large seat
Spring
Small seat
Shutter power
element
housing
b. Straighten distorted manual control
handle using suitable tools.
4-24. REASSEMBLY. Refer to figure 4-2
and reassemble the control assembly in the
reverse order of index numbers assigned.
Pay particular attention to the following:
a. Apply a thin film of oil to packing
(12), Position nut (13) and packing (12) on
power element (11). Screw power element
into housing (20) until top of power element
is 2.75 inches above flat or flange. Hold
power element stationary and tighten nut (13).
b. Tighten nut (6) tight enough to apply
spring tension on manual control handle (10)
and still permit movement of handle.
Change 1
4-5
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
4-25. INSTALLATION. Refer to Operator
and Organizational Maintenance Manual and
install control assembly.
4-26.
and carefully remove cotter pin (1). Slide
rod (3) free of block (4), Remove nut (5),
lock washer (6) and screw (7) retaining
block (4) to control bar (12).
SHUTTER.
4-27. REMOVAL. Refer to Operator and
Organizational Maintenance Manual and
remove shutter.
4-28. DISASSEMBLY. Refer to figure 4-3
and disassemble the shutter as follows:
a. Place shutter face down on a clean,
dirt-free work bench. Secure spring (2)
b. Remove closing spring (8) and unscrew spring studs (9) free, from left angle
(21).
c. Carefully remove retaining rings (10).
Slide control rods (11) and (12) clear of vanes
(23). Remove bushings (13) from control
bars (11 and 12). Carefully remove retaining rings (14).
Figure 4-3. Shutter, exploded view
4-6
Change 1
P-8-627-34
TM-07464A-35
Legend to figure 4-3:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Cotter pin
Spring
Rod
Block
Nut
Lock washer
Screw
Closing spring
Spring stud
Retaining ring (8)
Control bar
d. Remove nuts (15), lock washers (16)
and screws (17). Remove the top rail (18)
and the bottom rail (19) from the shutter.
Carefully remove right angle (20) and left
angle (21) from vanes (23) and remove
bushings (22).
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
Compressed air used for cleaning and
drying purposes can create airborne
particles that may enter the eyes.
Pressure shall not exceed 30 psig.
Eye protection is required.
4-29. CLEANING. Clean all parts in an
approved cleaning solvent and dry thoroughly
using filtered, low pressure compressed
air and clean, lint-free cloth. If shutter is
not to be fully disassembled, utilize same
procedure above.
4-30.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
T O 35C2-3-442-2
TM 5-6115-457-34
Control bar
Bushing
Retaining ring (8)
Nut
Lock washer
Screw
Top rail
Bottom rail
Right angle
Left angle
Bushing
Vane (16)
d. Inspect bushings for out-of-roundness,
cuts, and cracks.
e. Inspect channel for distortion and for
elongated holes.
f. Inspect vanes for cracks and nicks,
burrs, and grooves on bushing contact
surfaces.
4-31. REPAIR.
a. Straighten distorted parts using
suitable tools.
b. Remove nicks or burrs from vane
bushing contact surfaces using a file or
stone.
4-32. REASSEMBLY. Refer to figure 4-3
and reassemble the shutter as follows:
a. On a clean, dirt-free work bench
place left angle (21) with vane pivot holes
perpendicular to the work bench,
INSPECTION.
b. Inspect control rod assembly for distortion and missing components.
b. Place bushings (22) into left angle
(21), Insert vane pivot arm closest to vane
into bushings (22). Secure with retaining
ring (14); one on the top vane and every
fifth vane the reafter.
c. Inspect spring for distortion and
broken ends.
c. Repeat procedure b. above for the
right angle (20).
a. Inspect threads for damage.
Change 8
4-7
T O 35C2-3-442-2
P-8-627-34
TM-07464A-35 TM 5-6115-457-34
d. Place top rail (18) between right
angle (20) and left angle (21) Secure with
nut (15), lock washer (16) and screw (17).
e. Repeat procedure d. above for the
bottom rail (19).
f.
Place bushings (13) into control bar
(12). Slide control bar (11) over vane pivot
arm. Secure with retaining ring (10); one
on the top vane and every fifth vane thereafter.
g. Repeat procedure f. above for
control bar (11).
4-8
Change 8
h. Fasten spring studs (9) into left angle
21. Secure closing spring (8) to spring studs
(9).
i. Attach block (4) to control bar (11)
utilizing nut (5) lock washer (6) and screw
(7). Insert rod (3) through block (4); place
spring (2) over rod (3) and secure with
cotter pin (1).
4-33. INSTALLATION. Refer to Operator
and Organizational maintenance manual and
install shutter.
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
CHAPTER 5
ELECTRICAL CONTROLS WIRING HARNESSES
REPAIR INSTRUCTIONS
GENERAL.
5-1.
The electrical controls wiring harnesses interconnect the electrical components of the generator set.
NOTE
Mode I relay boxes are used on
50/60 hertz generator sets and
mode H relay boxes on 400 hertz
generator sets.
a.
ness.
J1 of
J2 of
Relay Box To Control Cubicle HarThe harness is connected to connector
the control cubicle (A3) ) and connector
the mode I or mode II relay box (A27).
b. Relay Box To Exciter Regulator Harness. The harness is connected to connector
J9 of the exciter regulator (A10 and All) and
connector J3 of the mode I or mode II relay
box (A27).
c. Tactical Relay Box To Load Measurement Unit Harness. The harness is connected to connector J4 of the tactical relay
box (A7) and connector J16 of the load measurement unit (A8).
d, Relay Box To Precise Relay Box Harness. The harness is connected to connector
J32 of the precise relay box (A25) and connector J31 of the mode I relay box (A27).
The harness is utilized on 50/60 hertz generator sets only.
e. Relay Box To Governor Control Unit
Harness. The harness is connected to connectors J21 and J17 of the governor control
unit (A23) and connector J8 of the precise
relay box (A25) on 50/60 hertz precise generator sets or connector J8 of the mode II
relay box on 400 hertz generator sets. The
harness is not used on utility generator sets.
f. Governor Control Unit To Governor
Actuator Harness. The harness is connected
to connectors J22 and J23 of the governor
control unit (A23) and connectors J24 and
J25 of the governor actuator (A24). The
harness is not used on utility generator sets.
g. Relay BOX To Reconnection Board
Harness (50/60 Hertz Generator Sets). The
harness is connected to connector J10 of the
mode I relay box (A27), connector J13 of the
exciter regulator (A10 and All), connector
J41 of the. load contactor (C32), connector
J48 of the convenience receptacle (A22),
connector J61 of generator (G1), and to terminals of the load board and terminal boards
(TB2 and TB6). The harness is not utilized
on 400 hertz generator sets.
h. Relay Box To Reconnection Board
Harness (400 Hertz Generator Sets). The
harness is connected to connector J10 of the
mode II relay box (A27), connector J13 of
the exciter regulator (A10 and Al1), connector J48 of the convenience receptacle
(A22), connector J61 of generator (G1), and
to terminals of the load board and terminal
boards (TB2 and TB6). The harness is not
utilized on 50/60 hertz generator sets.
i. Relay Box To
cator Harness. The
to connector J12 of
indicator (A9) and
Fault Locator Indiharness is connected
the fault locator
to connector J6
Change
8
5-1
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
of the mode I or mode 11 relay box
(A27).
harness straps for condition, security, and
proper spacing.
NOTE
j. Parallel Receptacle Harness. The
harness is connected to connector J15 of
the mode I or mode II relay box (A27). The
three connectors of the harness J45, J46,
and J47 are the parallel receptacles located
at the rear of the generator set.
k. Relay Box to Tactical Relay Box
Harness. The harness is connected to connector J51 of the tactical relay box (A29) and
connector J50 of the mode I or mode II
relay box (A27).
5-2.
d. Check each harness wire for continuity from connector pin to wire end.
Check connector pins for shorts to case
and surrounding pins. Refer to figures 5-1
through 5-11.
5-5.
REMOVAL.
Refer to Operator and Organizational
Maintenance Manual and remove the wiring
harnesses.
5-3.
Interconnecting wiring diagram is
contained in the Operator and
Organizational Maintenance Manual.
REBUILD.
a. Refer to figure 5-1 and rebuild relay
box to control cubicle harness.
b. Refer to figure 5-2 and rebuild relay
box to exciter regulator harness.
CLEANING.
WARNING
Compressed air used for cleaning and
drying purposes can create airborne
particles that may enter the eyes.
Pressure shall not exceed 30 psig.
Eye protection is required.
a. Clean connector pins with low pressure, filtered compressed air.
b. Clean connectors and terminal lugs
with a clean lint-free cloth moistened
in an approved cleaning solvent and dry
thoroughly.
c. Remove oil and grease from wires
using a clean lint-free cloth.
5-4. INSPECTION.
a. Inspect connectors for loose, bent,
and damaged pins; damaged threads; and
defective keys.
b. Check terminal lugs for security
and condition.
c. Inspect harness wires for defective
insulation, illegible wire numbers. Check
5-2
Change 8
c. Refer to figure 5-3 and rebuild
tactical relay box to load measurement unit
harness.
d. Refer to figure 5-4 and rebuild relay
box to precise relay box harness on
50/60 hertz precise generator sets.
e. Refer to figure 5-5 and rebuild relay
box to governor control unit harness on
precise generator sets.
f. Refer to figure 5-6 and rebuild governor control unit to governor actuator
harness on precise generator sets.
g. Refer to figure 5-7 and rebuild relay
box to reconnect on board harness on
50/60 hertz generator sets.
P-9-TM-457-35
TM-07464A-35
h. Refer to figure 5-8 and rebuild relay
box to reconnection board harness on
400 hertz generator sets.
i. Refer to figure 5-9 and rebuild relay
box to fault locator indicator harness.
j. Refer to figure 5-10 and rebuild
parallel receptacle harness.
T.O. 35C2-3-442-2
TM 5-6115-457-34
k. Refer to figure 5-11 and rebuild
relay box to tactical relay box harness.
5-6.
INSTALLATION.
Refer to Operator and Organizational
Maintenance Manual and install the wiring
harnesses.
Figure 5-1. Relay box to control cubicle wire harness
(sheet 1 of 2)
5-3
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 5-1. Relay box to control cubicle wire harness
(sheet 2 of 2)
5-4
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 5-2. Relay box to exciter regulator wire harness
5-5
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 5-3. Tactical relay box to load measuring unit wire harness
5-6
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 5-4. Relay box to precise relay box wire harness, 50/60 Hertz generator sets
5-7
P-9-TM-457-35
TM-07464A-35
5-8
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 5-5.
Figure 5-6.
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
5-9
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
5-10
Figure 5-7.
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 5-7. Relay box to reconnection panel wire harness, 50/60 Hertz generator sets
(sheet 2 of 2)
5-11
P-9-TM-457-35
TM-07464A-35
5-12
T.O. 35C2-3-442-2
TM 5-6115-457-34
Change 3
Figure 5-8.
P-9-TM-457-35
TM-07464A-35
Figure 5-8.
T. O. 35C2-3-442-2
TM 5-6115-457-34
Relay box to reconnection panel wire harness,
400 Hertz generator sets (sheet 2 of 2)
Change 3
5-13
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 5-9. Relay box to fault locator indicator wire harness
5-14
Figure 5-10.
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
5-15
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-074644-35 TM 5-6115-457-34
Figure 5-11. Relay box to tactical relay box wire harness
5-16
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
CHAPTER 6
GENERATOR SET CONTROL GROUP REPAIR INSTRUCTIONS
Section I. CONTROL CUBICLE
6-1.
GENERAL.
The control cubicle is located at the
generator end of the set. It contains controls, switches, instruments, and circuitry
necessary to start, operate, and monitor
the generator set. The instruments and
controls are mounted on a hinged front
panel of the cubicle which permit easy access to the interior of the cubicle. Devices
on the front panel are divided into an engine
group and a generator group.
a. Instruments that monitor the generator output are: frequency meter M6; kilowatt meter M7; percent rated current meter
M8; ac voltmeter M9; ammeter-voltmeter
selector switch S8; and the synchronizing
lights DS4 and DS5. Devices that control
the generator output are: a frequency adjust rheostat R1 for precise sets; a voltage
adjust rheostat R2; parallel unit - single
unit operation switch S6; battle short
switch S7 and indicator DS7; voltage sensing (remote-local) switch S5; and ac load
contactor switch S3 and indicator DS6.
Utility generator sets utilize a manual
speed control located adj scent to the control cubicle, for adjustment of frequency
through the utility governor.
b. Instruments that monitor engine
operation are: oil pressure meter Ml;
coolant temperature indicator M2, fuel
level meter M3, battery charge ammeter
M4, and total running time meter M5.
Devices that control the engine are a
START-RUN-STOP switch S2 and an engine
primer switch S1. Also included is an
engine air cleaner condition indicator DS8.
c. Located in the control cubicle are
the thermal watt converter Al, control
panel relay assembly A4, frequency meter
transducer A2, control box relay assembly, and a wire harness. The thermal
watt converter senses the generator power
output and converts it to a proportional dc
signal for display by the kilowatt meter.
The frequency meter and transducer are a
matched set. A single phase ac voltage of
the generator output is applied to the transducer which produces dc signal proportional to the generator frequency for display by
the frequency meter. The control box
relay assembly contains stop-run relay K1,
remote voltage sensing relay K6, rectifier
bridge CR1, and resistor R10.
6-2.
THERMAL WATT CONVERTER
(A1).
6-3.
TEST ON EQUIPMENT.
a. Symptoms and Isolation of Malfunction. A malfunction of the thermal watt
converter is usually indicated by low or no
kilowatt meter reading. An open circuit
coil in the thermal watt converter will also
effect the AC ammeter reading for the
phase which is open. To isolate the malfunction, proceed as follows:
6-1
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
1. Loosen three captive studs and
hinge control box door open.
2. Start generator set and apply
6-5. INSPECTION. Inspect case for evidence of cracks or tears and the terminal
board for cracked insulation, stripped
threads, and missing jumper strips.
load.
6-6. TEST. Connect the thermal watt
converter to the test equipment as illustrated in figure 6-1 and proceed as follows:
Exercise extreme care not to touch
exposed electrical connections when
working inside control cubicle with
generator set operating.
3. Measure input voltages at terminals V1-N1, V2-N2 and V3-N3. Voltage
should be 120 VAC with the generator output voltage adjusted for rated output. If
above requirement is not met, check wiring
back to voltage source.
Note
All test readings are ±20 percent.
a. Adjust all autotransformers T1, T2,
and T3 to their MIN positions.
b. Close switch S1 and open switches
S2 and S3.
c. Energize the power source.
4. Measure current to terminal L1,
L2, and L3. The current should vary between 0-0 75 AC amperes as the generator
set load is varied from 0 to 100 percent of
rated output. If there is no current shut
down generator set and check for continuity
between terminals L1-S1, L2-S2 and L3S3. If there is continuity, check wiring
back to current source.
5. Measure the output signal at the
(+) and (-) terminals with a vacuum tube DC
voltmeter. The output signal should vary
between 0 to 10.4 mv as the generator set
load is varied between 0 and 100 percent of
rated output, If the above requirement is
not met and the inputs’ are correct, the
thermal watt converter should be replaced.
b. Removal. Refer to Operator and
Organizational Maintenance Manual and remove the thermal watt converter.
d. Adjust T1 until 1 ampere is indicated
on ammeter Al. Voltmeter V1 should indicate 6.4 mv.
e. Close switch S2 and adjust T2 until
1 ampere is indicated on ammeter A2.
Voltmeter V1 should indicate 13 mv.
f. Close switch S3 and adjust T3 until
1 ampere is indicated on ammeter A3.
Voltmeter should indicate 18.6 mv.
g. Remove test equipment. Replace
defective thermal watt converter.
6-7. INSTALLATION. Refer to Operator
and Organizational Maintenance Manual and
install the thermal watt converter.
6-8.
FREQUENCY METER (M 6) AND
TRANSDUCER (A2).
6-9. TEST ON EQUIPMENT.
6-4. CLEANING. Clean the thermal watt
converter using a clean lint-free cloth,
moistened with an approved cleaning solvent and dry thoroughly.
6-2
a. Symptoms and Isolation of Malfunction. A malfunction of the frequency meter
or transducer is usually indicated by off
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 6-1. Thermal watt converter (Al) test setup
scale, high or low readings with the frequency adjusting controls set in their normal positions. To isolate the malfunction,
proceed as follows:
1. Loosen three captive studs and
hinge control box door open.
2. Start generator set and apply
load.
WARNING
Exercise extreme care not to touch
exposed electrical connections when
working inside control cubicle with
generator set operating.
3. Measure input voltage to frequency transducer (A2) at terminal 1 and 2.
Voltage should be 120 ± 10 percent vac, if
not check wiring back to voltage source.
4. Connect a test frequency meter
(table 2-1) to the convenience receptacle
or generator output terminal. Check panel
frequency meter accuracy against test
meter while varying engine speed using
manual speed control on utility generator
sets or frequency adjust rheostat on precise generator sets. If meters do not indicate the same, replace frequency meter
and transducer.
b. Removal. Refer to Operator and
Organizational Maintenance Manual and
remove the frequency meter and transducer.
6-10. CLEANING. Clean the frequency
meter and transducer using a clean lint-
6-3
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
free cloth, moistened with unapproved
cleaning solvent and dry thoroughly.
6-11. INSPECTION. Inspect the frequency
meter and transducer cases for cracks or
tears and the electrical connectors for bent
pins and insulation breakdown.
6-12.
TEST.
NOTE
The frequency meter and transducer
are a matched set and must be tested
as a set.
a. Connect a variable frequency 120
VAC frequency generator to the AC side of
the frequency transducer as shown in figure
6-2.
b. Connect a reference frequency meter
across the input. The master frequency
meter shall have 5 times the accuracy of
the set frequency meter and transducer
(1/20 of 1 percent).
c. Vary the frequency from lowest
scale reading to full scale reading.
d. The error at any point on frequency
meter shall not be greater than 1/4 of 1
percent.
e. Remove test equipment. Replace
defective frequency meter and transducer.
6-13. INSTALLATION. Refer to Operator
and Organizational Maintenance Manual
and install the frequency meter and transducer.
6-14.
CONTROL BOX RELAY ASSEMBLY
(A4).
6-15.
TEST ON EQUIPMENT.
a. Symptoms and Isolation of Malfunction. A malfunction of the control box
6-4
Figure 6-2. Frequency meter (M6) &
transducer (A2) test setup
relay assembly (A4) is usually indicated by
failure of the generator set to run when the
start- run-stop switch (S2) is positioned to
RUN or by inability to control voltage from
a remote location. To isolate the malfunction proceed as follows:
1. Loosen three captive studs and
hinge control box door open.
WARNING
Exercise extreme care not to touch
exposed electrical connections when
working inside control cubicle with
generator set operating.
P-8-627-34
TM-07464A-35
NOTE
Steps 2. through 7. pertain to stoprun relay K1 and steps 8. through
10. pertain to remote voltage sensing
relay K6. All test readings should
be ±20 percent.
2. Energize DC circuit breaker.
3. Start engine. If engine shuts
down when start-run-stop switch is positioned to RUN, restart engine and hold
switch to START. Measure voltage at relay assembly terminal board across terminals 2 and 8. Voltage should be 24 VDC.
4. If voltage across terminals 2 and
8 is not 24 VDC, shut down generator set.
Disconnect wire P50A from terminal 9 and
insulate wire end.
5. Restart generator set and measure voltage across terminals 2 and 9.
Voltage should be 24 VDC. Connect wire
P50A.
6. If voltage across terminals 2 and
9 is not 24 VDC, shut down generator set.
Remove wire P80E from terminal 8 and
check resistance across terminals 2 and 8.
Resistance should be 300 ohms. If not
replace stop-run relay K1.
7. If values in steps 2. through 6.
are met and circuit is still inoperative,
remove control box relay assembly (A4)
and bench test.
8. Connect a suitable cable between
one of the convenience receptacle outlets
(J55) and remote voltage sensing connector
(J29). Position convenience receptacle circuit breaker (CB3) OFF. Start engine and
position the remote local voltage switch
(S5) to the REMOTE position and place convenience receptacle circuit breaker (CB-3)
ON. Measure voltage at relay assembly
terminal board across terminals 4 and 12, 5
and 11, 6 and 10. Voltage should be 120
VAC nominal.
T O 35C2-3-442-2
TM 5-6115-457-34
9. If voltages in step 8. are correct and the remote voltage sensing circuit
is still inoperative, shut down generator
set. Remove wires X29A and X31A from
terminals 4 and 12. Measure resistance
at terminals, resistance should be approximately 7K ohms. If not replace remote
voltage sensing relay K6.
10. If values in steps 8. and 9. preceding are obtained and circuit is still inoperative, replace control box relay
assembly (A4).
b. Removal.
1. Disconnect harness at rear of
control cubicle.
2. Loosen three captive studs and
hinge open control box door.
3. Tag and disconnect wiring to
control box relay assembly terminal
boards.
NOTE
The control box relay assembly is
mounted inside the control box on
the lower center sections of the
rear wall.
4. Remove the four nuts located at
the back of the rear wall, securing the control box relay to the control cubicle assembly.
6-16.
TEST.
a. Connect the control box relay assembly to the test equipment as illustrated
in figure 6-3.
b. Perform test specified in table 6-1.
NOTE
All voltage values are ±20 percent.
Change
8
6-5
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Figure 6-3.
Control box relay assembly (A4) test setup
6-17. DISASSEMBLY.
NOTE
Test control box relay assembly as
outlined in paragraph 6-16, then
disassemble only to the extent necessary to effect repair.
a. Refer to figure 6-4 and disassemble
the control box relay assembly in the order
of index numbers assigned.
WARNING
Avoid breathing fumes generated by
unsoldering/soldering. Eye protection is required.
b. Exercise care when unsoldering
components to avoid damage resulting from
application of excessive heat.
6-6
Change 8
6-18. CLEANING. Clean the control box
relay assembly using a clean lint-free
cloth, moistened with an approved cleaning solvent and dry thoroughly.
6-19. INSPECTION.
a. Inspect terminal boards for cracked
insulation, circuit integrity, warping,
burned or discolored areas and illegible
stenciling.
b. Check forward and reverse resistance of diodes. Measured from anode (+)
to cathode (-), value should be low. Reverse leads, value should be infinity.
Table 6-1.
6-7
P-8-627-34
T O 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Change 8
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
b. Repair printed circuits by soldering
a jumper wire across defective area.
c.
Replace all defective components.
d. Solder replacement components
using solder conforming to Federal Specification QQ-S-571 Sn 60.
6-21. REASSEMBLY.
Refer to figure 6-4 and reassemble
control box relay assembly in reverse
order of index numbers assigned. Pay
particular attention to the following.
Figure 6-4. Control box relay assembly, exploded view
Legend to figure 6-4:
10. Lock washer (4)
1. Nut (8)
11. Relay socket (2)
2. Washer (4)
12. Spacer
3. Screw (4)
13. Silicone bridge
4. Terminal
rectifier
board (2)
14. Fixed resistor
5. Screw (4)
15. Capacitor
6. Washer (4)
16. Terminal board
7. Relay (2)
8. Nut (4)
9. Washer (4)
c. Check resistor for proper ohmic
value. (15 K Ohms.)
d. Check capacitor for proper capacitance value.
e. Inspect relay sockets for cracked
insulation and broken pin receptacles.
f. Test plug in relays for actuation
as illustrated in figure 6-5.
6-20. REPAIR.
a. Restencil illegible reference designations.
Avoid breathing fumes generated by
unsoldering/soldering. Eye protection is required.
6-8
Change 8
a. When replacing soldered components, use a suitable heat sink. Solder
joints and/or component leads shall not
project more than 0.094 inch beyond the
surface of the board.
WARNING
Insulating Compound, MIL-I-46058 is
flamable and slightly toxic to eyes,
skin and respiratory tract. Eye and
skin protection required. Good general ventilation is normally adequate.
b. Spray or brush a conformal coating,
0.005 inch thick, of a transparent dielectric compound corresponding to Specification MIL-I-46058, Grade S, Type PUR to
the assembly.
NOTE
The compound shall securely anchor
the components to the terminal
board. Terminals for connection to
external circuits shall not be coated.
c. Test control box relay assembly as
outlined in paragraph 6-16.
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
PROCEDURE:
STEP 1. PLUG RELAY INTO TEST SOCKET.
TURN ON POWER SUPPLY.
STEP 2. CLOSE SWITCH Sl; INDICATOR DS1
SHOULD LIGHT.
STEP 3. CLOSE SWITCH S2; INDICATOR DS2
SHOULD LIGHT AND INDICATOR DS1
SHOULD GO OUT.
STEP 4. TURN OFF POWER SUPPLY AND
REMOVE RELAY FROM TEST EQUIPMENT. REPLACE DEFECTIVE RELAY.
Figure 6-5. Plug in relay test setup
6-22.
INSTALLATION.
a. Position the control box relay assembly inside the control cubicle and secur e it to the rear wall with four nuts.
b. Connect wiring to the control box
relay assembly terminal boards. Refer to
figure 1-7 and check wires for proper connection.
c. Close and secure control box door.
d. Connect harness at rear of control
cubicle.
6-23.
AC CURRENT METER (M8).
6-24. TEST ON EQUIPMENT.
a. Symptoms and Isolation of Malfunction. A malfunction of the AC current
meter is usually indicated by abnormal
readings when a known load is connected to
the generator set. To isolate the malfunction proceed as follows:
1. Loosen three captive studs and
hinge control box door open.
2. Connect suitable test ammeter in
series with AC current meter.
6-9
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
3. Start generator set and apply
full rated load.
4. Check meter indication, AC current meter should indicate 100 percent
and test ammeter should indicate 0.75
amperes. Check indication at each phase
by rotating voltmeter-ammeter selector
switch (S8), readings should be the same.
5. If current reading is incorrect
check wiring back to current source.
6. If current is correct remove
AC current meter.
b. Removal. Refer to Operator and
Organizational Maintenance Manual and
remove the AC current meter.
6-25. CLEANING. Clean the AC current
meter using a clean, lint-free cloth,
moistened with an approved cleaning solvent and dry thoroughly.
6-26. INSPECTION. Inspect case for
evidence of cracks or tears and electrical
connector for security.
6-27. TEST. Connect the AC current
meter to the test equipment as illustrated
in figure 6-6 and proceed as follows:
a. Adjust auto-transformer T1 so-that
ammeter Ml reads 1 ampere. AC current
meter should indicate 133 percent load.
b. Adjust auto-transformer T1 so that
meter Ml reads 0.75 ampere. AC current
meter should indicate 100 percent load.
c. Remove test equipment. Replace
AC current meter if meter error is
greater than 2 percent of full scale value.
6-10
Change 1
6-28. INSTALLATION. Refer to Operator
and Organizational Maintenance Manual
and install the AC current meter.
6-29. CONTROL CUBICLE.
6-30. TEST ON EQUIPMENT.
a. Symptoms and Isolation of Malfunction. A malfunction of the control cubicle
is usually indicated by the conditions described and isolated in paragraphs 6-3,
6-9, 6-15 and 6-24. If a malfunction
exists which is not traceable to those assemblies, perform a continuity check on
the wires comprising the control cubicle
assembly harness.
b. Removal. Refer to paragraph 2-6
and figure 2-2 and remove the control
cubicle assembly.
6-31. DISASSEMBLY. Refer to figure
6-7 and disassemble control cubicle assembly in the order of index numbers assigned.
Pay particular attention to the following:
a. Loosen three captive studs (23) and
hinge open control box door (25).
b. Tag and disconnect wires of harness
(15) from components.
c. Refer to Operator and Organizational Maintenance Manual and remove components from control box door (25), and
the thermal watt converter and frequency
transducer from the box (36).
d. Remove the control box relay from
the rear wall of box (36).
e. Hinge (32) and receptacle (35) are
riveted to box (36) and should be removed
only if damaged.
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Figure 6-6. AC current meter (M8) test setup
6-32. CLEANING.
a. Clean electrical components and instruments with a clean lint-free cloth
moistened in an approved cleaning solvent
and dry thoroughly.
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
b. Clean metal parts in unapproved
cleaning solvent and dry thoroughly.
6-33. INSPECTION.
NOTE
Figure l-6 is the schematic for the
control cubicle.
a. Inspect meters and gauges for damaged cases and faces.
b. Check switches for continuity.
c. Inspect terminal boards for cracked
insulation, stripped threads, and missing
jumper strips.
d. Check capacitors for opens and
shorts.
e. Check resistor for continuity and
proper ohmic values.
f. Check rheostats for continuity and
for proper adjustable range of resistance.
g. Inspect terminal lugs for security
and condition.
h. Inspect wiring for defective insulation and electrical connectors for damaged
threads; bent, loose, or missing pins.
Check each harness wire from connector
pin to wire end for continuity, refer to
figure 6-8. Check connector pins for shorts
to case and surrounding pins.
i. Inspect sheet metal parts for bent
corners, distortion, cracks, tears, and
dents.
6-34. REPAIR.
a. Straighten dents or distorted areas
of the box using proper tools.
Welding operations produce heat,
highly toxic fumes, injurious
radiation, metal slag and airborne particles. Welding goggles, with proper tinted lenses,
apron or jacket and welder’s
boots are required.
b. Minor cracks may be repaired by
welding.
Change 8
6-11
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Figure 6-7. Control cubicle exploded view
6-12
Change 8
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Legend to figure 6-7:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Nut (2)
Clamp (2)
Nut (2)
Screw (2)
Nut
Screw
Clamp
Nut
Screw
Clamp
Insulator (3)
Insulator (3)
Nut (4)
Screw (4)
Harness
Nut (2)
Washer (2)
Screw (2)
c. Repaired areas and those surfaces
requiring refinishing shall be cleaned with
a suitable abrasive paper, then primed and
repainted.
d. Re-stencil as required.
6-35. REBUILD. Rebuild the control
cubicle wire harness (15, figure 6-7) according to figure 6-8.
6-36. REASSEMBLY. Refer to figure
6-7 and reassemble control cubicle assembly in the reverse order of index numbers
assigned. Pay particular attention to the
following:
a. Install control box relay on rear
wall of box (36). Secure in position with
four nuts.
b. Refer to Operator and Organizational
Maintenance Manual and install components
19.
20,
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
Door holder (2)
Nut (6)
Screw (6)
Cross pin (3)
Stud (3)
Grommet (3)
Control box door
Screw (6)
Terminal board jumper (3)
Nut (2)
Screw (2)
Terminal board
Rivet (6)
Hinge
Spacer
Rivet (6)
Receptacle (3)
Box
on control box door (25), and thermal watt
converter and frequency transducer in
box (36).
c. Install harness (15) connector in
box (36) with key way on top. Connect
wires of harness to components, refer to
figure 1-7.
d. When installing clamp (2, figure
6-7) nearest control box door (25), leave
nut (1) loose enough to permit harness to
pivot when control box door is opened and
closed.
6-37. TEST. Refer to figure 1-7 and
perform continuity test of circuitry.
6-38. INSTALLATION. Refer to paragraph 2-6 and figure 2-2 and install the
control cubicle assembly.
6-39. ADJUSTMENT. Refer to Operator
and Organizational Maintenance Manual
and zero adjust all instruments.
6-13
Change 3
P-9-TM-457-35 T.O. 35C2-3-442-2
TM 5-6115-457-34
TM-07464A-35
6-14
Figure 6-8.
Figure 6-8.
Change 3
P-9-TM-457-35
TM-07464A-35
6-19
T.O. 35C2-3-442-2
TM 5-6115-457-34
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Section II. DC CIRCUIT BREAKER BOX
6-40.
GENERAL.
The dc circuit breaker box is located
at the rear of the generator set to the right
of the control cubicle assembly panel. The
circuit breaker box contains a 7.5 ampere
circuit breaker CBI, associated wiring, and
a connector for electrical connection to the
generator set dc system. 400 hertz generator sets also include an expanded scale
voltmeter and generator/bus selector switch,
used for paralleling operations. Circuit
breaker CB1 is electrically connected between the batteries and the START-RUNSTOP switch S2 in the dc system. It protects all control circuits energized from
the batteries except those for the winteriza tion heater and dc alternator. In the close
position the pushbutton only shows black.
When tripped, the button is extended and
the white portion is visible.
6-41.
REMOVAL.
Refer to Operator and Organizational
Maintenance Manual and remove dc circuit
breaker box.
6-42.
DISASSEMBLY.
6-43. CLEANING.
Clean parts with a clean lint-free
cloth moistened in an approved cleaning
solvent and dry thoroughly.
6-44.
INSPECTION.
Inspect dc circuit breaker box components as follows:
a. Inspect sheet metal parts for dents,
cracks, and distortion.
b. Inspect connectors for bent, broken,
and missing pins. Refer to table 6-2 and
test wires and connectors for continuity,
shorts to case and surrounding pins. Check
terminal lugs for condition and security.
c. Check circuit breaker automatic
tripping with load application above 7.5
ampere.
6-45. REPAIR.
Repair defective wiring in accordance
with table 6-2.
6-46. REASSEMBLY.
Refer to figure 6-9 and disassemble
dc circuit breaker box in the order of index
numbers assigned. Pay particular attention
to the following:
Refer to figure 6-9 and reassemble
dc circuit breaker box in the reverse order
of index numbers assigned. Pay particular
attention to the following:
a. Remove screws (1) and separate
cover (6) and chassis (10) so that wires can
be disconnected from circuit breaker (9).
and expanded scale voltmeter (9G).
a. Install connectors (5 and 5D) with
keyway up.
b. Tag and disconnect electrical wiring
from circuit breaker and voltmeter.
6-20
Change 3
6-47.
INSTALLATION.
Refer to Operator and Organizational
Maintenance Manual and install DC circuit
breaker box.
P-9-TM-457-35 T. O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
1.
2.
3.
4.
5.
*5A.
*5B.
*5C.
*5D.
6.
7.
SCREW AND WASHER ASSEMBLY (4)
8.
WASHER
SCREW AND WASHER ASSEMBLY (4)
9.
CIRCUIT BREAKER
*9A. NUT’
NUT AND WASHER ASSEMBLY (4)
*9B. LOCK WASHER
TERMINAL LUG (3)
CONNECTOR
*9C. TOGGLE SWITCH
*9D. SCREW (3)
SCREW (4)
NUT (4)
*9E. NUT (3)
*9F. LOCK WASHER (3)
TERMINAL LUG (2)
*9G. EXPANDED SCALE VOLTMETER
CONNECTOR
COVER
10.
CHASSIS ASSEMBLY
NUT
*USED ONLY ON 400 HERTZ GENERATOR SETS.
Figure 6-9. DC circuit breaker box, exploded view
Change 3
6-20A/(6-20B blank)
T.O. 35C2-3-442-2
P-9-TM-457-35
TM-07464A-35 TM 5-6115-457-34
Table 6-2. Circuit Breaker Box Hookup Wire Data
WIRE
INDENT.
NO.
P40
P141
P141
*X9
*X12
*X27
*X28
FROM
J39-A
J39-B
J39-C
J70-C
J70-B
J70-A
M10-1
TERMINATION
NOTE
1,
1,
1,
1,
1,
1,
3,
4,
4,
4,
5,
5,
5,
5
6,
6,
6,
6,
6,
6,
7
7
7
7
7
7
TO
TERMINATION
NOTE
CB1-2
CB1-1
CB1-1
S10-1
M10-2
S10-3
S10-2
2
2
2
1, 6, 7
3
1, 6, 7
1, 6, 7
WIRE
LENGTH
(INCHES)
4
4
4
6
6
6
6
*400 hertz generator sets only.
NOTES
10
Solder, use Federal Specification QQ-S-571, Sn 60.
2.
Secure end with terminal lugs, MS25036-156.
3.
Secure ends with terminal lugs, MS25036-154.
4.
Wire is M5086/2-12-9 per MIL-W-5086.
5.
Wire is M5086/2-16-9 per MIL-W-5086.
6.
Use 5/8 inch long insulation tubing over each contact after soldering.
7.
Insulation is TYPE F FORM Ua, GRADE A, CLASS 1, CAT. 1
per MIL-I-631.
Change 3
6-21
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Section III. FAULT LOCATING INDICATOR BOX
6-48.
GENERAL.
The fault locating indicator box
(A9) is a self-contained unit with solid
state circuitry. On its front panel are ten
red malfunction indicators, each for a
specific fault, a one ampere fuse to protect against overload, and a two pole, two
position, spring loaded switch. The function of the indicator box is to illuminate a
particular malfunction indicator when one
of the protective devices senses a malfunction and closes its malfunction signal contacts. This causes a dc signal to be impressed across a series parallel RC network for one of the ten SCR, silicon
controlled rectifier, circuits in the fault
locating indicator box (refer to figure 1-8).
When the voltage across the capacitor is
sufficient, the current to the gate of the
SCR will be sufficient to trigger it. The
particular indicator lamp in series with
this SCR will be energized. Relay K1 is
also energized and its normally closed
contacts open to deenergize the fault signal
input to the SCR. When the switch is
momentarily positioned to TEST or RESET,
the SCR will be turned off because its negative return from cathode is open. All indicator lamps will be energized, and relay
K1 will stay energized. When the switch
is released back to normal position, and
if the fault is cleared, the indicator lights
will de-energize and the circuit will be
quiescent. If the malfunction is still
present the SCR and indicator lamp for that
particular malfunction will again energize.
With no malfunction input and the switch
momentarily positioned to TEST or RESET,
all indicator lamps will energize. With its
release again, all lamps will be de-energized and the circuit is again quiescent.
The purpose of capacitor C 11 is to block
6-22
transient d. c. voltage and frequency chatter
from causing a false malfunction indication.
6-49. TEST ON EQUIPMENT.
a. Symptom and Isolation of Malfunction. A malfunction of the fault locating indicator box is usually the absence of a fault
indication during a fault condition. Another
malfunction is a false indication which cannot be reset when a no fault condition exists.
To isolate the malfunctions proceed as
follows :
NOTE
Refer to figures 1-8 and 1-9 for circuitry, and component layout and
wiring.
1. No Indication.
(a) Press the switch S1 to TEST
OR RESET, all the indicator lights DSl
through DS10 should illuminate.
(b) Check for defective indicator
lamp if one or two do not illuminate.
(c) If no lamp illuminates check
fuse F1.
(d) If fuse F1 is not defective remove plug P12 and check pins A(+) and
B(-) for 24 VDC.
(e) With the above requirements
met and indicators not illuminating, check
wiring to fault sensor. For example high
coolant pins C-K on connector P12 with
fault simulated should have continuity. Reconnect P12 and simulate a high coolant
fault if indicator lamp DS7 does not illuminate, repair or replace the fault indicator
box. Similar tests procedure will apply to
remaining faults.
P-8-627-34
TM-07464A-35
2. False Fault Indication Cannot Be
Reset.
(a) Remove P12 and check for
continuity from pin C to applicable pin of
P12 for the circuit showing false indication.
Open circuit should be indicated.
(b) If circuit is open, remove,
repair or replace the fault indicator box.
b. Removal. To remove the fault locating indicator box (located adjacent to control cubicle), disconnect plug P12 from the
receptacle connector (J12) in the rear wall
of the box, then remove the four screws
securing the box to the rear housing.
6-50. TEST.
NOTE
Figure 1-8 is the fault locating indicator box schematic. Refer to this
schematic when checking individual
components for their required values
or operating characteristics.
6-51.
b. Tag and disconnect wires of harness
(19) from components.
WARNING
Avoid breathing fumes generated by
unsoldering/soldering. Eye protection is required.
c. Exercise care not to apply excessive
heat when unsoldering components.
d. Remove relay (22) by removing
screw (20) and lockwasher (21).
6-52. CLEANING.
Clean all components with a clean
lint-free cloth moistened in an approved
cleaning solvent and dry thoroughly.
6-53. INSPECTION.
a.
Connect the fault locator to test
equipment as illustrated in figure 6-10 and
perform test specified in procedural analysis table 6-3.
DISASSEMBLY.
Refer to figure 6-11 and disassemble
fault locating indicator box in the order of
index numbers assigned. Pay particular
attention to the following:
NOTE
Disassemble the fault locating indicator box only to the extent necessary to accomplish repair.
a. Remove cover (2) by removing
screws (l).
T O 35C2-3-442-2
TM 5-6115-457-34
Harness.
1. Inspect harness wiring for defective insulation and continuity.
2. Inspect harness connector for
damaged threads; bent, loose or missing
pins and for shorts.
b. Electrical Components.
1. Check electrical components for
opens, shorts, continuity, and proper
values.
2. Check diodes for forward and
reverse values. Measured from anode (+)
to cathode (-) value should be low. Reverse
leads, value should be infinity.
c.
Printed Circuit Board.
1. Inspect printed circuit boards
(component side) for damage, burns, discolored areas, and signs of overheating.
2. Inspect components for security.
3. Inspect circuits of printed circuit
boards for breaks and damage.
Change 8
6-23
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Figure 6-10.
6-24
Change 8
Fault locating indicator box (A9), test setup
Table 6-3.
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
6-25
P-9-TM-457-35
TM-07464A-35
6-26
T.O. 35C2-3-442-2
TM 5-6115-457134
Table 6-3.
T O 35C2-3-442-2
P-8-627-34
TM-07464A-35 TM 5-6115-457-34
4. Inspect base of printed circuit
board for cracks, warping, burned or discolored areas and illegible stenciling.
d. Inspect sheet metal parts for bent
corners, distortion, cracks, tears and
dents.
e. Check terminal lugs for security and
condition.
f. Inspect relay socket for damage,
shorts to case, and surrounding pins.
g. Inspect for damaged indicator lenses.
h. Check fuse for continuity.
6-54. REPAIR.
a. Repair or fabricate fault locating indicator box wiring harness according to
figure 6-12.
b. Repair or fabricate fault locating
indicator box heating wire in accordance
with table 6-4.
c. Replace indicator lenses, if cracked.
d. Replace fuse if defective.
e. When replacing feed thru terminals,
swage in place.
f. Repair printed circuit board as
follows :
1. Restencil all illegible reference
designations.
WARNING
Avoid breathing fumes generated by
unsoldering/soldering. Eye protection is required.
CAUTION
Prolonged use of soldering equipment could cause damage to components due to excessive heat.
2. Repair printed circuits by soldering a jumper wire across defective area.
3. Replace all defective components.
4. Solder replacement components
on the printed circuit boards using solder
conforming to Federal Specification QQ-S571 Sn 60.
WARNING
Insulating Compound, MIL-I-46058 is
flammable and slightly toxic to eyes,
skin and respiratory tract. Eye and
skin protection required. Good general ventilation is normally adequate.
5. Solder joints and/or component
leads must not project more than O. 094
inch beyond surface of board.
6. After replacement of components
on the printed circuit boards, coat the
boards with protective coating, conforming
to Military Specification MIL-I-46058,
grade S, type PUR, 0.005 minimum thickness. Air bubbles should be prevented
during coating so that legibility of identification or information markings are not impaired. The coating shall be applied so
that it anchors the components to the board.
Terminals utilized for connection to external circuits shall not be coated.
g. Straighten dented or distorted sheet
metal parts using proper tools. Blend in
repaired area with suitable abrasive paper.
Prime and touch up damaged painted surfaces.
6-55. REASSEMBLY.
Refer to figure 6-11 and reassemble
fault locating indicator box in the reverse
order of index numbers assigned. Pay particular attention to the following:
NOTE
Mount connector (J12) with keyway
in top position.
Change 8
6-27
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Figure 6-11.
6-28
Change 8
Fault locating indicator box, exploded view
T.O. 35C2-3-442-2
P-9-TM-457-35
TM-07464A-35 TM 5-6115-457-34
Legend to figure 6-11:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Screw (5)
Cover
Nut
Toggle switch
Strap (2)
Capacitor
Insulation (2)
Fuse cap
Fuse
Nut
Fuseholder
Indicator lenses (10)
Incandescent lamp (10)
Nut (10)
Light indicator housing (10)
Screw (4)
Fault indicator panel
Screw (4)
Wiring harness
Screw (2)
a. Connect hookup wires and wires of
harness to components. Refer to tables
6-4 and figures 6-12 and 1-9 for proper
connection.
b. Exercise care not to apply excessive
heat to components when soldering connections.
c. Install relay (22, figure 6-11) in
relay socket (25) squarely so as not to damage pins.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Washer (2)
Relay
Screw (4)
Fault indicator component board
Relay socket
Standoff
Resistor (10)
Resistor (10)
Silicon controlled rectifier (10)
Silicon rectifier (10)
Capacitor (10)
Insulation
Terminal stud (50)
Board
Screw (4)
Bottom plate
Standoff (4)
Plate
Chassis
d. Test fault locating indicator box as
specified in paragraph 6-50.
e. Install cover (2) by installing screws
(l).
6-56. INSTALLATION.
Install the fault locating indicator
box in the rear housing and secure in position with four screws. Connect plug P12
to receptacle connector J12 located in the
rear wall of the box.
6-29
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 6-4. Fault Locating Indicator (A9) Hook Up Wire Data
COLOR
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WHT
WIRE
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
WIRE
LENGTH
INCHES
1-1/2
2-1/2
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
3/4
3/4
1
1/2
1-1/2
FROM
S1-1
S1-6
XDS6
XDS10
XDS9
XDS8
XDS7
XDS1
XDS2
XDS3
XDS4
S1-5
XK1-8
XK1-6
XK1-3
XK1-7
NOTES
1. Solder. Use Federal Specification QQ-S-571, Sn 60.
2. Wire is in accordance with MIL-STD-454, requirement 20.
3. Use wire conforming to MIL-W-16878, Type 22 black or white.
4. Protect capacitor C11 leads using insulated sleeving.
6-30
TO
S1-6
XDS6
XDS10
XDS9
XDS8
XDS7
XDS1
XDS2
XDS3
XDS4
XDS5
XF1
XK1-1
XK1-2
XK1-2
TB1-50
Figure 6-12.
P-9-TM-457-35
T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
6-31
P-9-TM-457-35
TM-07464A-35
6-32
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 6-12.
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Section IV. CONVENIENCE RECEPTACLE ASSEMBLY
6-57.
GENERAL.
The 50/60 hertz convenience receptacle assembly (A22) contains a 125 volt,
15 ampere duplex receptacle, while the
400 hertz type contains a 125 volt, 15 ampere receptacle and a 125/250 volt, 30
ampere receptacle. Each receptacle has a
spring- loaded weatherproof cover. Both
types have their receptacles connected in
parallel electrically, and have their receptacles protected by a 15 ampere circuit
breaker.
6-58.
50/60 HERTZ CONVENIENCE
RECEPTACLE ASSEMBLY.
6-62.
INSPECTION.
a. Inspect connectors for bent, broken
and missing pins. Refer to table 6-5, and
check wires for continuity, shorts to case
and surrounding pins.
b. Check terminal lugs and soldered
connections for condition and security.
c. Check circuit breakers and receptacles for continuity.
d. Inspect sheet metal parts for dents,
cracks, and distortion.
6-63. REPAIR.
6-59. REMOVAL, To remove the assembly (located below the control cubicle),
disconnect plug P48 from the receptacle
connector J48 in the rear of the assembly,
then remove the six screws and lockwashers
securing the assembly to the rear housing.
b. Straighten dented or distorted sheet
metal parts using proper tools.
6-60. DISASSEMBLY. Refer to figure
6-13 and disassemble the 50/60 hertz convenience receptacle assembly in the order
of index numbers assigned. Pay particular
attention to the following:
6-64, REASSEMBLY. Refer to figure
6-13 and reassemble 50/60 hertz electronic
component assembly in the reverse order
of index numbers assigned. Pay particular
attention to the following:
a. Remove six screw assemblies (1)
and separate the cover (9) from the housing
(24).
a. Connect wires in accordance with
table 6-5.
b. Tag and disconnect wires from connector (4) circuit breaker (20) and the
duplex receptacle (17).
6-61. CLEANING. Clean all components
with a lint-free cloth moistened with an
approved cleaning solvent and dry thoroughly.
a. Repair defective wiring in accordance with table 6-5.
b. Install connector plug (4) with keyway up.
6-65. INSTALLATION. Install the 50/60
hertz convenience receptacle assembly in
the rear housing and secure in position
with six screws and lockwashers. Connect
plug P48 to connector J48 in the rear of
the assembly.
6-33
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 6-13. 50/60 hertz convenience receptacle assembly, exploded view
6-34
Change 4
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115 -457-34
Legend to figure 6-13:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
6-66.
Screw assembly (6)
Screw assembly (4)
Nut assembly (4)
Connector
Cable strap
Terminal lug
Wire (5)
Insulating tubing
Cover
Screw assembly (4)
Nut assembly (4)
Cover
400 HERTZ CONVENIENCE
RECEPTACLE ASSEMBLY.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Screw (2)
Gasket
Screw assembly (2)
Screw assembly (2)
Duplex receptacle
Nut
Lock washer
Circuit breaker
screw (2)
Nut (2)
Identification plate
Housing
approved cleaning solvent and dry thoroughly.
6-67. REMOVAL. To remove the assembly (located below the control cubicle), disconnect plug P48 from the receptacle connector J48 in the rear of the assembly,
then remove the six screws and lockwashers
securing the assembly to the rear housing.
6-70. INSPECTION.
6-68. DISASSEMBLY. Refer to figure
6-14 and disassemble the 400 hertz convenience receptacle assembly in the order
of index numbers assigned. Pay particular
attention to the following:
b. Check terminal lugs and soldered
connections for condition and security.
a. Remove six screw assemblies (1)
and separate the cover (5) from the housing
(26).
a. Inspect connectors for bent, broken
and missing pins. Refer to table 6-6, and
test wires for continuity, shorts to case
and surrounding pins.
c. Check circuit breakers and receptacles for continuity.
d. Inspect sheet metal parts for dents,
cracks, and distortion.
6-71. REPAIR.
b. Tag and disconnect wires from connector (4), circuit breaker (22), and receptacles (13 and 19).
a. Repair defective wiring in accordance with table 6-6.
6-69. CLEANING. Clean all components
with a clean lint-free cloth moistened in an
b. Straighten dented or distorted sheet
metal parts using proper tools.
6-35
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 6-5. 50/60 Hertz Convenience Receptacle Assembly
WIRE
IDENT
NO.
F ROM
TERMINATION
NOTE
X9JJ12
J48-B
X12NN12
TO
WIRE
LENGTH
(INCHES)
TERMINATION
NOTE
COLOR
IDENT
2
CB3-1
7
3
Black
J48-C
2
J55-2
12
3
Black
JUMPER
No. 1
J55-1
3
CB3-1
6
3
None
G1A12
J55-3
3
GROUND
LUG
11
3
Black
NOTES
1. Marking of wire numbers shall be in accordance with Military
Specification MIL-W-5088.
2. Solder, using Federal Specification QQ-S-571, Sn 60.
3. Secure ends with terminal lugs, MS25036-156.
4. Strip all wires 0.38 inch.
5. Wire is M5086/2-12-9 per MIL-N-5086.
6. Use 5/8 inch long insulation tubing over each contact after soldering.
7. Insulation is TYPE F FORM Ua, GRADE A, CLASS 1, CATA-1
per MIL-I-631.
8. Cable straps MS3367-4-9 are to be installed at 3 inch intervals
to form harness.
6-36
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Table 6-6. 400 Hertz Convenience Receptacle Assembly
WIRE
IDENT
NO.
FROM
X12NN16
J48-C
3
J55-1
18
4
‘Black
X9JJ16
J48-B
3
CB3-2
14
4
Black
JUMPER
NO. 1
J55-1
4
J56-RED
6
2
None
X24A12
J55-2
4
CB3-1
8
4
Black
JUMPER
NO. 2
J56-BLK
2
CB3-1
6
4
None
JUMPER
NO. 3
J55-3
4
J56-W
6
2
None
G1A16
J55-3
4
GROUND
LUG
9
4
Black
TERMINATION
NOTE
TO
WIRE
LENGTH
(INCHES)
TERMINATION
NOTE
COLOR
IDENT
NOTES
1. Marking of wire numbers shall be in accordance with Military
Specification MIL-W-5088.
2. Strip all wires back 0.38 inches.
3. Solder, use Federal Specification QQ-S-571 Sn 60.
4. Secure end with terminal lubs, MS25036-156.
5. Wire is M5086/2-12-9 per MIL-N-5086.
6. Use 5/8 inch long insulation tubing over each contact after soldering.
7. Insulation is TYPE F FORM Ua, GRADE A, CLASS 1, CATA-1
per MIL-I-631.
8. Cable straps MS3367-4-9 are to be installed at 3 inch intervals
to form harness.
6-37
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 6-14. 400 hertz convenience receptacle assembly, exploded view
Legend to figure 6-14:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Screw assembly (6)
Screw assembly (4)
Nut assembly (4)
Connector
Cover
Cable strap (4)
Terminal lug (9)
Wire (9)
Insulation tubing
Screw (4)
6-38
Change 4
11. Nut (4)
12. Cover gasket
13. Single receptacle
(15 ampere)
14. Screw assembly (4)
15. Nut assembly (4)
16. Cover
17. Nut assembly (4)
18. Screw assembly (4)
19. Single receptacle
(30 ampere)
20. Nut
21. Lock washer
22. Circuit breaker
23. Screw assembly (2)
24. Nut assembly (2)
25. Identification plate
26. Housing
P-9-TM-457-35
T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
6-72. REASSEMBLY, Refer to figure 6-14
and reassemble 400 hertz electronic component assembly in the reverse order of
index numbers assigned. Pay particular
attention to the following:
a. Connect wires in accordance with
table 6-6.
b. Install connector (4) with keyway up.
6-73. INSTALLATION. Install the 400
hertz convenience receptacle assembly in
the rear housing and secure in position with
six screws and lock washers. Connect plug
P48 to connector J48 in the rear of the
assembly.
Section V. EXCITER-REGULATOR
6-74.
GENERAL.
a. The exciter All, (figures 1-11 and
1-13) and voltage regulator A 10 operate as
integral components of the excitation system. The excitation system energizes the
main rotor field coils of the generator and
regulates the magnitude of the magnetic
field thus produced so as to maintain a constant voltage output from the stator of the
generator under all rated load conditions.
b. The excitation system is comprised
of a dynamic exciter, a static exciter assembly, a voltage regulator assembly,
current transformers and a cross current
compensation network to permit parallel
operation of two or more generator sets.
1. The static exciter and voltage
regulator are electronic assemblies packaged in a single enclosure and mounted outside the generator housing.
2. The dynamic exciter consists of
a field coil stator integral with the generator housing, a set of rotor coils and solid
state rectifiers mounted on the generator
shaft. The static exciter energizes the
field coils of the dynamic exciter. The
resultant field couples with the rotor coils
of the exciter. The induced currents are
rectified and then fed to the coils of the
generator rotor, the fields of which induce
the output currents in the coils of the generator stator. Brushes or slip rings are
not required. The disposition of the rotors
and stators of both the dynamic exciter and
the generator including the rectifier ring
are shown in figure 7-1.
c. The exciter-regulator circuitry is
illustrated in figures 1-10 and 1-12. The
assembly operates as follows:
1. The regulated exciter field voltage at pins S-R of connector J13 is obtained
by means of saturable core transformer
T 1. The inductance of this transformer
can be varied with the control winding 5-7
so that the voltage ratio between the windings 1-2 and 3-4 may be increased or decreased in proportion to the direct current
flowing in the winding 5-7, When the magnitude of the control current increases the
inductance decreases and there is a lowered
magnetic coupling between the windings
which carry the alternating currents, hence
a lowered voltage output. The reverse
occurs when the control current is decreased.
2. The input at J-K of connector
J13 derives from current transformers
Change 1
6-39
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
CT4, CT5, CT6, on the load lines of the
generator (figures 1-4 and 1-5). The voltage at L-M of connector J13 is from phase
C (T9 - T12 on generator). The two inputs
are combined by T1 (figures 1-24 and 1-26)
under control of winding 5-7, then rectified
by bridge CR1 through CR4 and fed to the
exciter field stator winding from S-R of
connector J13. In the event of a short circuit, the voltage at L-M can drop to zero
but there is a high voltage at J-K from the
current transformers so that the exciter
provides sufficient field for the generator
output to actuate the protective devices to
shut down the set.
3. The voltage at S-R of connector
J13 is compared to the reference voltage at
Q1 (located in voltage regulator A10) and
Zener diode VR1 of the differential amplifier Q1 - Q2. Any difference or error signal at the collector of Q2 is amplified by
Q5 - Q6 and Q3 - Q4 and then fed to the
control winding 5-7 of the control trans former T1 which increases or decreases
the exciter field coil current to reduce the
error signal to zero thereby maintaining
the output of the generator set within the
range as preset by R33. The networks
R31-C1 and R32-C3 are utilized for phase
shift compensation. If hunting is present,
adjustment of R32 will provide the proper
amount of feedback to eliminate the hunting.
Adjustment of R31 will smooth and improve
the transient response.
4. The voltage at pins A-B of connector J9 is derived from phase C (T9 T12 on generator) through the operators
voltage adjust rheostat and from the cross
current compensation network (figures 1-4
and 1-5) when two or more generator sets
are connected in parallel. This voltage is
stepped down in transformer T5, rectified
by bridge CR12 - 15, filtered by R16, R22,
C2, C5 and fed to the reference side of the
differential amplifier Q1- Q2.
6-40
5. The generator output voltage is
determined by the level of the reference
voltage and is controlled by the setting of
R33 which adjusts the range voltage and
operators rheostat (R2, figures 1-4 and
1-5 ) which sets the actual output. During
parallel operation, the reference voltage is
dependent on the cross current compensation network. For example, if one generator draws more current, the network will
increase the magnitude of the reference
voltage causing the voltage regulator to
sense more voltage and thereby causing a
decrease in current to the exciter field
stator winding. This provided parallel
operation with droop.
6. Power for the transistor amplifiers and the control winding (5-7 of Tl)
current is obtained from pins L-M of connector J13 thru stepdown transformer T4
and bridge rectifier CR8 through CR11.
Diode CR17 and resistor R21 provide positive feedback to the amplifiers to enhance
the gain.
7. When the start switch of the generator set is actuated, 24 volts D. C. is
applied to the exciter field stator windings
at pins S-R of connector J13 thru the limiting resistor R17A, R17B and isolation diode
CR16 from input pins C-D of connector J11
(field flashing). The purpose is to quickly
build up the magnetic field in the main
rotor windings to produce an immediate
output from the generator. The flashing
voltage is then automatically removed.
6-75. TEST
AND REMOVAL. .
— ---a. Symptom and Isolation of Malfunction. A malfunction of the voltage regulator
section (Al0) is usually indicated by a high
generator output voltage with no control.
A malfunction of the exciter section (A11)
is usually indicated by no generator output
or by low output voltage when the load is
T.O. 35C2-3-442-2
P-9-TM-457-35
TM-07464A-35 TM 5-6115-457-34
applied. To isolate the malfunction proceed
as follows:
Exercise extreme care not to touch
electrical connections when working on the exciter-regulator assembly with the generator set operating.
NOTE
Remove cover from exciter regulator to gain access to test points,
see figure 6-15.
1. With the generator set operating
at rated speed, measure the voltage across
(A10)TB1-7 and (A10)TB1-8 (nominal voltage is 105 VAC). Refer to figures 1-10 and
1-12. If sensing voltage at TB1-7 and
TB1-8 is normal measure voltage across
(A10)TB2-6 and (A10)TB2-7, minimum voltage should be 50 VAC.
(a) If there is no voltage at
TB2-6 and TB2-7 measure voltage across
(A11)TB2-2 and (A11)TB2-3 which is the
generator coil voltage (T9-T12). Shut down
generator set if voltages are normal.
(b) Measure for continuity from
plug P11 pin H to plug P11 pin G, the reading should be 21 ohms. Pins G, and H of
J11 should read 13 ohms, observe polarity.
Figure 6-15. Location of exciter
regulator and mode I, mode II,
precise and tactical relay
assemblies
(c) If circuit is open replace exciter (A11). If all readings are normal,
replace regulator (A10).
(a) If flashing voltage is observed connect an ac voltmeter (0-150 volt
scale) across choke (A11)L1 and observe
for ac voltage when the field is flashed.
2. To check exciter regulator performance when there is no generator output
voltage, connect a dc voltmeter (0-50 volt
scale) across resistor (A11)R17 and observe
for field flashing voltage when generator
set is started.
(b) If voltage is observed across
choke but the generator output voltage does
not build up, shut down generator set and
check for shorted diode CR1, CR2, CR3, or
CR4. If diodes are shorted, replace the
exciter.
6-41
P-9-TM-457-35
T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
(c) If diodes checkout, disconnect wires U135C16 and U134C16 from
(A11)TB1-2 and TBl-3, connect wires
together.
(e) If readings are low, replace
exciter-regulator. If readings are normal
or high, test generator diodes for an open
condition.
(d) Start generator set; if voltage
builds up check for short circuit in booster
transformers CT4, CT5, or CT6, refer to
figures 1-4 and 1-5. Check transformer
wiring.
b. Removal. Disconnect plug P13 and
P9 from the exciter regulator, then remove
the four screws and nuts securing the assembly in position. See figure 6-15.
6-76. TEST.
(e) If voltage doesn’t build up,
transformer (A11)T1 is defective.
3. To inspect for the cause of low
output voltage when the generator set is
under load, shut down generator set and
check for an open diode (A11)CR1, CR2,
CR3, or CR4. If defective, replace the
exciter assembly.
(a) If diodes are not defective,
connect ac ammeter (0-25 amp scale) in
series with wire from TB1-6 and TB1-6
terminal and measure current from the
booster transformers CT4, CT5 or CT6.
a. Connect the exciter-regulator to
test equipment as illustrated in figure
6-16 and perform test specified in procedural analysis table 6-7.
NOTE
Figures 1-10 and 1-12 are the
exciter-regulator schematics.
Refer to these schematics when
checking individual components
for their required values or
operating characteristics.
b. Remove test equipment.
(b) With the generator set under
full rated load, the reading should be
14 ± 2 amps. A low reading indicates an
open current transformer (CT4, CT5, or
CT6).
(c) If voltage reading is normal,
connect a dc ammeter (0-25 amp) in series
with the exciter field and a dc voltmeter
(0-30 volt scale) across (A1l)TB1-5(+) and
(A1l)TB1-6.
(d) Start the generator set and
measure exciter field voltage and current
under full rated load. The reading should
be 10 ± 2 volts dc at 6 to 8 amps for 50/60
hz units, and 22 ± 4 volts dc at 14 to 16
amps for 400 hz units.
6-42
6-77. DISASSEMBLY.
Refer to figure 6-17 and disassemble the exciter regulator in the order of
index numbers assigned. Pay particular
attention to the following:
NOTE
The exciter-regulator assembly
should be tested prior to disassembly as specified in paragraph
6-76. Disassemble the exciterregulator assembly to the extent
necessary to accomplish repair.
a. Remove cover (2, figure 6-17) by
removing eight screw assemblies (1).
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 6-16. Exciter regulator (Al0, All) test setup
Change 7 6-43
P-9-TM-457-35
TM-07464A-35
6-44 Change 7
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 6-7.
Table 6-7.
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Change 7 6-45
Change 10
P-9-TM-457-35
TM-07464A-35
6-46
TO 35C2-3-442-2
TM 5-6115-457-34
Table 6-7.
Table 6-7.
P-9-TM-457-35
TM-07464A-35
6-47
TO 35C2-3-442-2
TM 5-6115-457-34
Change 10
P-9-TM-457-35
TM-07464A-35
6-48 Change 10
TO 35C2-3-442-2
TM 5-6115-457-34
Table 6-7.
TO 35C2-3-442-2
P-8-627-34
TM-07464A-35 TM 5-6115-457-34
b. Tag and disconnect wires of wiring
harnesses (18) from components. Note
polarity and location of components when
tagging .
Avoid breathing fumes generated
by unsoldering/soldering. Eye
protection is required.
c. Exercise care not to apply excessive heat when unsoldering components.
d. Refer to figure 6-18 and disassemble the voltage regulator assembly (4,
figure 6-17) to the extent necessary to
accomplish repair.
e. Refer to figure 6-19 and disassemble the voltage regulator sub-assembly
(3, figure 6-18) to the extent necessary
to accomplish repair.
6-78. CLEANING.
Clean all components with a clean
lint-free cloth moistened with an approved Cleaning solvent and dry
thoroughly.
6-79.
INSPECTION.
Inspect the exciter-regulator components in accordance with paragraph 653.
b. Inspect terminal boards for
cracked, insulation, stripped threads
and missing jumper strips.
c. Inspect wiring harnesses for evidence of insulation breakdown and security of connections, refer to figure 620, and figure 6-21.
6-80.
REPAIR.
a. Repair voltage regulator subassembly wiring in accordance with table 6-8.
b. Repair printed card circuits
according to paragraph 6-54, step f.
c. Straighten dented or distorted
sheet metal parts using proper tools.
Blend in repaired area with suitable
abrasive paper. Prime and touch up
damaged surfaces.
d. Broken T5 transformer leads can be
repaired by soldering a 1.5 inch long,
MIL-W-16878/2C 18 AWG stranded, Stressrelief wire from the transformers broken
lead to its soldering terminal on the
board (see figure 6-17).
6-81. REBUILD.
Rebuild the exciter regulator wiring harnesses according to figures 6-20
and 6-21.
6-82.
REASSEMBLY.
Refer to figure 6-17 and reassemble the exciter-regulator in the reverse
order of index numbers assigned. Pay
particular attention to the following:
Mount connectors with keyway in
top position.
a. Refer to figure 6-19 and reassemble the voltage regulator sub-assembly.
b. Refer to figure 6-18 and reassemble the voltage regulator assembly.
c. Secure components mechanically
prior to wiring.
d. Connect wires on voltage regulator
sub-assembly to components according to
table 6-8.
e. Connect wiring harnesses in accordance with figures 6-20 and 6-21.
f . Exercise care not to apply excessive heat when soldering components.
g. Check wiring to components. Refer
to figures 1-11 or 1-13.
h. Test exciter-regulator as specified in paragraph 6-76.
i . Install the exciter after adjustments on page 6-51.
Change 9
6-49
P-8-627-34
T O 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 6-17. Exciter regulator, exploded view
6-50
Change 9
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Legend to figure 6-17:
1. Screw assembly (8)
Cover (2)
3. Screw assembly (4)
4. Voltage regulator assembly
5. Screw assembly (4)
6. Transformer
7. Screw assembly (4)
8. Control transformer
9. Screw assembly (4)
10. Nut assembly (4)
11. Reactor
12. Screw assembly (2)
13. Terminal board
14. Screw assembly (4)
15. Nut assembly (4)
16. Screw assembly (4)
17. Nut assembly (4)
18. Wiring harness
19. Screw assembly
20. Bridge rectifier assembly
21. Screw (2)
22. Nut assembly (2)
23. Washer (2)
2.
6-83. INSTALLATION.
Refer to figure 6-15 and install the
exciter regulator. Secure the assembly in
position with four screws and nuts, then
connect plugs P9 and P13.
6-84. ADJUSTMENT.
a. Set voltage range resistor R33 in a
position so that generator output voltage
can be adjusted at any loads between no load
and rated load. Adjust VOLTAGE ADJUSTMENT resistor R2 (on control cubicle) to
meet the following requirements.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
Terminal board
Screw
Standoff
Shoulder washer (4)
Insulated plate (2)
Nut
Rectifier diode (2)
Nut
Rectifier diode (3)
Heatshield diode
Heatshield diode
Screw assembly (4)
Nut assembly (4)
Screw (4)
Nut (4)
Lock washer (4)
Resistor (2)
Resistor
Resistor
Mica washer (8)
Washer (8)
Bracket (2)
Chassis
1. Between 395 and 480 volts for the
240/416 volt connection and between 197
and 240 volts for the 120/208 volt connection; (60 Hz Mode I set).
2. Between 380 and 426 volts for the
240/416 volt connection and between 190
and 213 volts for the 120/208 volt connection; (50 Hz Mode I set).
3. Between 395 and 458 volts for the
240/416 volt connection and between 197
and 229 volts for the 120/208 volt connection; (400 Hz Mode II set).
Change 1
6-51
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-35
Figure 6-18. Voltage regulator exploded view
6-52
T.O. 35C2-3-442-2
P-9-TM-457-35
TM-07464A-35 TM 5-6115-457-34
Legend to figure 6-18:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Screw assembly (4)
Standoff (4)
Voltage regulator
Screw assembly (4)
Nut assembly (4)
Terminal board (2)
Nut
Variable resistor
Variable resistor
Variable resistor
Screw assembly (4)
Nut assembly (4)
Screw assembly (2)
Self locking nut (2)
Terminal lug
Shoulder washer (2)
Transistor
Mica washer
Screw assembly (4)
Nut assembly (4)
Terminal lug
b. Set feedback resistor R32 and rate
resistor R31 to mid-point, and start generator set. If voltage is stable turn feedback resistor R32 counterclockwise until
voltage becomes unstable, then turn clockwise until voltage is stable.
1. If voltage is still unstable turn
22.
23,
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39*
40.
41.
Wiring harness
Screw assembly (4)
Self locking nut (4)
Shoulder washer (8)
Heatsink assembly
Screw assembly (2)
Self locking nut (2)
Terminal lug
Transistor
Heatsink
Bracket
Screw assembly (2)
Standoff (2)
Component board assembly
Resistor (2)
Transistor (2)
Resistor
Eyelet (8)
Component board
Chassis assembly
feedback resistor R32 slowly counterclockwise until voltage is stable.
2. If voltage stability is still not
achieved, adjust rate resistor R31 slightly
counterclockwise from mid-point and
readjust with feedback resistor R32.
6-53
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 6-19. Voltage regulator subassembly
Legend to figure 6-19:
1.
2.
3.
4.
5.
6.
7.
8.
9.
6-54
Terminal lug (17)
Cable strap (16)
Screw assembly (2)
Nut assembly (2)
Washer (2)
Transformer
Eyelet (3)
Resistor
Diode
10.
11.
12.
13.
14.
15.
16.
17.
18.
Resistor
Eyelet (24)
Resistor
Resistor (4)
Capacitor (14)
Transistor (2)
Transistor pad (2)
Capacitor
Diode
19.
20.
21.
22.
23.
24.
25.
Capacitor (2)
Resistor
Resistor
Resistor
Resistor
Capacitor
Printed circuit
board
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 6-20. Exciter regulator wiring harness (Sheet 1 of 2)
6-55
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-35
Figure 6-20. Exciter regulator wiring harness (Sheet 2 of 2)
6-56
T.O. 35C2-3-442-2
P-9-TM-457-35
TM-07464A-35 TM 5-6115-457-34
Figure 6-21. Voltage regulator wiring harness
6-57
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-35
Table 6-8. Voltage Regulator Sub-Assembly Wire Data
WIRE
DENT
NO.
TERMINATION
NOTE
FROM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
1
2
3
4
5
6
7
8
11
12
13
14
15
18
19
24
17
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
18
Terminal 27
1
W IRE
LENGTH
(±0.25
TO
inches)
8.0
TB1-1
8.0
TB1-2
8.0
TB1-3
8.0
TB1-4
8.0
TB1-5
8.0
TB1-6
8.0
TB1-7
8.0
TB1-8
11.0
TB2-1
9.0
TB2-2
9.0
TB2-3
TB2-4
9.0
12.0
TB2-5
11.0
TB2-6
10.0
TB2-7
14.0
TB2-8
Terminal
5.0
25
TB2-8
5.0
TERMINATION
NOTE
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
1
Brown
Yellow
Green
Blue
W/Red
Red
W/Blue
W/Blue
W/Brown
Violet
W/Violet
W/Black
W/Green
W/Grey
W/Grey
Blue
W/Blue
3
Blue
NOTES
1. Solder, use Federal Specification QQ-S-571, Sn 60
2, Strip all wires back 0.38 inches.
3. Secure ends with terminal lugs #6 in accordance with MS25036-101.
4. Secure wires with cable straps MS3367-1-9.
6-58
COLOR
IDE NT
P -9 -TM-457 -35
TM-07464A-35
T.O. 35 C2-3-442-2
TM 5-6115-457-34
Section VI. MODE I RELAY BOX ASSEMBLY
6-85. GENERAL.
The Mode I relay box assembly
(A27) is a junction box which is utilized to
interconnect certain electronic componentry, for 50/60 hertz precise and utility
generator set operation. The relay box
contains a DC relay assembly, cross current transformer, a variable resistor, a
shorting plug, the engine crank relay (K3 ),
the battery charging ammeter shunt (R13)
and interconnecting harnesses.
clockwise, will cause the corresponding
set to increase its share of the total reactive KVA.
c. The shorting plug connected to
Mode I relay box connector J31 converts
the Mode I relay box from precise to utility
set operation. Removing this shorting plug
allows the precise relay box harness to be
connected to J31, thus connecting from
utility to precise set operation.
6-86. DC RELAY ASSEMBLY (A5).
a. The dc relay assembly (A5) is a component mounted printed circuit board. It contains the field flash relay K5 (figure 1-14),
parallel operation voltage sensor rectifier
bridge CR4 and relay K7, fuel level relay
K8, start circuit diode CR3, fuel pumps
diode CR6, and paralleling lights resistors
R6 through R9. Resistor R3, rectifier
bridge CR4, and relay K7 are connected in
parallel with winding T6-T9 of the generator
assembly. When the generator output is
connected for 120/208 VAC output; T9 is
reconnected to T3 and T6 is connected to
T12. The voltage across this phase coil is
rectified by CR4 and then applied to relay
K7. This causes its contacts to short out
resistors R9 and R6 in series with the
synchronizing lights DS4 and DS5. When
the generator output voltage is reconnected
for 240/416 VAC; terminals T6 and T9 are
connected together. This de-energizes
relay K7, and resistors R6 and R9 are
connected in series with synchronizing
lights DS4 and DS5.
b. The variable resistor (R29) is a
potentiometer which permits adjustment of
reactive KVA between sets operating in
parallel. Its slotted shaft, when rotated
6-87. TEST ON EQUIPMENT.
a. Symptoms and Isolation of Malfunction. A malfunction of the DC relay assembly (A5) is usually indicated by failure of
one or more of the following circuits to
function normally: the generator field
flashing circuit, synchronizing lights circuit, engine fuel pump circuit, engine
cranking circuit, or the low fuel level
fault circuit. To isolate the malfunction,
refer to figure 1-14 and proceed as follows:
WARNING
Exercise extreme care not to
touch electrical connections when
working on the electrical components with generator set operating.
NOTE
Remove cover from mode I relay
box to gain access to the test points,
see figures 6-15 and 6-22.
1. Start engine , as engine comes up
to speed, measure voltage across terminals
6-59
P-9-TM-457-35
TM-07464A-35
T O 35 C2-3-442-2
TM 5-6115-457-34
A5-1 and A5-15 (20-32 VDC), A5-13 and
A5-15 (20-32 VDC), and terminals A5-2
and A5-14 (20-32 VDC). If there is no
voltage measured at terminals A5-2 to
A5-14, replace the A5K5 relay.
2. With the generator set connected
for 240/416 volts and operating at rated
speed and voltage, the voltage measured
across terminals A5-18 and A5-22 should
be O volts AC. Measure the resistance
from terminals A5-19 to A5-20, and terminals A5-7 to A5-8 with an ohm-meter.
The meter should read 7.5K ohms. If the
above measurement is 2.5K ohms, replace
the A5K7 relay. If resistance is infinite,
replace whichever resistor measures open.
3. With the generator set connected
for 120/208 volts and operating at rated
speed and voltage, measure the voltage
across terminals A5-18 and A5-22. The
nominal voltage should read 120 VAC.
Measure resistance from terminal A5-19
to A5-20, and terminals A5-7 to A5-8 with
an ohmmeter. The meter should read 2. 5K
ohms. If the measurements are infinity,
replace resistor R7 or R8, if resistance
measured is 7.5K ohms, replace relay
A5K7.
Figure 6-22. Mode I and mode II relay box assembly, cover removed
6-60
Change 9
P-8-627-34
TM-07464A-35
4. Place the battle short switch S7
to the ON position and measure the voltage
across terminal A5-21 and terminal A5-15.
The voltage should read 20-32 VDC. When
the start-run-stop switch S2 is placed in
the run position. Also measure voltage
across terminal A5-23 to terminal A5-15.
The voltage should read 20-32 VDC. If
voltage is measured at A5-21 but not at
A5-23, disconnect wire from A5-21 and
check for continuity between terminal A5-21
and terminal A5-23 with A5-21 positive. If
there is no continuity, replace diode CR6.
5. Measure the voltage across terminal A5-12 to terminal A5-15. The voltage
should read 20-32 VDC when the start-runstop switch S2 is placed in the START position. Also measure voltage across terminal
A5-9 to terminal A5- 15. The voltage should
read 20-32 VDC. If voltage is measured at
terminal A5-12 and not at terminal A5-9,
disconnect wire from terminal A5-12 and
check for continuity across terminals A5- 12
to terminal A5-9 with A5-12 positive. If
there is no continuity, replace diode CR3.
6. Disconnect connector P33 from
the float switch located in the day tank and
install a jumper between pins C and D of
P33 to simulate a low fuel fault condition.
Place the battle short switch S7 in the on
position. Place the start-run-stop switch
S2 in the RUN position and measure the
voltage from terminal A5-6 to terminal
A5-15. The voltage should read 20-32 VDC.
Disconnect the wire from terminal A5-17
and check continuity across terminal A5-5
to terminal A5-17 with voltage applied to
terminal A5-6. If voltage is measured at
terminal A5-6 and there is no continuity
from terminal A5-5 to terminal A5-17, replace relay A5K8. Remove jumper from
pins C and D of P33.
T O 35C2-3-442-2
TM 5-6115-457-34
b. Removal. Refer to figure 6-22 and
tag, then disconnect wiring to the DC relay
terminal board. Remove the four nuts securing the relay in position.
6-88. TEST.
a. Connect the DC relay assembly to
test equipment as illustrated in figure 6-23
and perform test specified in procedural
analysis table 6-9.
NOTE
Figure 1-14 illustrates the DC relay
assembly schematic. Refer to this
s thematic when checking individual
components for required values.
b. Remove the DC relay from the test
equipment.
6-89. DISASSEMBLY. Refer to figure
6-24 and disassemble the DC relay assemble to the extent necessary to accomplish
repair. Pay particular attention to the
following:
WARNING
Avoid breathing fumes generated by
unsoldering /soldering Eye protection is required.
a. Exercise care not to apply excessive
heat when unsoldering components.
b. Remove relay socket (10) by removing nut (7), lock washer (8) and washer (9),
spacer (11) will fall free.
6-90. CLEANING. Clean all components
with a clean lint-free cloth moistened with
an approved cleaning solvent and dry
thoroughly.
Change 8
6-61
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Figure 6-23.
DC relay assembly (A5) test setup
6-91. INSPECTION.
a. Inspect electrical components and
printed circuit board in accordance with
paragraph 6-53.
b. Inspect relays in accordance with
figure 6-5.
c. Inspect relay sockets for damage,
shorts to case and surrounding pins.
6-92. REPAIR. Repair printed circuit
board in accordance with paragraph 6-54,
step f.
6-93. REASSEMBLY. Refer to figure
6-24 and reassemble dc relay assembly in
reverse order of index numbers assigned.
Pay particular attention to the following:
6-62
Change 8
Avoid breathing fumes generated by
unsoldering/soldering. Eye protection is required.
a. Exercise care not to apply excessive
heat to components when soldering connec tions.
b. Press relay (6) into relay socket (10)
squarely and secure in position with screw
(5).
c. Test dc relay assembly as outlined
in paragraph 6-88.
Table 6-9.
P-8-627-34
TM-07464A-35
6-63
T O 35C2-3-442-2
TM 5-6115-457-34
Change 8
T O 35C2-3-442-2
TM 5-6115-457-34
Change 8
P-8-627-34
TM-07464A-35
6-64
Table 6-9. (cont)
Table 6-9. (cont)
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35
TM 5-6115-457-34
6-65
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
6-94. INSTALLATION. Refer to figure
6-22 and install the DC relay assembly.
Secure the assembly in position with four
nuts, then refer to figure 1-15 and reconnect wiring to the relay terminal board.
Replace mode I relay box cover.
F i g u r e 6-24. DC relay assembly (A5)
exploded view
Legend to figure 6-24:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
6-66
Screw (4)
Nut assembly (8)
Washer (4)
Terminal board (2)
Screw assembly (6)
Relay (3)
Nut (6)
Lock washer (6)
Washer (6)
Relay socket (3)
Spacer
Resistor (2)
Resistor (2)
Resistor
Silicone junction rectifier
Silicone bridge rectifier
Silicone junction rectifier
Board
Change 1
6-95.
MODE I RE LAY BOX ASSEMBLY
(A27).
6-96.
ON EQUIPMENT TEST.
a. Symptom and Isolation of Malfunction. A malfunction of the mode I relay
box assembly is usually indicated by a
failure of the DC relay assembly, failure
of the engine to crank when the start-runstop switch S2 is energized, and unequal
reactive load sharing when the generator
set is operated in parallel. To isolate the
malfunction, refer to figure 1-14 and proceed as outlined in steps b. through d.
WARNING
Exercise extreme care not to
touch electrical connections when
working on the electrical components with the generator set operating.
b. To isolate a malfunction of the DC
relay, refer to paragraph 6-87.
NOTE
Remove cover from mode I relay
box to gain access to the test
points, see figures 6-15 and
6-22.
P-9-TM-457-35 T. O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
c. To isolate a malfunction of the engine crank relay, place the start-run-stop
switch S2 in the START position and measure the voltage across A27K3 relay terminals as follows:
1. Voltage across Xl(-) and X2(+)
should read 20-32 VDC.
2. Voltage across Al or A2(+) to
TB2-1(-) should read 20-32 VDC.
NOTE
If the voltage is measured at Xl and
A2, but not at Al, replace the relay.
d. To isolate a malfunction in the reactive droop circuit, install a shorting plug
on paralleling receptacle J45, J46 or J47
located below the manual speed control
knob. Proceed as follows:
1. With the generator set operating
at 100 percent 0.80 PF load, position the
parallel switch S6 to the PARRALLE L
position. Voltage measured across resistor R1 located in this Mode I relay box,
as the reactive current rheostat R29,
located on the Mode I relay box, is rotated
counterclockwise should increase to
approximately 9 VAC, then decrease to 0
VAC as R29 is rotated full clockwise.
2. If the voltage values (step 1
above) are not met, connect a 0-3 amp ammeter in series with current transformer
CT7. Current measured should be approximately 1.5 amperes at 100 percent, 0.8PF
load.
3. If the current value (step 2
above) is not met, check continuity of the
circuit through current transformer CT7
and reactive current rheostat R29. If the
circuitry is proper, check R29 for full resistance range 0-12 ohms.
4. If the current value (step 2 preceding) is met, measure voltage across
terminals of transformer T1. Voltage
across terminals 1-2, and 3-4 should be
identical, if not transformer T1 is
defective.
d. Removal. Refer to figure 6-15.
Disconnect all electrical plug connectors at
mode I relay box assembly receptacles,
then remove the four screws and nuts securing the assembly in position. Remove
the mode I relay box assembly.
6-97. BENCH TEST.
a. Refer to table 6-10 and perform a
continuity test of mode I relay box circuitry.
b. Connect the mode I relay box assembly to test equipment as illustrated in
figure 6-25 and perform test specified in
procedural analysis table 6-11
6-98. DISASSEMBLY, Refer to figures
6-22 and 6-26, and disassemble the mode I
relay box assembly in the order of index
numbers assigned. Pay particular attention
to the following.
NOTE
Disassemble the mode I relay box
assembly to the extent necessary
to accomplish repair.
a. Remove ten screw assemblies (2,
figure 6-26) and washers (3) and left cover
(1) from chassis assembly (39).
b. Tag, then disconnect harness wiring
from components.
c. Remove battery charging ammeter
shunt (R13) engine cranking relay (K3),
Change 1
6-67
T.O. 35 C2-3-442-2
TM 5-6115-457-34
Change 1
P-9-TM-457-35
TM-07464A-35
6-68
Figure 6-25.
P-9-TM-457-35 T.O. 35C2-3-442-2
TM 5-6115-457-34
TM-07464A-35
Table 6-10. Mode I Relay Box Assembly (A27) Continuity Test
REQUIRED RESULT
FROM
TO
J50-L
J50-L
J50-L
J50-L
J50-L
J50-L
J50-L
J50-L
J50-L
J50-B
J2-W
J31-E
J1O-N
J10-E
J5-K
J5-C
J5-E
A5-21
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
J50-P
J50-P
J50-P
J50-P
J50-P
J50-P
J31-K
J6-C
J5-M
J5-Z
J5-W
A5-17
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
J50-R
J50-R
J2-F
J10-B
Continuity
Continuity
J50-S
J50-S
J2-E
J10-A
Continuity
Continuity
J50-H
J50-H
J50-B
J2-H
Continuity
Continuity
J50-W
J50-W
J50-W
J50-W
J50-W
J50-W
J50-W
J50-W
J50-W
J50-W
J50-W
J50-W
J50-W
J50-W
J50-W
J2-P
J2-R
J50-M
J31-D
J31-Z
J7-A
J10-L
J29-E
J5-T
J5-U
J5-H
J5-G
J5-S
K3-X1
A5-15
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
6-69
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Table 6-10. Mode I Relay Box Assembly (A27) Continuity Test (Continued)
6-70
FROM
TO
REQUIRED RESULT
J50-J
J50-J
J50-J
J50-J
J31-A
J2-Z
J10-C
A5-18
Continuity
Continuity
Continuity
Continuity
J50-K
J50-K
J50-K
J31-B
J10-W
J2-Y
Continuity
Continuity
Continuity
J50-D
J50-V
J50-U
J50-T
J50-A
J50-E
J50-X
J50-N
J2-D
J10-D
J10-E
J10-F
J10-M
J31-L
J31-U
J31-S
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
J2-T
J2-H
J2-H
J31-H
J31-R
J10-B
—
Continuity
Continuity
Continuity
J2-L
J2-M
J2-N
J2-T
J2-B
J2-C
J2-X
J2-V
J2-W
J2-X
J2-Y
J2-Y
J2-Z
J2-P
J2-S
J2-U
J2-A
J2-B
J2-C
J3-A
J31-M
J31-N
J31-T
J31-P
J5-G
J5-H
J5-I
J5-J
J5-K
J5-Z
J7-E
R13-3
T1-2
J29-B
R1-2
J10-J
J10-H
J10-G
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
P-9-TM-457-35
TM-07464A-35
T.O. 35 C2-3412-2
TM 5-6115-457-34
Table 6-10. Mode I Relay Box Assembly (A27) Continuity Test (Continued)
FROM
TO
REQUIRE D RESULT
J2-G
J2-1
J2-J
J2-K
J2-0
J2-A
J2-U
J2-V
J10-A
J10-D
A5-19
A5-8
J29-C
J10-F
J29-A
A5-1
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
J2-K
J2-K
J29-H
J10-C
Continuity
Continuity
J2-M
J2-M
J2-M
J5-P
J5-P
J5-R
Continuity
Continuity
Continuity
J2-N
J2-N
J2-V
J3-B
Continuity
Continuity
J2-E
J2-E
J2-E
J29-F
A5-16
J5-N
Continuity
Continuity
Continuity
J2-G
J2-G
J5-D
J29-G
Continuity
Continuity
J2-R
J2-R
J6-A
J29-D
Continuity
Continuity
J50-C
J50-D
J50-F
J50-G
J50-A
J6-I
J6-H
J6-F
J6-M
J5-E
Continuity
Continuity
Continuity
Continuity
Continuity
J5-F
J5-J
J5-W
J5-W
J5-W
J31-C
K3-A1
R13-4
K3-A2
J5-L
Continuity
Continuity
Continuity
Continuity
Continuity
6-71
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115 -457-34
Table 6-10. Mode I Relay Box Assembly (A27) Continuity Test (Continued)
6-72
FROM
TO
REQUIRED RESULT
J5-D
J5-D
J5-F
A5-24
Continuity
Continuity
J5-A
J5-B
J5-C
J5-Z
J5-M
J5-U
J5-V
J5-Y
J5-B
J6-K
J6-E
J6-D
R13-1
A5-1
A5-12
A5-13
A5-4
A5-6
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
J15-J
J15-J
J15-J
J15-F
J15-F
J15-F
J15-E
J15-A
J10-G
J31-J
J15-K
J15-B
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
J15-L
J15-L
J15-L
J15-G
J15-C
J10-H
Continuity
Continuity
Continuity
J15-M
J15-M
J15-M
J15-H
J15-D
T1-1
Continuity
Continuity
Continuity
J10-K
J10-J
J1O-X
J1O-Y
J1O-Z
J1O-T
J1O-S
J31-G
R29-2
A5-22
R29-1
R29-3
A5-7
A5-20
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
J3-C
J3-D
J31-F
J6-B
J6-L
R1-1
R1-2
A5-14
A5-2
J6-G
A5-3
A5-5
T1-4
T1-3
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Continuity
Table 6-11.
P-9-TM-457-35 T.O. 35C2-3-442-2
TM 5-6115-457-34
TM-07464A-35
6-73
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
6-74
Table 6-11. (cont)
P-8-627-34
TM-07464A-35
transformer (T1) and resistor (R1) by removing their attaching screws and nuts
(2 each). See figure 6-22.
d. Remove dc control relay assembly
(A5) by removing the four nuts securing
the assembly in position.
TO 35C2-3-442-2
TM 5-6115-457-34
Output measured at terminals 3 and 4 shall
be 9 VAC.
c. Test engine cranking relay K3 by
applying 24 VDC to terminals Xl and X2.
Normally open contacts A 1 -A2 shall close.
6-101. REPAIR.
NOTE
Refer to paragraph 6-86 for dc
relay assembly maintenance instructions.
e. Remove nut (4, figure 6-26) and
washer (5) securing rheostat (6) to chassis
assembly (39).
f. Remove wire harness (25) by removing the four screws and nuts securing
each of the ten connectors to the chassis
assembly (39).
NOTE
Electrical connector covers (7 and
8) will fall free.
6-99. CLEANING. Clean all components
with a clean lint-free cloth moistened in
an approved cleaning solvent and dry thoroughly.
6-100. INSPECTION AND BENCH TEST.
a. Harness.
1. Inspect harness wiring for defective insulation and continuity.
a. Repair or fabricate mode I relay box
assembly wiring harness according to figure
6-27.
b. Straighten dented or distorted sheet
metal parts using proper tools. Blend in
repaired area with a suitable abrasive
paper and touch up painted surfaces. Restencil panel markings as necessary.
6-102. REASSEMBLY. Refer to figure
6-26 and reassemble the mode I relay box
assembly in reverse order of index numbers assigned. Pay particular attention to
the following:
a. Assemble battery charging ammeter
shunt (R13), engine cranking relay (K3),
transformer (T1), and resistor (R1) in
position using two each, screws and nuts.
See figure 6-22.
b. Assemble DC control relay assembly
(A5) in position using four nuts,
c. Install wire harness (25, figure
6-26) in chassis (39) and secure in position
with four screws and nuts at each of the
ten connectors.
WARNING
Avoid breathing fumes generated by
unsoldering/soldering. Eye protection is required.
2. Inspect harness connectors for
damaged threads; bent, loose or missing
pins and for shorts.
d. Connect wire harness leads to componentry using figure 1-15 as a guide.
b. Test transformer T1 by applying
9 VAC, to terminals 1 and 2. (Excitation
current shall be less than 0.1 ampere. )
Solder connections shall be made
using solder, Federal Specification
QQ-S-571, Sn 60.
NOTE
Change 8
6-75
P-8-627-34
TM-07464A-35
T O 35 C2-3-442-2
TM 5-6115-457-34
Figure 6-26.
6-76
Change 8
Mode I relay box assembly (A-27), exploded view
P -9-TM-457 -35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Legend to figure 6-26:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Cover
Screw assembly (10)
Washer (10)
Nut
Washer
Rheostat (R29)
Electrical connector cover
Electrical connector cover
Screw assembly (16)
Nut assembly (16)
Screw assembly (4)
Nut assembly (4)
Screw assembly (4)
Nut assembly (5)
Connector assembly
Chain assembly
Connector
Dummy connector
Screw assembly (8)
Nut assembly (8)
Screw assembly (8)
e. Test mode I relay box assembly as
outlined in paragraph 6-97.
f. Secure cover (1, figure 6-26) to
chassis assembly (39) using ten screw
assemblies (2) and washers (3).
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
Nut assembly (8)
Screw assembly (8)
Nut assembly (8)
Screw assembly (8)
Nut assembly (8)
Wire harness
Screw assembly
Washer
Jumper terminal board
Terminal board assembly
Screw assembly (8)
Nut assembly (8)
Terminal board (4)
Bracket
Screw assembly (6)
Washer (6)
Electronic component
assembly
37. Rivet (4)
38. Identification plate
39. Chassis assembly
6-103. INSTALLATION. Refer to figure
6-15, and install the mode I relay box assembly. Secure the assembly in position
using four screws and nuts. Refer to the
Operator and Organizational Maintenance
Manual and reconnect all electrical plug
connectors to the assembly receptacles.
6-77
P-9-TM-457-35 T.O. 35C2-3-442-2
TM 5-6115-457-34
TM-07464A-35
6-78
Figure 6-27.
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 6-27, Mode I relay box wiring harness (Sheet 2 of 4)
6-79
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-2-442-2
TM 5-6115-457-34
Figure 6-27. Mode I relay box wiring harness (Sheet 3 of 4)
6-80
T.O. 35C2-3-4 42-2
P-9-TM-457-35
TM-07464A-35 TM 5-6115-457 -34
Figure 6-27. Mode I relay box wiring harness (Sheet 4 of 4)
6-81
P-9-TM-457-35 T.O. 35C2-442-2
TM-07464A-35 TM 5-6115-457-34
Section VII. MODE II RELAY BOX ASSEMBLY
6-104. GENERAL.
The mode II relay box assembly
(A27) is a junction box which is utilized to
interconnect certain electronic componentry
for 400 hertz precise generators sets. The
relay box contains the dc relay assembly,
the under frequency relay, under voltage
relay, permissive paralleling relay, engine
crank relay, governor paralleling control,
voltage regulator paralleling control governor feedback capacitor, frequency adjust
device fixed resistors, cross current transformer and burden resistor, and the battery
charging ammeter shunt. Refer to schematic
figure 1-16.
a. The dc relay assembly (A5) is a
component mounted printed circuit board.
It contains the field flash relay K5, figure
1-16, parallel operation voltage sensor
rectifier bridge CR4 and relay K7, fuel
level relay K8, start circuit diode CR3,
fuel pumps diode CR6, and paralleling lights
resisters R6 through R9. Resister R3,
rectifier bridge CR4, and relay K7 are connected in parallel with winding T6-T9 of the
generator assembly. When the generator
output is connected for 120/208 VAC output;
T9 is reconnected to T3 and T6 is connected
to T12. The voltage across this phase coil
is rectified by CR4 and then applier to relay
K7. This causes its contacts to short out
resisters R9 and R6 in series with the
synchronizing lights DS4 and DS5. When the
generator output voltage is reconnected for
240/416 VAC; terminals T6 and T9 are connected together. This de-energized relay
K7, and resistors R6 and R9 are connected
in series with synchronizing lights DS4 and
DS5.
6-82
Change 3
b. The underfrequency relay (K12) is
a solid state device which funtions to protect the load in the event generator frequency decreases below preset limits. It
actuates when generator frequency drops
below 370 ± 5 hertz. Upon actuation, contacts within the underfrequency relay close
to signal the fault locator and open to deenergize the load contactor, resulting in
display of fault condition and removal of
load from generator.
c. The under voltage relay (K11) is a
solid state device which functions to protect
the load in the event generator voltage decreases below preset limits. It senses
single phase 120 VAC. The time lag between an under voltage condition and activation of relay switching depends upon the
magnitude of the voltage sensed. When the
input voltage drops below 48 VAC, the device shall operate instantaneously. For
voltages above 72 VAC, the device shall
operate in 6 ± 2 seconds. Upon actuation,
contacts within the under voltage relay,
close to signal the fault locator and open to
de-energize the load contactor, resulting
in display of the fault condition and removal
of the load from the generator.
d. The permissive paralleling relay
(K16) is utilized only on precise generator
sets. Its function is to ensure that a generator set cannot be paralleled with other
generator sets until synchronization is accomplished. It accomplishes this by sensing
the voltage drop across one of the synchronization lights. When the voltage exceeds 9
VAC, the relay contacts are open. When
the voltage is less than 7 VAC, its contacts
close. Since its contacts are connected be-
P-9-TM-457-35
TM-07464A-35
tween the load contactor switch S3 and the
load contactor relay coil CB2, it will allow
or prevent the contactor from being energized. When this generator set is perfectly
synchronized with the other sets, the voltage across the synchronizing lights will be
minimum (less than 7 VAC). This causes
the permissive paralleling relay to close its
contacts and allow the generator set to be
paralleled with other generator sets by closing of its load contactor switch S3. If the
generator set is not perfectly synchronized,
the voltage across the synchronizing lights
will be above 9 VAC. This causes the permissive paralleling relay to have its contacts open and prevents the load contactor
CB2 from closing.
e. The electronic components assembly
(A6) consists of Cl, R4, and R5. The assembly connects to the ‘governor control
unit and acts as a feedback circuit to provide
the governor with greater frequency stablilzation.
f. The variable resistor (R29) is a
potentiometer which permits adjustment of
the reactive KVA between sets operating in
parallel. Its slotted shaft, when rotated
clockwise, will cause the corresponding
set to increase its share of the total reactive
KVA .
g. The governor paralleling control is
a rheostat (R28) which permits initial
matching of the governor paralleling circuits for sets operating in parallel. Its
function is to ensure proper real load
sharing. It has a slotted shaft with locking
device which when rotated counterclockwise
will cause an increase in signal appearing
at paralleling receptacles, causing the generator to assume a greater share of the
load.
T.O. 35 C2-3-442-2
TM 5-6115-457-34
6-105. DC RELAY ASSEMBLY (A5).
Refer to paragraph 6-86 through
6-94 for dc relay assembly (A5) maintenance
instructions.
6-106. 400 HERTZ UNDER FREQUENCY
RELAY (K12).
6-107. ON EQUIPMENT TEST
a. Symptom and Isolation of Malfunction. A malfunction of the underfrequency
relay K12 is usually indicated by the illumination of the UNDERFREQUENCY fault
light or by failure of the load contactor to
close with the generator output frequency
normal. To isolate the malfunction, proceed as follows:
WARNING
Exercise extreme care not to touch
exposed electrical connections when
working inside mode II relay box
with generator set operating.
NOTE
Remove cover from mode II relay
box to gain access to the test points,
see figures 6-15 and 6-22.
1. With the generator set operating at rated speed and voltage, measure
the voltage from terminal 1 to terminal
2 of the K12 relay. The nominal voltage
is 120 VAC.
2. If the voltage at terminals 1
and 2 is normal and fault light is still
illuminated, remove the wire from terminal 6 of K12 relay and reset fault lamp.
If fault lamp can be reset, relay K12 is
defective.
Change 3
6-83
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
1
3. If the voltage at terminals
and 2 is normal and the contactor CB2
will not clo se, measure the voltage from
terminal 3 of K12 to TB2-1. The voltage
should read 20-32 VDC when the contactor
switch S3 is placed in the closed position.
Measure the voltage from terminal 4 of
K12 to TB2-1. The voltage should read
20-32 V DC with the contactor switch in the
closed position. If no voltage is present,
K12 relay is defective. The under frequency relay should trip when the frequency
is below 370 ± 5 Hz.
b. Removal. Refer to figure 6-22 and
tag, then disconnect wiring to the underfrequency relay. Remove the four screw
assemblies securing the relay in position.
6-108. BENCH TEST.
a. Connect the underfrequency relay to
the test equipment as illustrated in figure
6−28.
WARNING
Exercise extreme care when
making tests as high voltages
present will cause injury to
personnel upon contact.
b. With switches S1 and S2 open, energize variable frequency supply and adjust
output to 120 VAC, 400 hertz. Close switch
S1 then S2. Indicator DS1 should energize
and DS2 should de-energize.
c. Lower frequency of variable frequency
supply until indicator DS1 de-energizes and
DS2 energizes. This should occur at 370 ±
5.0 hertz.
d. If the underfrequency relay does not
meet the requirements of the above tests
replace the relay.
e. Remove the underfrequency relay
from the test equipment.
Figure 6-28. 400 hertz underfrequency relay (K12) test setup
6-84 Change 7
P-9-TM-457-35
TM-07464A-35
6-109. INSTALLATION. Refer to figure
6-22 and install the underfrequency relay
in the mode II relay box. Secure the relay in position with four screw assemblies,
then refer to figure 1-17 and reconnect
wiring. Replace mode II relay box cover.
6-110. 400 HERTZ UNDERVOLTAGE
RELAY (K11).
6-111. ON EQUIPMENT TEST.
a. Symptom and Isolation of Malfunction. A malfunction of the undervoltage
relay K11 is usually indicated by the illumination of the UNDERVOLTAGE fault
light, or by failure of the load contactor
to close with the generator output voltage
normal. To isolate the malfunction, proceed as follows:
WARNING
Exercise extreme care not to
touch exposed electrical connections when working inside mode
II relay box with generator set
operating.
NOTE
Remove cover from mode II
relay box to gain access to
the test points, see figures
6-15 and 6-22.
1. With the generator set operating
at rated speed and voltage, measure the
voltage from terminal 1 to terminal 2 of
the K11 relay. The nominal voltage is 120
VAC. Remove the wire from terminal 3 of
K11 and reset fault light. If fault light can
now be reset, relay K11 is defective.
2. If the voltage at terminals 1 and
2 is normal and the contactor CB2 won't
close, measure the voltage from terminal
7 of K11 to TB2-1. The voltage should
T.O. 35C2-3-442-2
TM 5-6115-457-34
read 20-32 VDC when the contactor switch
S3 is placed to the clo se position.
3. Measure the voltage from terminal 8 of K11 to terminal board TB2-1.
The voltage should read 20-32 VDC with
contactor switch to the close position; if
no voltage replace K11 relay. The undervoltage relay should trip when the voltage
is lowered below 99 ± 4 volts in 6 ± 2
seconds.
b. Removal. Refer to figure 6-22 and
tag, then disconnect wiring to the undervoltage relay. Remove the four screws
securing the relay in position.
6-112. BENCH TEST.
a. Connect the undervoltage relay to
the test equipment as illustrated in
figure 6-29.
WARNING
Exercise extreme care when
making tests as high voltages
will cause injury to personnel
upon contact.
b. Energize variable voltage AC supply
and adjust to 120 VAC, 400 hertz. Energize 24VDC supply and close switches S2
and S1. Indicator DS2 should energize and
DS1 should deenergize.
c. Adjust the variable voltage supply
to 99 VAC. Indicator DS2 should deenergize and DS1 should energize after
6 ± 2 seconds.
d. If the undervoltage relay does not
meet the requirements of the above test,
replace the relay.
e. Remove the under voltage relay
from the test equipment.
Change
3
6-85
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 6-29. Undervoltage relay (K11), test setup
6-113. INSTALLATION. Refer to figure
6-22 and install the undervoltage relay in
the mode II relay box. Secure the relay in
position with four screw assemblies, then
refer to figure 1-17 and reconnect wiring.
Replace mode II relay box cover.
6-114. PE RMISSIVE PARALLELING
RELAY (K16), 400 HERTZ.
6-115. ON EQUIPMENT TEST.
a. Symptom and Isolation of Malfunction. A malfunction of the permissive
paralleling relay K16 is usually indicated
by the load contactor CB2 closing when the
set voltage is out of phase with the buss
voltage. To isolate the malfunction, proceed as follows:
WARNING
Exercise extreme care not
to touch exposed electrical
connections when working
inside mode II relay box with
generating set operating.
6-86
Change 3
NOTE
Remove cover from mode II
relay box to gain access to the
test points, see figures 6-15
and 6-22.
1. Remove wire from terminal 7 of
the K16 relay to prevent the contacts from
closing. With the generator set operating
at rated speed and voltage and the-load buss
energized by a second set, measure the
voltage from terminal 3 to terminal 4 of
the K16 relay. The voltage should read
20-32 VDC.
2. Measure the voltage from terminal
1 to terminal 2 of K16 with the contactor
switch (S3) in the close position. Connect
an ohmmeter across terminal 7 and 8 of
K12. Observe that the ohmmeter does not
read continuity when the voltage across
terminals 1 and 2 is above 10 VAC; if the
contacts close with a higher voltage the K16
relay is defective.
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
b. Removal. Refer to figure 6-22 and
tag, then disconnect wiring to the permissive paralleling relay. Remove the four
screws securing the relay in position.
6-118. 400 HERTZ ELECTRONIC
COMPONENTS ASSEMBLY (A6) .
6-116. BENCH TEST.
a. Symptom and Isolation of Malfunction.
A malfunction of the electronic component
assembly (A6) usually is indicated by an unstable generator frequency or by loss of
frequency control. To isolate this malfunction, refer to figure 1-16 and proceed as
follows :
a. Connect the permissive paralleling
relay to the test equipment as illustrated
in figure 6-30.
6-119. ON EQUIPMENT TEST.
WARNING
Exercise extreme care not to touch
exposed electrical connections when
working inside mode II relay box
with generator set operating.
NOTE
Remove cover from mode II relay
box to gain access to the test
points, see figures 6-15 and 6-22.
Figure 6-30. Permissive Paralleling
relay (K16) test set up
b. With switches S1 and S2 open, energize
variable voltage supply and adjust to 15 VAC.
Close switches S1 and S2. Indicator DS1
should energize and DS2 should de-energize.
c. Decrease voltage of variable voltage
supply until indicator DS1 de-energizes. The
voltage should be 8 ± 1 VAC.
d. If the permissive paralleling relay does
not meet the requirements of the above tests,
replace the relay.
1. To check for cause of unstable
generator frequency, connect an ohmmeter,
set to the R x 10,000 scale, to capacitor
C1. The meter should indicate 0 resistance
and slowly rise to infinite resistance. If
capacitor C1 does not meet the above requirements, the capacitor is defective.
2. To check for lack of frequency
control, measure the resistance of resisters
R4 and R5. The resistance should be 249
ohms ± 1 percent, if not, the resistors are
defective.
b. Removal. Refer to figure 6-22 and
tag, then disconnect wiring to the electronic
components assembly. Remove the three
screw assemblies securing the assembly in
position.
e. Remove the permissive paralleling
relay from the test equipment.
6-120. BENCH TEST.
6-117. INSTALLATION. Refer to figure
6-22 and install the permissive paralleling
relay in the mode II relay box. Secure the
relay in position with four screw assemblies,
then refer to figure 1-17 and reconnect
wiring. Replace mode II relay box cover.
Using an ohmmeter test the electronic components assembly for values as
noted in figure 6-31.
Change 8
6-87
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Figure 6-31.
NOTE
Figure 6-31 illustrates the electronic components assembly schematic and includes required values.
If the required value is not obtained, replace the faulty component.
6-121. DISASSEMBLY. Refer to figure
6-32 and disassemble the electronic components assembly to the extent necessary
to accomplish repair. Pay particular attention to the following.
a. Tag, then disconnect hook-up wire.
WARNING
Avoid breathing fumes generated by
unsoldering/soldering. Eye protection is required.
b. Exercise care not to apply excessive
heat to components when unsoldering components.
6-88
Change 8
6-122. CLEANING. Clean all components
with a clean lint-free cloth moistened in
an approved cleaning solvent and dry thoroughly.
6-123. INSPECTION.
a. Check electrical components for
opens, shorts, continuity and proper
valves.
b. Inspect components for security.
c. Inspect wiring for defective insulation and continuity.
d. Inspect terminal board for cracks,
warping, burned or discolored areas and
illegible stenciling.
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
c. Replace all defective components.
WARNING
Figure 6-32. Electronic component
assembly (A6), exploded view
Legend to figure 6-32:
1.
2.
3.
4.
5.
6.
7.
8.
90
10.
11.
12.
13.
14.
Standoff
Lockwasher
Washer
Screw
Cable strap
Wire
Standoff (2)
Lock washer (2)
Washer (2)
Screw (2)
Terminal board
Resistors, R4 and R5
Capacitor, Cl
Terminal board assembly
6-124. REPAIR.
a. Repair or fabricate electronics components assembly hookup wire in accordante with table 6-12.
b. Restencil all illegible reference
designations.
Insulating Compound, MIL-I-46058 is
flammable and slightly toxic to eyes,
skin and respiratory tract. Eye and
skin protection required. Good general ventilation is normally adequate.
d. After replacement of components,
coat the terminal board with protective
coating, conforming to Military Specification MIL-I-46058, grade S, type PUR,
0.005 minimum thickness. Air bubbles
should be prevented during coating, so that
legibility of identification or information
markings are not impaired. The coating
shall be applied so that it anchors the
components to the board. Terminals utilized for connection to external circuits
shall not be coated.
6-125. REASSEMBLY. Refer to figure
6-32 and reassemble the electronic components assembly in reverse order of index
numbers assigned. Pay particular attention to the following.
a. Exercise care not to apply excessive
heat to components when soldering connections.
b. Connect wires from components to
terminal board according to table 6-12,
and figure 1-17.
c. Test electronics components assembly in accordance with figure 6-31.
6-126. INSTALLATION. Refer to figure
6-22 and install the electronic components
assembly in the mode II relay box. Secure
the relay in position with three screw assemblies, then refer to figure 1-17 and reconnect wiring. Replace mode H relay
box cover.
Change 8
6-89
P-8-627-34
TM-07464A-35
T O 35 C2-3-442-2
TM 5-6115-457-34
Table 6-12. Electronics Components Assembly (A6) Hook Up Wire Data
1. Solder using Federal Specification Q-Q-S-571, Sn 60
2. Wire is in accordance with MIL-STD-454, requirement 20
6-127. MODE II RELAY BOX ASSEMBLY
(A27), 400 HERTZ.
1. To isolate a malfunction of the
dc relay, refer to paragraph 6-87.
6-128. ON EQUIPMENT TEST.
2. To isolate a malfunction of the
uncle rf requency relay, refer to paragraph
6-107.
a. Symptom and Isolation of Malfunction. A malfunction of the mode II relay
box assembly is usually indicated by a
failure of the dc relay assembly, underfrequency relay, undervoltage relay, permissive paralleling relay, electronic
components assembly, failure of the engine
to crank when the start-run-stop switch S2
is energized, and unequal reactive and
real load sharing when the generator set
is operated in parallel. To isolate the
malfunction, refer to figure 1-16 and proceed as outlined in steps 1. through 8.
WARNING
Exercise extreme care not to touch
electrical connections when working
on the electrical components with
the generator set operating.
NOTE
Remove cover from the mode II
relay box to gain access to the test
points, see figures 6-15 and 6-22.
6-90
Change 8
3. To isolate a malfunction of the
undervoltage relay, refer to paragraph
6-111.
4. To isolate a malfunction of the
permissive paralleling relay, refer to
paragraph 6-115.
5. To isolate a malfunction of the
electronic components assembly, refer
to paragraph 6-119.
6. To isolate a malfunction of the
engine crank relay, refer to paragraph
6-96, step c.
7. To isolate a malfunction in the
reactive droop circuit, refer to paragraph
6-96, step d.
8. To isolate a malfunction in the
real load sharing circuit, measure resistance of rheostat R28. Resistance shall
P-8-627-34
TM-07464A-35
readjustable in the range of 0-15K ohms
± 10 percent. Refer figure 1-16 and 1-17.
b. Removal. Refer to figure 6-15, disconnect all electrical plug connectors at
mode II relay box assembly receptacles,
then remove the four screws and nuts securing the assembly in position. Remove
the mode II relay box assembly.
6-129. BENCH TEST.
a. Refer to table 6-13 and perform a
continuity test of mode II relay box circuitry.
T O 35C2-3-442-2
TM 5-6115-457-34
b. Connect the mode H relay box assembly to test equipment as illustrated in
figure 6-33 and perform test specified in
procedural analysis table 6-14.
6-130. DISASSEMBLY. Refer to figures
6-22 and 6-34 and disassemble the mode II
relay box in the order of index numbers
assigned. Pay particular attention to the
following.
NOTE
Disassemble the mode II relay
box to the extent necessary to
accomplish repair.
Table 6-13. Mode II Relay Box Assembly (A27) Continuity Test
Change 8
6-91
P-8-627-34
TM-07464A-35
T O 35 C2-3-442-2
TM 5-6115-457-34
Table 6-13. Mode II Relay Box Assembly (A27) Continuity Test (Continued)
6-92
Change 8
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Table 6-13. Mode II Relay Box Assembly (A27) Continuity Test (Continued)
Change 8
6-93
TO 35C2-3-442-2
Table 6-13. Mode II Relay Box Assembly (A27) Continuity Test (Continued)
6-94
Change 11
TO 35C2-3-442-2
Table 6-13. Mode II Relay Box Assembly (A27) Continuity Test (Continued)
a. Remove ten screw assemblies (2,
figure 6-40) and washers (3) and lift cover
(1) from chassis assembly (39).
d. Remove underfrequency relay (K12),
undervoltage relay (K11) and permissive
paralleling relay (K16) by removing their
attaching screws (4 each).
b. Tag, then disconnect harness wiring
from components.
NOTE
c. Remove battery charging ammeter
shunt (R13 ) , engine crank ing relay (K3),
transformer (T1) and resistor (R1), b y
removing their attaching screws and nuts
(2 each). See figure 6-22.
Refer to paragraphs 6-106, 6-110,
and 6-114 respectively for relay
maintenance instructions.
e. Remove dc control relay assembly
(A5) by removing the four nuts securing
the assembly in position.
Change 11
6-95
Change 8
P-8-627-34
TM-07464A-35
6-96
T O 35C2-3-442-2
TM 5-6115-457-34
Figure 6-33.
P-9-TM-457-35
TM-074644-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 6-34. Mode II relay box assembly (A27), exploded view
Change 3
6-97
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Legend to figure 6-34:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Cover
Screw assembly (10)
Washer (10)
Nut
Washer
Rheostat (R29)
Nut
Washer
Rheostat (R28)
Electrical connector cover
Electrical connector cover
Screw assembly (16)
Nut assembly (16)
Screw assembly (4)
Nut assembly (4)
Screw assembly (3)
Screw assembly (8)
Nut assembly (8)
Screw assembly (8)
Nut assembly (8)
NOTE
Refer to paragraph 6-86 for dc
relay assembly maintenance instructions.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39,
Screw assembly (8)
Nut assembly (8)
Wiring harness
Screw assembly (6)
Washer (6)
Terminal board jumper (13)
Terminal board assembly
Screw assembly (8)
Nut assembly (8)
Terminal board (4)
Bracket
Screw assembly (6)
Washer (6)
Electronic component assembly
Rivet
Identification plate
Rivet
Identification plate
Chassis assembly
h. Remove wire harness (23) by removing the four screws and nuts securing
each of the ten connectors to the chassis
assembly (39).
NOTE
f. Remove electronic components assembly (A6) by removing the three screw
assemblies securing the assembly in position.
NOTE
Refer to paragraph 6-118 for electronic component assembly maintenance instructions.
g. Remove nuts (4 and 7, figure 6-34)
and washers (5 and 8) securing rheostats
(6 and 9) to chassis assembly (39).
6-98
Change 3
Electrical connector covers (10
and 11) will fall free.
6-131. CLEANING. Clean all components
with a clean lint-free cloth moistened in
an approved cleaning solvent and dry thoroughly.
6-132. INSPECTION.
a. Harness.
1. Inspect harness wiring for defective insulation and continuity.
Table 6-14.
P-9-TM-457-35
TM-074641-35
6-99
T.O. 35C2-3-442-2
TM 5-6115-457-34
Change 3
T.O. 35C2-3-442-2
TM 5-6115-45734
Change 3
P-9-TM-457-35
TM-07464A-35
6-100
Table 6-14.
P-8-627-34
TM-074644-35
6-101
T O 35C2-3-442-2
TM 5-6115-457-34
Change 8
P-8-627-34
TM-0746U-35
T O 35C2-3-442-2
TM 5-6115-45734
2. Inspect harness connectors for
damaged threads; bent, loose or missing
pins and for shorts.
6-133. REPAIR.
a. Repair or fabricate mode II relay
box assembly wiring harness according to
figure 6-35.
6. Straighten dented or distorted sheet
metal parts using proper tools. Blend in
repaired area with a suitable abrasive
paper and touch up painted surfaces. Restencil panel markings as necessary.
missive paralleling relay (K16), in position
using four each, screws.
e. Assemble battery charging ammeter shunt (R13), engine cracking relay
(K3), transformer (T1) and resistor (R1)
into position using two each, screws and
nuts.
WARNING
Avoid breathing fumes generated -by
unsoldering/soldering. Eye pro
tection is required.
f. Connect wire harness loads to componentry using figure 1-17 as a guide.
NOTE
6-134. REASSEMBLY. Refer to figure
6-34 and reassemble the mode II relay box
assembly in reverse order of index numbers assigned. Pay particular attention
to the following:
a. Install wire harness (23) in chassis
(39) and secure in position with four
screws and nuts at each of the ten connectors.
b. Assemble electronic components
assembly (A6) in position using three
screw assemblies. See figure 6-22.
c. Assemble dc control relay assembly
(A5) in position using four nuts.
d. Assemble underfrequency relay
(K12), undervoltage relay (K11) and per-
6-102
Change 8
Solder connections shall be made
using solder, Federal Specification
QQ-S-571, Sn 60.
g. Test mode II relay box assembly as
outlined in paragraph 6-129.
h. Secure cover (1, figure 6-34) to
chassis assembly (39) using ten screw
assemblies (2) and washers (3).
6-135. INSTALLATION. Refer to figure
6-15, and install the mode II relay box
assembly. Secure the assembly in position using four screws and nuts. Refer to
the Operator and Organizational Maintenance Manual and reconnect all electrical
plug connections to the assembly
receptacles.
P-9-TM-457-35
T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 6-35. Mode II relay box assembly (A27) wiring diagram (Sheet 2 of 4)
Change 3
6-105
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 6-35. Mode II relay box assembly (A27) wiring diagram (Sheet 3 of 4)
6-106
Change 3
T O 35C2-3-442-2
P-8-627-34
TM-07464A-35 TM 5-6115-457-34
Figure 6-35. Mode II relay box assembly (A27) wiring diagram (Sheet 4 of 4)
Change 8
6-107
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Section VIII. RECONNECTION BOARD ASSEMBLY, LOAD CONTACTOR, MOTOR
OPERATED CIRCUIT BREAKER ASSEMBLY, LOAD BOARD ASSEMBLY,
AND TRANSFORMER ASSEMBLY
6-136.
GENERAL.
The reconnection board assembly,
load contactor, load bus bars, load board
assembly, and transformer assembly are
located on the right side of the generator.
The motor operated circuit breaker assembly,
used in place of the load contactor on 400
hertz generator sets, is located on the left
side of the generator.
or circuit breaker assembly are connected to
the load terminal board where the load is ele ctrically tonne cted. The load terminal board
has four terminals which are marked L1, L2,
L3, and LO, respectively. Terminals L1, L2,
and L3 are connected through cable, bus bars,
and the load contactor or circuit breaker
assembly to generator output leads T1, T2,
and T3, respectively. The load contactor also
contains auxiliary dc contacts and a connector
for connection of these auxiliary contacts in
the generator set electrical system.
a . The voltage reconnection system permits reconnection of the generator phase wind6-137. RECONNECTION BOARD
ings to provide 120/208 or 240/460 output
ASSEMBLY.
voltages. One end of each coil of each phase
6-138. REMOVAL. Refer to figure 6-36 and
winding runs from the generator through an
remove reconnection board assembly as
instrumentation and a static exciter current
follows:
transformer to the reconnection panel. This
assures current sensing in each phase rea . Remove protective cover (3) by regardless of voltage connection at the reconmoving loosening studs (1).
nection board assembly. The reconnection
board assembly is equipped with a voltage
b . Remove brackets (6 and 7) by rechange board to permit easy conversion to
moving screws (4) and nuts (5).
12 0/208 or 240/416 generator output voltage.
Positioning of the voltage change board conc. Remove support bracket (8) by renects two coils of each phase in series or
moving screws (28), lock washers (29),
parallel. In parallel the output is 120/208,
and washers (30).
in series the output is 240/416 VAC. The
terminals on the reconnection board assembly
NOTE
for connection to the generator loads are
Tag electrical leads with locanumbered according to the particular coil end
tion to insure proper installation.
of each phase of the generator to ensure proper connections.
d. Remove nuts (9), washers (10), electrical leads (11), and bus bars (12) from
b. The output terminals at the reconreconnection board assembly (13).
nection board assembly are connected to the
load contactor through bus bars or to the
circuit breaker with cable assemblies. The
6 - 1 3 9 . DISASSEMBLY. Refer to figure
Ioad contactor and circuit breaker have
6-37 and disassemble reconnection board
three main contacts within it which serve to
assembly in the order of index numbers
connect or disconnect the load from the
assigned. Pay particular attention to the
generator 3 phase, 4 wire, Y connected
following:
output . Three cables from the load contactor
6-108
Change 8
P-8-627-34
TM-07464A-35
a. Each stud is numbered, note numbering sequence prior to removal to insure
proper reassembly.
T O 35C2-3-442-2
TM 5-6115-457-34
6-144. LOAD CONTACTOR.
6-145. ON EQUIPMENT TEST.
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
6-140. CLEANING. Clean parts in an
approved cleaning solvent and dry
thoroughly.
6-14i. INSPECTION.
a. Inspect threads for damage.
b. Inspect terminal board and bus bars
for cracks, warping, and burnt spots.
c. Inspect for broken electrical leads
(due to missing flat washers). Caused by
lock washers cuting into leads without flat
washers.
6-142. REASSEMBLY. Refer to figure
6-37 and reassemble reconnection board
ass embly in the reverse order of index
numbers assigned. Pay particular attention
to the following.
a. Make sure studs are installed in
proper numbering sequence.
6-143. INSTALLATION. Refer to figure
6-36 and install reconnection board assembly as follows:
a. Connect bus bars (12), electrical
leads (11), washers (10) and nuts (9) to reconnection board assembly (13) studs.
b. Position reconnection board assembly (13), support bracket (8) and brackets
(7 and 6) into mounting position on generator, and secure with screws (4 and 28),
nuts (5), lock washers (29) and washers (30).
a. Symptom and Isolation of Malfunction. A malfunction of the load contactor
is usually indicated by the load contactor
opening when the generator is operating
within normal parameters or the contactor
will not close to apply power to the load.
NOTE
Test should be accomplished with
generator not operating and load
cables disconnected.
1. Remove protective cover (3,
figure 6-36) by loosening stud (l).
2. Disconnect electrical connector
from load contactor connector J41. Connect
a suitable voltmeter across pins A and B of
connector P41. Refer 1-2 or 1-3.
3. Energize DC control circuit
breaker, position start-run-stop switch to
RUN, and position battle short switch to
ON.
4. Position ac load contactor
switch to CLOSE, voltmeter should indicate
approximately 24 VDC. If voltage is present, check resistance of contactor coil between contactor connector J41 pins A and
B, resistance should be 6.7 ohms. Replace defective contactor. If voltage is not
present, check wiring back to its source
and correct malfunction.
c. Install protective cover (3) and secure by tightening studs.
Change 8
6-109
P-8-627-34
TM-07464A-35
Figure
6-110
T O 35C2-3-442-2
TM 5-6115-457-34
6-36. Reconnection board assembly, load contactor, and load board
assembly, removal and installation
Change 9
T.O. 35C2-3-442-2
P-9-TM-457-35
TM-07464A-35 TM 5-6115-457-34
Legend to figure 6-36:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35,
36.
37.
38.
39.
40.
Stud (6)
Cross pin (6)
Protective cover
Screw (4)
Nut (4)
Bracket
Bracket
Support bracket
Nut (3)
Washer (3)
Electrical lead
Bus bar (3)
Reconnection board assembly
Screw (2)
Nut (2)
Spacer (2)
Strap
Screw (2)
Cover
Nut (3)
Washer (3)
Nut (3)
Nut and washer (4)
Screw and washer assembly
Mounting bracket
Contactor
Contactor cable (3)
Screw (4)
Lock washer (4)
Washer (4)
Load board assembly
Nut (8)
Lock washer (4)
Load terminal (4)
Screw
Nut
Washer (2)
Lead
Neutral bus bar
Terminal board
Change 3
6-111
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Legend to figure 6-36A:
1. Identification
Plate
2. Wiring diagram
Plate
3. Screw
4. Lock washer
5. Washer
6. Terminal cover
7. Screw
8. Washer
9. Screw
10. Lock washer
11. Washer
12. Gasket
13. Gasket
14. Cover assembly
15. Primary contactor
16. Screw
17. Lock washer
18. Washer
19. Chamber base
20. Gasket
21. Main contact
operator assembly
22. Nut
23, Lock washer
24. Adjusting bushing
25. Retainer
26. Locating bushing
27. Spring
28. Shim
29. Main contact
bridge assembly
30. Main contact
31. Nut
32. Lock washer
33. Terminal washer
34. Base assembly
35. Arc chute
36. Arc chute
spacer
6-112
Change 3
Grommet
Nut
Lock washer
Washer
Contact assembly
Main base
Screw
Washer
Actuator assembly
Auxiliary contact
assembly connector
47. Screw
48. Washer
49. Screw
50. Washer
51. Auxiliary contact
assembly
52. Nut
53, Lock washer
54. Spring
55. Guide rod
56. Nut
57. Lock washer
58. Spacer
59. Core and rod
assembly
60. Post and operator
61. Screw
62. Lock washer
63. Washer
64. Screw
65. Lock washer
66. Washer
67. Screw
68. Lock washer
69. Switch bracket
70. Licon switch
71. End plate
72. Coil
73. Coil washer
74. Core frame
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 6-36A. Main load contactor (sheet 1 of 2)
Change 3
6-113
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 6-36A. Main load contactor (sheet 2 of 2)
6-114
Change 3
P-9-TM-457-35
TM-07464A-35
5. Position load contactor switch
to OPEN, battle short switch to OFF, and
start-run-stop switch to STOP. De-energize circuit breaker,
6. Connect connector to load contactor and install protective cover.
b. Removal. Refer to figure 6-36 and
remove load contactor as follows:
1. Remove protective cover (3) by
loosening studs (l).
2. Disconnect bracket (17) by
removing screws (14), spacers (16), and
nuts (15).
T.O. 35C2-3-442-2
TM 5-6115-457-34
3. Disconnect cover (19) from load
contactor by removing screws (18). Disconnect bus bar (12) and contactor cables
(27) from load contactor by removing nuts
and washers.
4. Loosen nuts (9) securing bus
bars (12) to reconnection board studs, to
remove bus bars from contractors.
5. Disconnect electrical connector
from connector J41 of load contactor.
6. Disconnect load contactor (26)
from mounting bracket (25) by removing
nuts (23) and screws (24).
Change 3
6-115
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 6-37. Reconnection board assembly, exploded view
Legend to figure 6-37:
1.
2.
3.
4.
5.
6.
Nut (13)
Voltage change board
Rivet (12)
Bus bar (6)
Nut (4)
Terminal board assembly
washer (4)
7. Nut (4)
6-116
Change 3
8.
9.
10.
11.
12.
13.
14.
Bus bar
Stud (4)
Stud Nut (9)
Stud Washer (9)
Stud Nut (9)
Stud (9)
Terminal board
P-8-627-34
TM-07464A
6-145A. REMOVAL. Refer to figure 6-36
and remove the load contactor as follows:
a. Remove protective cover (3) by
loosening studs (1). Disconnect strap (17)
by removing screws (14), spacers (16), and
nuts (15),
b. Disconnect cover (19) from load
contactor by removing screws (18). Disconnect bus bar (12) and contactor cables
(27) from load contactor by removing nuts
and washers.
c. Loosen nuts (9) securing bus bars
(12) to reconnection board studs, to remove bus bars from contractors. Disconnect electrical connector from connector J41 of load contactor.
d. Disconnect load contactor (26) from
mounting bracket (25) by removing nuts
(23) and screws (24).
6-146.
BENCH TEST.
a. Apply 24 Vdc at pins A and B of
main load contactor (3) connector. When
main load contactor operates, it should
create a distinctive noise.
b. With an ohmmeter, check for continuity between terminal Al and A2, B1 to
B2, and Cl to C2 on top of the main load
contactor.
c. At the connector, check for continuity between pins C to D, E to F, G to H,
J to K, and R to T.
d. At the connector, check for an open
circuit between pins L to M, N to P, and
R to S.
e. Remove the 24 Vdc and check for the
opposite of the conditions (continuity or open
circuit) listed in steps (2), (3), and (4).
T O 35C2-3-442-2
TM 5-6115-457-34
6-146A. DISASSEMBLY. Refer to figure
6-36A and disassemble the main load contactor as follows:
a, Remove screws (3), lock washers
(4), washers (5) and two terminal covers
(6) from the primary contactor assembly
(15). Remove screws (7) and washers (8)
holding the auxiliary contact connector (46)
to the cover assembly (14).
b. Remove screws (9), lock washer (10)
and washers (11) from the primary contactor assembly (15). Push in on the auxiliary contact connector (46) freeing it and
the gasket (12) from the cover assembly (14).
Remove the primary contactor assembly (15)
and gasket (13) from the cover assembly (14).
c. Remove screws (16), lock washers
(17) and washers (18) from the chamber base
(19), Remove the chamber base (19) and
gasket (20) from the main base (42),
d. Disassemble the main contact operator assembly (21) in the following manner.
Remove nut (22) and lock washer (23) from
adjusting bushing (24). Remove retainer
(25) and locating bushing (26) from the main
contact bridge assembly (29). Remove the
main contact (30), spring (27) and shim (28)
from the main contact bridge assembly (29).
e. Remove the arc chute (35), arc chute
spacer (36) and grommet from the main
base (42). Remove nuts (31 and 38), lock
washers (32 and 39), terminal washers (33)
and washers (40) from contact assembly (41).
Remove contact assembly (41) from main
base (42).
WARNING
Avoid breathing fumes generated by
unsoldering/soldering. Eye protection is required.
I
f. Remove screws (43) and washers (44)
from the end plate (71) and remove same
from the main base (42). Remove screws
(47 and 49) and washers (48 and 50) and remove the actuator assembly (45). Tag and
Change 8
6-117
T O 35C2-3-442-2
P-8-627-34
TM-07464A-35 TM 5-6115-457-34
unsolder the leads from the connector (46)
to the auxiliary contact assembly (51).
c. Repair damaged threads with a die
or by filing with a fine mill file.
g. Remove nuts (52) and washer (53)
from guide rod (55); carefully remove
spring (55). Remove nuts (56) and washers
(57) and remove the post and operator (60),
core and rod assembly (59) and spacer (58)
from end plate (71).
6-146E. REASSEMBLY. Refer to figure
6-36A and reassemble the main load contactor as follows:
h. Remove screws (61), lock washers
(62) and washers (63) from the core frame
(74). Carefully slide the core frame (74)
containing the coil (72) and coil washer (73)
out from the end plate (71). Remove screws
(64 and 67), lock washers (65 and 68) and
washers (66) and remove the switch bracket
(69) and licon switch (70) from the end plate
(71).
6-146B. CLEANING. Clean all components
with a clean lint-free cloth moistened with
an approved cleaning solvent and dry thoroughly .
a. Install switch bracket (69) and licon
switch (70) to end plate (71) using screws
(64 and 67), lock washers (65 and 68) and
washers (66).
b. Insert coil washer (73) and coil (72)
over center pin on coil frame (74). Carefully align end plate (71) over the coil (72)
and coil frame (74). Place space (58), core
and rod assembly (59) and post and operator (60) onto end plate (71). Fasten post
and operator (60) to end plate (71) utilizing
guide rod (55), spring (74), nuts (52) and
washers (53). Install screws (61), lock
washers (62) and washers (63) and tighten
snug. Install nuts (56) and lock washers
(57) to the core and rod assembly (59).
WARNING
6-146C.
INSPECTION.
a. Inspect harness wiring for defective
insulation and continuity.
b. Inspect harness connector for damaged threads; bent, loose or missing pins
and for shorts.
c. Check electrical components for
opens, shorts, continuity, and proper
values.
6-146D. REPAIR,
a. Replace contactor coil (72, figure
6-36A) if defective.
b. Replace contacts if badly pitted or
burned.
6-118
Change 8
Avoid breathing fumes generated by
unsoldering/soldering. Eye protection is required.
c. Connect and solder electrical leads
from connector (46) to auxiliary contact
assembly (51). Install actuator assembly
(45) to end plate (71) and core frame (74)
using screws (47 and 49) and washers (48
and 50). Carefully clamp post and operator
(60) and the core frame (74), so that no air
space exists between the coil (72) and the
core and rod assembly (59). Also check
that no air space exists between the spacer
(58) and end plate (71). Tighten screws
(47 and 61). Remove the clamp and insert
a .150±. 010, feeler gage, between the coil
(72) and core and rod assembly (59). Adjust the guide rods (55) until the gage is
snug. Secure after adjustment by tightening
nuts (52).
P-9-TM-457-35
TM-07464A
d. Assemble the base assembly (34) by
installing contact assembly (41) to main
base (42). Secure with nut (38), lock
washer (39) and washer (40). Install nut
(31), lock washer (32) and washer (33) to
contact assembly (41). Place the arc chute
(35), arc chute spacer (36) and grommet
(37) atop the contact assembly (41).
e, Assemble the main contact operator
assembly (21) by placing shim (28) and
spring (27) onto the main contact bridge
assembly (29). Assemble three contact
bridge assemblies and carefully insert into
the main contact (30). Press down on the
main contact (30) and place the locating
bushings (26) and retainers (25) over the
main contact bridge assembly (29) After
reassembly of the main contact operator
assembly (21), check each individual contact at its edge with a suitable force gage,
Preload shall be 1 1/2 - 2 1/2 lbs. Preload is checked by the initial breakaway of
the retainer (25).
f. Fasten adjusting bushing (24) to the
main base (42). Carefully seat the main
contact operator assembly (21) onto the
adjusting bushings (24) and are chutes (35).
Install nuts (22) and lock washers (23).
Place gasket (20) and chamber base (19)
onto base assembly (34) and fasten with
screws (16), lock washers (17) and washers
(18).
NOTE
Before proceeding with the final
phase of reassembly, it is mandatory that adjustment of the contactor
be performed, Refer to paragraph
6-146E.
g. Seat gasket (13) into groove or main
base (42). Place gasket (12) over the aux-
T.O. 35C2-3-442-2
TM 5-6115-457-34
iliary contact connector (46). Insert the
primary contactor assembly (15) into the
cover assembly (14), Insert and seat the
connector in the receptical opening of the
cover assembly (14). Attach with screws
(7) and washers (8). Carefully seat the
main base (42) of the primary contactor
assembly (15) onto the cover assembly (14);
check that the gasket (13) forms an airtight
seal. Install screws (9), lock washers (10)
and washers (11). Place terminal cover (6)
onto the primary contactor assembly (15).
Secure with screws (3), lock washers (4)
washers (5). Do not overly tighten screws
(3) as the terminal cover (6) may crack.
6-146F.
ADJUSTMENT.
a. Contact Overtravel. Adjust the main
load contactor for contact overt ravel as
follows:
1. Attach a suitable ohmmeter to
terminals A1-A2 and C1-C2 on main base
(42) .
2. Insert .035 feeler gage between
the coil (72) and core and rod assembly (59),
3. Apply 24VDC to the coil.
4. Adjust bushing (24) until continuity is made at A1-A2 and C1-C2. Secure
adjustment by tightening screw (22).
5. Check that continuity is attained
at .035 and no continuity at .040. Readjust
if necessary,
b. Licon Switch. Adjust the main load
lican switch (70) as follows:
1. Adjust switch bracket (69) to
licon switch (70). Check that white button
is fully depressed, and allow .010 clearance between white button and tap operator.
Change 3
6-119
TO 35C2-3-442-2
P-8-627-34
TM-07464A-35 TM 5-6115-457-34
Secure with screws (64 and 67).
2. Insert .010 feeler gage between
coil (72) and core and rod assembly (59).
3. Apply 24VDC to the coil.
4. Adjust lower tab by bending to
licon switch.
5. Check that switch transfer is
attained at .010 and that no switch transfer
is attained at .018, Readjust if necessary,
6-147. INSTALLATION. Refer to figure
6-36 and install load contactor as follows:
Application requiring HB2OOA
(50603) will require modification to Bracket 714642. Those
using alternate PN B3O1EA
(74063) will not.
a. Position load contactor (26) on
mounting bracket (25) and secure with
screws (24) and nuts (23).
b. Connect electrical connector to load
contactor connector J41.
c. Position bus bars (12) and contactor
cables (27) on contactor studs and secure
with nuts and washers. Tighten nuts (9) to
secure bus bars (12) to reconnection board
studs. Connect cover (19) to load contactor and secure with screws (18).
d. Connect bracket (17) and secure
with screws (14), spacers (16), and nuts
(15).
e. Install protective cover (3) and secure by tightening studs (l).
6-147A. CIRCUIT BREAKER ASSEMBLY.
6-147B. TEST ON EQUIPMENT.
a.
Symptom and Isolation of Malfunction. A malfunction of the circuit breaker
is usually indicated by the circuit breaker
opening when the generator is operating
within normal parameters or the circuit
breaker will not close to apply power to the
load.
NOTE
Test should be accomplished
with generator not operating
and load cables disconnected.
Table 6-15. Load Contactor (CB2), Test
OHMMETER CONNECTION POINTS
Al to A2
B1 to B2
Cl to C2
J41C to J41D
J41E to J41F
J41G to J41H
J41J to J41K
J41L to J41M
J41N to J41P
J41R to J41T
J41R to J41S
6-120
Change 9
OHMMETER INDICATION
CONTINUITY
CONTINUITY
CONTINUITY
CONTINUITY
CONTINUITY
CONTINUITY
CONTINUITY
NO CONTINUITY
NO CONTINUITY
CONTINUITY
NO CONTINUITY
P-9-TM-457-35
TM-07464A-35
1. Disconnect electrical connector
from circuit breaker relay box connector
J41. Connect a suitable voltmeter across
pins M and B with B negative. Energize
DC control circuit breaker. There should
be approximately 24 volts.
2. Connect a suitable voltmeter
across pins A and B of J41. Position
start-run-stop switch to RUN, and position
battle short switch to ON.
3. Position circuit breaker switch
to CLOSE; voltmeter should indicate approximately 24 volts.
4. If voltage is not present in either
step 2 or 3, check wiring back to its source
and correct malfunctions.
5. If voltage is present but the
contactor still will not close, check K26
Relay, OFF-ON Limit Switch, and Motor
Bl, and correct malfunction.
6. If the contactor closes and will
not stay in the closed position, check undervoltage relay inside the circuit breaker.
7. Position load contactor switch to
OPEN, battle short switch to OFF, and
start-run-stop switch to STOP. Deenergize circuit breaker.
8. Install connector plug P41 to
circuit breaker relay box.
b. Removal. Refer to figure 6-37A and
remove circuit breaker assembly as follows:
NOTE
Tag electrical leads with
location to insure proper
installation.
1. Tag and disconnect three top electrical leads and electrical connector P41
from circuit breaker assembly (7).
T. O. 35C2-3-442-2
TM 5-6115-457-34
2. Disconnect three circuit breaker electrical leads from load board; loosen
clamp at base of generator.
3. Remove screws (1 and 4), lock
washers (2 and 5) and washers (3 and 6).
4. Remove clamps (7B) by removing screws (7B) and remove circuit
breaker and three electrical leads.
6-147C.
TEST.
a.
Connect circuit breaker assembly
to test equipment as illustrated in figure
6-37B and perform test specified in procedural analysis table 6-15A.
b.
Remove test equipment.
6-147D. DISASSEMBLY. Refer to figure
6-37C and disassemble circuit breaker
assembly in the sequence of index numbers
assigned. Pay particular attention to the
following’
Remove screws (1), lock washers
(2) and washers (3). Remove bracket (4)
from bracket (29).
Remove clamp (7) from bracket
b.
(29) by removing nut and washer assembly
(5) and screw and washer (6).
Remove screw and washer assembl
(8) securing relay box (9) to top of bracket
(29).
Remove relay (11) from relay
d.
socket (14) by removing screw and washer
assemblies (10).
NOTE
Do not disconnect electrical leads
from relay socket (14) unless replacement is required.
Change 3
6-120A
P-9-TM-457-35
TM-07464A-35
1.
2.
3.
4.
5.
6.
T.O. 35C2-3-442-2
TM 5-6115-457-34
SCREW (2)
LOCK WASHER (2)
WASHER (2)
SCREW (2)
LOCK WASHER (2)
LOCK WASHER (2)
7.
MOTOR OPERATED
CIRCUIT BREAKER
ASSEMBLY
7A. SCREW (2)
7B. CLAMP (2)
8. BRACKET
Figure 6-37A. Motor operated circuit breaker assembly
(CB2), removal and installation
6-120B
Change 3
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 6-37B. Circuit breaker assembly (CB2), test setup
Change 3
6-120C
P-9-TM-457-35
TM-07464A-35
6-120D
T.O. 35C2-3-442-2
TM 5-6115-457-34
Change 3
Table 6-15A.
Table 6-15A.
P-9-TM-457-35
TM-07464A-35
Change 3
T.O. 35C2-3-442-2
TM 5-6115-457-34
6-120E
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 6-37C. Motor operated circuit breaker assembly
(CB2), exploded view
6-120F
Change 3
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Legend to figure 6-37C:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Screw (2)
Lock washer (2)
Washer (2)
Bracket
Nut and washer assembly
Screw and washer assembly
Clamp
Screw and washer assembly (4)
Relay box
Screw and washer assembly (4)
Relay (2)
Screw and washer assembly (4)
Standoff
Relay socket (2)
Terminal lug
Wire
Jumper wire (2)
Screw and washer assembly (4)
Nut and washer assembly (4)
Connector
Screw and washer assembly (2)
Nut and washer assembly (2)
Terminal board
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
Relay box cover
Screw (4)
Nut (4)
Washer (4)
Motor control
Bracket
Circuit breaker
Terminal shield (2)
Screw (3)
Lock washer (3)
Cable assembly
Circuit breaker terminal extender (3)
Screw (3)
Nut (3)
Washer (3)
Cable assembly
Trip rod assembly
Handle
Handle shield
Undervoltage relay
Auxiliary switch assembly
Cover
Circuit breaker base
Change 3
6-120G/(6-120H blank)
P-8-627-34
TM-07464A-35
e. Tag and disconnect leads from terminal board (23), and remove socket (14)
with attaching leads from relay box (9) by
removing screw and washer assemblies
(12) and standoff (13).
NOTE
Do not disconnect electrical
leads from connector J41 (20)
unless replacement is required.
f. Tag and disconnect leads from terminal board (23), and remove connector J41
(20) with attaching leads from relay box (9)
by removing screw and washer assemblies
(18) and nut and washer assemblies (19).
g. Tag and disconnect remaining
electrical leads from terminal board (23).
h. Remove terminal board (23 ) from
relay box cover (24 ) by removing screw
and washer assemblies (21) and nut and
washer assemblies (22).
i . Remove screws (25), nuts (26) and
washers (27). Separate motor control (28),
bracket (29) and circuit breaker (30).
WARNING
The circuit breaker must be in
the tripped position before removing cover (45).
Drilling operations create metal chips which may enter the
eye. Eye protection is required.
Drill out circuit breaker case securement rivets and separate cover (45)
from circuit breaker base (46).
WARNING
Keep hands clear of mechanism
at all times.
k. Remove undervoltage relay (43) and
auxiliary switch assembly (44) from circuit
breaker base (46).
6-147E.
T. O. 35C2-3-442-2
TM 5-6115-457-34
CLEANING.
Clean all components with a clean
a.
lint-free cloth moistened with an approved
cleaning solvent and dry thoroughly.
6-147F.
INSPECTION ,
a.
Inspect wiring for evidence of
damaged insulation and continuity.
b.
Inspect terminal block for cracked
insulation and stripped threads.
c.
Inspect relay socket for cracked
insulation and broken pin receptacles.
d.
Inspect electrical connector for
cracked housing, broken or loose pins, and
stripped threads.
Inspect circuit breaker contact
e.
points for signs of corrosion or excessive
pitting and arcing. Minor pitting and arcing
is normal to breaker operation.
6-147G.
REPAIR.
a.
Repair cracked sheet metal parts
by welding. Straighten distorted parts
using suitable tools.
b.
Chase damaged threads in mount.
c.
Remove damaged paint. Blend in
edge, prime, and paint damaged areas.
d.
Repair or fabricate circuit breaker
wiring in accordance with figure 6-37D and
6-37F.
Replace damaged or defective
e.
componentry.
6-147H.
REASSEMBLY. Refer to figure
6-37C. and reassemble circuit breaker
Change 8
6-120I
P-8-627-34
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 6-37D. Motor operated circuit breaker assembly
(CB2), wiring diagram
6-120J
Change 8
P-9-TM-457-35
TM-07464A-35
TO 35C2-3-442-2
TM 5-6115-457-34
Figure 6-37E. Motor operated circuit breaker assembly
(CB2), schematic
GPO 585-000/80589
Change 10
6-120K
P-9-TM-457-35
TM-07464A-35
assembly in the reverse sequence of index
numbers assigned. Pay particular attention to the following:
—
WARNING
Keep hands clear of mechanism
at all times.
a. Carefully install the auxiliary switch
assembly (44) and undervoltage relay (43)
into circuit breaker base (46). Be sure
insulative material surrounds both the
auxiliary swtich assembly (44) and undervoltage relay (43 ) so as not to cause any
shorting.
NOTE
Insure that when circuit breaker
is in the OPEN position, auxiliary
switch actuator does not depress
auxiliary buttons. Auxiliary
switch buttons are depressed
only when the circuit breaker is
in the ONE position.
T. O. 35C2-3-442-2
TM 5-6115-457-34
f.
Install terminal board (23) in relay
box cover (24) and secure with nut and washer
assemblies (22) and screw and washer assemblies (21).
Install connector (20) onto relay box
g.
cover (24) and secure with nut and washer
assemblies (19) and screw and washer
assemblies (18).
h.
Thread standoffs (13) onto relay
sockets (14) and secure to relay box cover
(24) using screw and washer assemblies (12)
i.
Connect all tagged electrical leads
to existing terminals.
Install relays (11) into relay sockets
j.
(14; and secure with screw and washer
assemblies (10).
k.
Install relay box (9) onto bracket
(29) and secure with screw and washer
assemblies (8).
l.
Secure clamp (7) to bracket (29)
with nut and washer assembly (6) and screw
and washer assembly (5).
b. Place handle shield (42) over handle
(41) then install onto circuit breaker actuator assembly.
m.
Fasten bracket (4) to side of
bracket (29) with washers (3), lock washers
(2) and screws (l).
c. Apply a suitable grease to trip rod
assembly (40) so as to retain it captive in the
circuit breaker cover (45) during assembly.
6-1471.
INSTALLATION. Refer to figure
6-37A, and install circuit breaker assembly
in the reverse sequence of index numbers
assigned. Pay particular attention to the
following:.
a.
Place circuit breaker assembly (7)
onto bracket (8) and install washers (7 and 6)
lock washers (5 and 3) and screws (4 and 1).
d. Install cover (45) onto circuit breaker
base (46).
e. Install motor control unit (28) on circuit breaker (30) with cover open and circuit
breaker handle in the OFF position. Adjust
the motor control unit, sliding carriage, until it engages the circuit breaker handle.
Adjustment is accomplished by turning slot
at end of worm gear with a screw driver.
Secure with washers (27), nuts (26) and
screws (25). Secure knurled locking knob
on motor control.
b.
Route three lower electrical leads
through clamp at base of generator and connect to load board terminals. Tighten clamp
Secure clamps (7B) using screws (7A).
c.
Connect electrical connector J41
and three top electrical leads to circuit
breaker assembly (7).
Change 3
6-120M/(6-120N blank)
P-8-627-34
TM-07464A-35
6-148.
LOAD BOARD ASSEMBLY.
REMOVAL AND DISASSEMBLY.
6-149.
Refer to figure 6-36 and remove and disassemble load board assembly as follows:
a.
Remove protective cover (3) by
loosening studs (l).
b.
Disconnect lead (38) from bus bar
(39). Tag and disconnect contactor cables
(27) from load terminals (34) by removing
nuts (32) and washers (33).
c.
Disconnect load board assembly
(21) by removing screws (28), lock washers
(28), and washer (30).
d.
Remove load terminals (34) and
bus bar (39) from terminal board (40) by
removing nuts (32).
T O 35C2-3-442-2
TM 5-6115-457-34
Refer to figure 6-36 and reassemble
and install load board assembly as follows:
Position load terminals (34) and bus
a.
bar (39) on terminal board (40) and secure
with nuts (32).
Position load board assembly (31)
b.
on bracket and secure with screws (28),
lock washers (29), and washers (30).
Connect lead (38) to bus bar (39)
c.
and secure with screw (35), nuts (36), and
washers (37). Connect contactor cables
(27) to load terminals (34) and secure with
nuts (32) and washers (33).
Install protective cover (3) and
d.
secure by tightening studs (1).
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protect ion required. Good general
ventilation is normally adequate.
NOTE
Note position of terminals
prior to removal to insure
proper installation.
6-150.
CLEANING. Clean parts in an
approved cleaning solvent and dry
thoroughly.
6-151.
a.
INSPECTION .
Inspect threads for damage.
b.
Inspect terminal board for cracks,
warping, and burnt areas.
6-152.
REASSEMBLY AND INSTALLATION.
6-153.
TRANSFORMER ASSEMBLY.
REMOVAL. Refer to figure 6-38
6-154.
and remove transformer assembly as
follows:
Remove shield cover (4) by
a.
removing screws (l), lock washers (2)
and washers (3).
Tag and disconnect electrical
b.
wiring from transformers and terminal
board.
Cut tiedown straps connecting
c.
generator leads together. Tag and disconnect six generator leads that pass
through transformer from reconnection board
studs. Remove leads from transformer.
Disconnect transformer assembly
d.
(9) from generator by removing spacers (2),
screws (7), and lock washers (6 and 8).
Change 8
6-121
T O 35C2-3-442-2
TM 5-6115-457-34
P-8-627-34
TM-07464A-35
1.
2.
3.
4.
5.
SCREW (4)
LOCK WASHERS (4)
WASHERS (4)
SHIELD
SPACER (2)
6.
70
8.
9.
LOCK WASHER (2)
SCREW (3)
LOCK WASHER (3)
TRANSFORMER ASSEMBLY
Figure 6-38. Transformer assembly, removal and installation
6-122
Change 8
P-8-627-34
TM-07464A-35
6-155. DISASSEMBLY. Refer to figure
6-39 and disassemble transformer assembly in the order of index numbers assigned.
Pay particular attention to the following.
a. Tag and disconnect transformer
leads prior to transformer removal.
T. O. 35C2-3-442-2
TM 5-6115-457-34
d. Inspect threads for damage.
e. Test transformers for proper
operation; refer to figure 6-40.
f. Inspect paint for damage.
6-158. REPAIR.
6-156. CLEANING.
a. Clean transformers with a clean
lint-free cloth moistened in an approved
cleaning solvent and dry thoroughly.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
b. Clean remaining parts in an approved
cleaning solvent and dry thoroughly,
6-157. INSPECTION.
a. Inspect transformer leads for defective insulation. Inspect terminal lugs for
condition and security.
b. Inspect terminal block for cracked
insulation, stripped threads and missing
jumper strips.
c. Inspect sheet metal parts for distortion and cracks.
Legend to figure 6-39:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Jumper (2)
Screw (2)
Terminal block TB2
Screw assembly (4)
Washer (4)
Exciter transformer (CT4)
Screw (4)
Washer (4)
Cross current transformer
assembly
10. Nut (2)
WARNING
Welding operations produce heat,
highly toxic fumes, injurious
radiation, metal slag and airborne particles. Welding goggles, with proper tinted lenses,
apron or jacket and welder's
boots are required.
a. Repair cracked sheet metal parts
by welding. Straightened distorted parts
using suitable tools.
b.
Chase damaged threads in bracket.
c. Remove damaged paint. Blend in
edge, prime, and paint damaged areas.
6-159. REASSEMBLY.
Refer to figure 6-39 and reassemble current transformer assembly in the
reverse order of index numbers assigned,
Connect transformer leads.
6-160. INSTALLATION. Refer to figure
6-38 and install transformer assembly as
follows.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Screw (2)
Current transformer CT7
Bracket
Screw (8)
Washer (8)
Exciter transformer (CT5, CT6)
Screw (12)
Washer (12)
Instrument transformer (CT1,
CT2, CT3)
20. Bracket
Change 8
6-123
T.O. 35C2-3-442-2
TM 5-6115-457-34
P-8-627-34
TM-07464A-35
Figure 6-39. Transformer assembly, exploded view
6-124 Change 8
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 6-40. Transformer inspection
a. Connect transformer assembly (9) to
generator and secure with spacers (2),
screws (7), and lock washers (6 and 8).
NOTE
Interconnecting wiring diagram is
contained in Operator and Organizational Maintenance Manual.
b. Refer to Operator and Organizational
Maintenance Manual and route six gene rater
leads through transformers. Leads passing through transformers CT4, CT5, and
CT6 make two turns around transformers.
d. Connect electrical wiring to transformers and terminal board.
c. Connect generator leads to reconnection board studs. Secure leads together
with tie straps.
e. Position shield over transformer
assembly and secure with screws (1),
lock washers (2) and washers (3).
Change 3
6-125
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Section IX. TACTICAL RELAY BOX
6-161.
GENERAL.
The tactical relay box (A29) is used
on both 50/60 and 400 hertz generator sets.
It contains the over voltage relay, reverse
power relay, short circuit relay, overload
relay, and the three current transformer
load resistors. Refer to schematic
diagram figure 1-18.
a. The over voltage relay (K2) is a solid
state device which functions to protect the
load in the event that generator voltage exceeds preset limits. It actuates after a time
delay from 180 to 800 milliseconds when generator voltage rises above 156 VAC (both
50/60 and 400 hertz sets). Upon actuation,
contacts within the over voltage relay, close
to signal the fault locator and open to shutdown the generator set.
b. The reverse power relay (K15) is a
solid state device which functions to protect
the generator in the event of a reverse power
operating state during parallel operation. It
operates in conjunction with the load measurement unit which produces a dc output voltage
whose polarity and magnitude is a function of
the total load on the generator set, regardless of phase or power factor. When the reverse power flow into the generator exceeds
twenty percent of rated load; the load measurement unit output has sufficient magnitude
and correct polarity to cause the reverse
power relay to actuate. For 50/60 hertz sets
this reverse power rating pertains to the 60
hertz rating. Upon actuation, contacts with
the reverse power relay; close to signal the
fault locator and open to de-energize the load
contactor, result in display of the fault condition and removal of the load from the
generator.
c. The short circuit relay (K13) is a
solid state device which functions to protect
the load in the event generator output current
in any phase exceeds 425 ± 25 percent of
rated current for 50/60 hertz sets and 180 ±
6-126
Change 3
percent for 400 hertz sets. For 50/60 hertz
sets this current rating pertains to the 60
hertz rating. When the above fault occurs,
the short circuit relay will actuate. Upon
actuation, contacts within the short circuit
relay; close to signal the fault locator and
open to de-energize the load contactor, resulting in display of the fault condition and
removal of the load from the generator.
d. The overload relay (K14) is a solid
state device whose function is to protect the
load in the event of an overload condition.
An overload condition is defined as the state
when generator output current in any phase
exceeds 110 percent of rated value. The
overload relay is a current sensing device
and operates on an inverse time principle as
the current in any phase exceeds the overload state. At the point just above 130 percent of rated current the overload relay will
actuate within 8 ± 2 minutes. For 50/60
hertz sets this current rating pertains to the
60 hertz rating. Upon actuation, contacts
within the overload relay; close to signal the
fault locator and open to de-energize the load
contactor, resulting in display of the fault
condition and removal of the load from the
generator.
6-162.
OVER VOLTAGE RELAY (K2).
6-163.
ON EQUIPMENT TEST.
a. Symptom and Isolation of Malfunction.
A malfunction of the overvoltage relay K2 is
usually indicated by failure of the generator
fault monitoring system to detect and react
to a voltage rise beyond preset limits. To
isolate the malfunction, proceed as follows:
WARNING
Exercise extreme care not to touch
exposed electrical connections when
working inside tactical relay box
with generator set operating.
P-9-TM-457-35
TM-07464A-35
NOTE
Remove cover from tactical relay
box to gain access to test points,
see figures 6-15 and 6-47.
1. With the generator set operating at the rated speed and voltage, and
with the contactor closed, measure the
voltage from terminal 1 to terminal 2 of
the K2 relay. Nominal voltage is 120 VAC.
Voltage from TB2-5 to K2 terminals 3 and
6 should measure 20-32 VDC. Shutdown
generator set.
2. Install a 250 ohm, 25 watt resistor in series with voltage adjustment rheostat
R2 between wire number X9F10 and TB1-7
located in the control cubicle. With the generator set operating at the rated speed and
voltage, increase output voltage such that
the voltage across terminals 1 and 2 of K2
relay measures 153 ± 3 volts. When the K2
relay actuates there should be a momentary
dc voltage measured from terminal 7 of K2
to TB2-5 and there should be no dc voltage
measured from terminal 3 of K2 to TB2-5.
If the above conditions are not met, replace
the K2 relay.
b. Removal. Refer to figure 6-47 and
tag, then disconnect wiring at the overvoltage relay terminals. Remove the four
screw assemblies securing the relay in
position.
T. O. 35C2-3-442-2
TM 5-6115-457-34
6-164. BENCH TEST.
a. Connect the overvoltage relay to the
test equipment as illustrated in figure 6-42.
WARNING
Exercise extreme care when making
tests as high voltages present will
cause injury to personnel upon contact.
b. With all switches open, energize the
60 hertz variable voltage supply and adjust
voltage to 120 VAC. Close switch S2 then
S3. Indicator DS1 should be energized and
DS2 should be de-energized.
c. Adjust 60 hertz variable voltage
supply to 157 VAC. Indicator DS1 should
de-energize and DS2 should energize.
d. Open switches S2 and S3 and energize
the 400 hertz variable voltage supply. Adjust the voltage to 120 VAC. Close switch
S1 then S3. Indicator DS1 should be
energized and DS2 de-energized.
e. Adjust 400 hertz variable voltage
supply to 151 VAC. Indicator DS1 should
de-energize and DS2 should energize.
f. If the overvoltage relay does not meet
the requirements of the above tests, replace
the relay.
g. Remove the overvoltage relay from
the test equipment.
Change 3
6-127
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
NOTES:
1. REMOVE THE FOUR SCREWS AND WASHERS
SECURING THE COVER TO THE CHASSIS TO
GAIN ACCESS TO THE TEST POINTS.
2. TACTICAL RELAY BOX MUST BE REMOVED
FROM GENERATOR SET TO ACCOMODATE
REPLACEMENT OF RELAYS. TO REMOVE THE
BOX ASSEMBLY, TAG AND DISCONNECT THE
TWO ELECTRICAL PLUG CONNECTORS AT J4
AND J51, THEN REMOVE TWO SCREW’S AND
WASHERS SECURING THE BOX IN POSITION.
3. REPLACE ASSEMBLY BY REVERSING ABOVE
PROCEDURES.
Figure 6-41. Tactical relay box (A29), cover removed
6-128
Change 3
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
6-165. INSTALLATION. Refer to figure
6-41 and install the over voltage relay
in position using four screw assemblies.
Refer to figure 1-19 and reconnect wiring.
Replace the tactical relay box and cover.
NOTE
Remove cover from tactical relay
box to gain access to test points,
see figures 6-15, 6-41, 6-43 and
paragraph 6-87.
6-166. REVERSE POWER RELAY (K15).
6-167. ON EQUIPMENT TEST.
a. Symptom and Isolation of Malfunction. A malfunction of the reverse power
relay K15 is usually indicated by failure
of the generator fault monitoring system
to detect and react to a reverse power condition when operating two or more generator
sets in parallel. To isolate the malfunction, proceed as follows.
WARNING
Exercise extreme care not to touch
exposed electrical connections when
working inside tactical relay box with
generator set operating.
1. Operate the generator set in
parallel with another like unit.
2. Adjust voltage and frequency to
rated value and mea sure the voltage across
terminals 3 and 4 of relay K15. In addition, measure the voltage from TB2-5 to
K 15 relay terminals 5 and 8. Voltage
should be 20-32 VDC at all points.
3. Slowly reduce the generator
set (unit under test) speed while monitoring the voltage across terminals 1 and 2
of relay K 15 (approximately 9.8 VDC,
terminal 2 positive, at 100 percent load).
When the voltage is zero, reverse the
Figure 6-42. Over voltage relay (K2), test setup
Change 3
6-129
TO 35C2-3-442-2
meter leads and continue lowering the speed.
Relay K15 should actuate when the voltage is
2 ± 0.1 VDC, 50/60 hertz sets; 5 ± 0.1 VDC,
400 hertz sets, and terminal 1 is positive.
If the relay does not actuate under the preceding conditions, replace the relay.
b. Removal. Refer to figure 1-19 and
6-41 and tag, then disconnect wiring from
the reverse power relay. Remove the four
screw assemblies securing the relay in
position.
c. Set Oscillator to 60 hertz, 10VAC
(peak to peak). Close switch S1 and set
S2 to position “A”. Increase variable
voltage DC power supply to 10VDC, then
return to ø VDC. Indicator DS2 should
remain energized and DS1 should remain
deenergized.
6-168. BENCH TEST.
d. Set switch S2 to position “B”. Increase
variable DC voltage slowly. Indicator DS2
should deenergize and DS1 energize at 2 VDC,
50/60 hertz sets; 5 VDC, 400 hertz sets or
less.
a. Connect the reverse power relay to
the test equipment as illustrated in figure
6-43.
e. If the reverse power relay does not
meet the requirement of the above tests, replace the relay.
b. Energize 24VDC power supply and
close switches S4 and S3. Indicator DS2
should be energized and DS1 should be
deenergized.
f. Remove the reverse power relay
from the test equipment. Reference
figure 1-19 for wiring diagram.
Figure 6-43. Reverse power relay (K15) test setup
6-130
Change 11
6-169. INSTALLATION. Refer to figure
6-41 and install the reverse power relay
in position using four screw assemblies.
Refer to figure 1-19 and reconnect wiring.
Replace the tactical relay box and cover.
6-170. SHORT CIRCUIT RELAY (K13).
6-171. ON EQUIPMENT TEST.
a. Symptom and Isolation of Malfunction. A malfunction of the short circuit
relay K13 is usually indicated by failure
of the generator fault monitoring system
to detect and react to a rise in generator
current output (in any phase) beyond preset
limits. To isolate the malfunction, proceed as follows.
WARNING
Exercise extreme care not to
touch exposed electrical connections when working inside tactical
relay box with generator set
operating.
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-0746A-35
TM 5-6115-457-34
NOTE
Remove cover from tactical relay
box to gain access to test points,
see figures 6-15 and 6-41.
1. With the generator set at rated
speed and voltage, and with the contactor
closed, measure the voltage from terminals
8 and 5 (+) of the K13 relay to TB 2-5 (-).
Voltage should read 20-32 VDC.
2. Apply 100 percent of rated load
and measure the voltage from terminals
1-4, 2-4 and 3-4 of short circuit relay K13.
Voltage should read 5.6 ± 0.5 VAC. If the
preceding conditions are met and the short
circuit relay K13 does not actuate with application of a short circuit, replace the K13
relay.
b. Removal. Refer to figure 6-41 and
tag, then disconnect wiring at the short
circuit relay terminals, Remove the four
screw assemblies securing the relay in
position.
Change 3
6-131
P-9-TM-457-35 T.O. 35C2-3-442-2
TM 5-6115-457-34
TM-0746A-35
6-172. BENCH TEST.
Refer to figure 1-19 and reconnect wiring.
Replace the tactical relay box and cover .-
a. Connect the short circuit relay to
the test equipment as illustrated in figure
6-44.
b. Energize 24 VDC power supply and
close switch S3. Indicator DS1 should be
energized and DS2 should be deenergized.
c. Energize 0 to 50 variable power supply, set switch S2 to position “A” then close
switch S1 and adjust power supply to obtain
3.375 amperes, 50/60 hertz sets; 1.429 amperes 400 hertz sets. Indicator DS2 should
energize and DSl should reenergize. Open
switch S1.
d. Repeat step c. for switch S2 positions
"B" and "C".
e. If the short circuit relay does not
meet the requirements of the above tests,
replace the relay.
f. Remove the short circuit relay from
the test equipment.
6-173. INSTALLATION. Refer to figure
6-41 and install the short circuit relay in
position using four screw assemblies.
6-132
Change 3
Figure 6-44. Short Circuit Relay (K13)
test setup
6-174. OVERLOAD RELAY (K14).
6-175. ON EQUIPMENT TEST.
a. Symptom and Isolation of Malfunction.
A malfunction of the overload relay K14 is
usually indicated by failure of the generator
fault monitoring system to detect and react
to a current rise in any phase, beyond
P-9-TM-457-35
TM-07464A-35
preset limits. To isolate the malfunction,
proceed as follows.
WARNING
Exercise extreme care not to
touch exposed electrical connections when working inside tactical
relay box with generator set
operating.
NOTE
Remove cover from tactical relay
box to gain access to test points,
see figures 6-15 and 6-41.
1. With the generator set operating
at rated speed and voltage, and with the
contactor closed, the voltage measured
across the plus (+) and minus (-) terminals
of the overload relay K14 should read
20-32 VDC. The voltage from the NO terminal (wire P200X16) to TB2-5 and from
the NC terminal (wire P62K16) to TB2-5
should read 20-32 VDC.
2. Apply 130 percent load to the
generator set. The relay should activate
in 8 ± 2 minutes. Determine that the unit
current meter indicates 130% of current on
all phases. No current reading would indicate an open current circuit. When the
relay actuates a momentary dc voltage
should be measured from the NO terminal
‘(wire P209D16) to TB2-5 and there should
be no dc voltage measured from the NC
terminal (wire P62K16) to TB2-5. If the
above conditions are not met, the K14 relay
should be replaced.
NOTE
The K14 relay should not actuate
with less than 110% load, if it does
the relay should be replaced.
T.O. 35C2-3-442-2
TM 5-6115-457-34
b. Removal. Refer to figure 6-41 and
tag, then disconnect wiring at the overload
relay terminals. Remove the four screw
assemblies securing the relay in position.
6-176. BENCH TEST.
a. Connect the overload relay to test
equipment as illustrated in figure 6-45.
b. With the 120/208 VAC power source
deenergized, turn on the 24 vdc power
supply and close switch S1. Indicator DSl
should energize and indicator DS2 should
be deenergized.
c. Energize the 120/208 VAC power
source and adjust autotransformers until
ammeters Al, A2, and A3 indicate 0. 75
amperes. Indicators DSl and DS2 should
not change states.
d. Adjust autotransformer T 1 until
ammeter A 1 indicates 0.975 amperes.
After 8 ± 2 minutes indicator DS1
should deenergize and indicator DS2 should
energize.
e. Repeat step d for autotransformer
T2 and T3. The test results should be the
same as the results for adjustment of autotransformer T1.
f. If the overload relay does not meet
the requirements of the above test, replace
the overload relay.
6-177. INSTALLATION. Refer to figure
6-41 and install the overload relay in
position using four screw assemblies. Refer to figure 1-19 and reconnect wiring.
Replace the tactical relay box and cover.
Change 3
6-133
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 6-45. Overload Relay (K14), test setup
6-178. TACTICAL RELAY BOX (A29).
6-179. ON EQUIPMENT TEST.
a. Symptom and Isolation of Malfunction. A malfunction of the tactical relay
box is usually indicated by a failure of the
overvoltage relay, reverse power relay,
short circuit relay, and overload relay.
To isolate the malfunction, refer to figure
1-18 and proceed as follows.
6-134
Change 3
WARNING
Exercise extreme care not to
touch exposed electrical connection when working inside tactical
relay box with generator set
operating.
NOTE
Remove cover from tactical relay
box to gain access to test points,
see figures 6-15 and 6-41.
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
1. To isolate a malfunction of the
overvoltage relay, refer to paragraph
6-163.
Table 6-16. Tactical Relay Box (A29)
Continuity Test
2. To isolate a malfunction of the
reverse power relay, refer to paragraph
6-167.
3. To isolate a malfunction of the
short circuit relay, refer to paragraph
6-171.
4. To isolate a malfunction of the
overload relay, refer to paragraph
6-175.
b. Removal. Refer to figure 6-15, disconnect the two electrical plug connectors
at the tactical relay box receptacles, then
remove the two screws and washers securing the box in position. Remove the tactical
relay box.
6-180. BENCH TEST.
a. Refer to table 6-16 and perform a
continuity test of the tactical relay box.
b. Connect the tactical relay box to
test equipment as illustrated in figure
6-46 and perform test specified in procedural analysis table 6-17.
6-181. DISASSEMBLY. Disassemble the
tactical relay box to the extent necessary
to accomplish repair. Refer to figures
6-41 and 6-47 and disassemble in the order
of index numbers assigned. Pay particular
attention to the following.
NOTE
Remove the four screws and washers
securing the cover to the relay
chassis.
a. Tag, then disconnect harness wiring
from components.
b. Remove overvoltage relay (K2),
overload relay K14), short circuit relay
(K13) and reverse power relay (K15) from
the chassis by removing their attaching
screw assemblies (4 each),
NOTE
Refer to paragraphs 6-162, 6-174,
6-170, and 6-166 respectively for
relay maintenance instructions.
c. Remove terminal board (TB2), governor resistor assembly (19), and mounting bracket (30) as an assembly by removing screw assembly (29).
d. Remove the wire harness (6) from
the chassis by removing eight screw assemblies (2 and 3) and nuts (4 and 5).
Change 3
6-135/(6-136 blank)
Table 6-17.
P-9-TM-457-35
TM-07464A-35
6-139
T.O. 35C2-3-442-2
TM 5-6115-457-34
Change 3
T.O.
35C2-3-442-2
TM 5-6115-457-34
Change 3
P-9-TM-457-35
TM-07464A-35
6-140
Table 6-17.
Table 6-17.
P-9-TM-457-35
TM-07464A-35
6-141
T.O. 35C2-3-442-2
TM 5-6115-457-34
Change 3
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35
TM 5-6115-457-34
Figure 6-47. Tactical Relay Box (A29), exploded view
6-142
Change 3
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Legend to figure 6-47:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Cover
Screw assembly (4)
Screw assembly (4)
Nut (4)
Nut (4)
Harness assembly
Screw assembly (2)
Nut assembly (2)
Terminal board
Screw assembly (4)
Over voltage relay (K2)
Screw assembly (2)
Overload relay (K14)
Screw assembly (4)
Short circuit relay (K13)
Screw assembly (4)
6-182. CLEANING. Clean all components
with a lint-free cloth moistened in an approved cleaning solvent and dry thoroughly.
6-183.
INSPECTION AND TEST.
a. Harness.
1. Inspect harness wiring for defective insulation and continuity.
2. Inspect harness connectors for
damaged threads; bent, loose or missing
pins and for shorts.
b. Inspect resistors R23, R24 and R25
for rated resistance; 7.5 ± 1 percent,
10 watts.
c. Inspect terminal board (TB2 for
cracks and missing hardware.
6-184. REPAIR.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
Reverse power relay (K15)
Screw assembly (2)
Governor resistor assembly
Wire
Terminal lug (4)
Screw (2)
Nut assembly (2)
Terminal board TB2
Screw (6)
Nut (6)
Resistor (R1, R2, R3)
Mount
Screw assembly (6)
Bracket
Chassis assembly
paper and touch up painted surfaces. Restencil panel markings as necessary.
6-185. REASSEMBLY. Refer to figures
6-41 and 6-47 and reassemble the tactical
relay box in reverse order of index numbers assigned. Pay particular attention
to the following.
a. Install wire harness (6) in chassis
assembly (31) and secure in position with
eight screw assemblies (2 and 3) and nuts
(4 and 5).
b. Assemble governor resistor assembly (19) and terminal board (9) to bracket
(30), then install the assembly in chassis
assembly (31).
a. Repair or fabricate tactical relay
box wire harness in accordance with figure
6-48.
c. Install overvoltage relay (11),
overload relay (13), short circuit relay (15),
and reverse power relay (17) in position
using four each screw assemblies.
b. Straighten dented or distorted sheet
metal parts using proper tools. Blend in
repaired area with a suitable abrasive
d. Refer to figures 6-48 and 1-19 and
connect wire harness leads to componentry.
Change 3
6-143
Change 3
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
6-144
Table 6-48.
P-9-TM-457-35
T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 6-48. Tactical Relay Box (A29), wiring harness (sheet 2 of 2)
Change 3
6-145
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
e. Test tactical relay box as outlined
in paragraph 6-180.
f. Secure cover (1) to chassis assembly (31) using four screw assemblies (16).
6-186. INSTALLATION. Refer to figure
6-15 and install the tactical relay box
in position using two screws and washers.
Reconnect electrical plug connector to
receptacles J4 and J51.
Section X. PRECISE RELAY BOX
6-187. G E N E R A L .
The precise relay box (A25) is-used
only for precise, 50/60 hertz generator
sets. It contains the under frequency relay,
under voltage relay, permissive paralleling relay, frequency mode selector switch,
governor paralleling control or load sharing rheostat, governor feedback capacitor,
and the frequency adjust device fixed resistors. (Refer to schematic diagram,
figure 1-20.
a. The 50/60 hertz under frequency
relay (K12) is a solid state device which
functions to protect the load in the event
generator frequency decreases below preset limits. It actuates when frequency decreases to 55 ± 1 hertz for 60 hertz operation and 46 ± 1 hertz for 50 hertz opera-
6-146
Change 3
tion. Upon actuation, contacts within the
underfrequency relay, close to signal the
fault locator and open to deenergize the
load contactor, resulting in display of the
fault condition and removal of the load from
the generator.
b. The under voltage relay (K11) is a
solid state device which functions to protect
the load in the event generator voltage decreases below preset limits. This relay
is identical to the K11 relay used in the
mode II relay box assembly. Refer to
paragraph 6-104, step c. for a description
of relay circuitry.
c. The permissive paralleling relay is
utilized only on precise generator sets, Its
function is to ensure that a generator set
P-9-TM-457-35
TM-07464A-35
cannot be paralleled with other generator
sets until synchronization is accomplished.
This relay is identical to the K16 relay used
in the mode II relay box assembly. Refer
to paragraph 6-104, step d. for a description of relay circuitry.
d. The electronic components assembly
(A6) consists of C1, R4, and R5. The
assembly connects to the governor control
unit and acts as a feedback circuit to provide the governor with greater frequency
stabilization. This assembly is identical
to the A6 assembly used in the mode II relay
box assembly.
e. The governor paralleling control is
a rheostat (R28) which permits initial
matching of the governor paralleling circuits for sets operating in parallel. Its
function is to ensure proper real load sharing. It has a slotted shaft with locking
device which when rotated counterclockwise
will cause an increase in signal appearing
at paralleling receptacles, causing the generator to assume a greater share of the
load. This rheostat is identical to the R28
rheostat used in the mode II relay box assembly.
6-1880 50/60 HERTZ UNDER FREQUENCY
RELAY (K12).
T.O. 35C2-3-442-2
TM 5-6115-457-34
WARNING
Exercise extreme care not to
touch exposed electrical connections when working inside precise
relay box with generator set
operating.
NOTE
Remove cover from precise relay
box to gain access to test points,
see figures 6-15 and 6-49.
1. With the generator set at rated
speed and voltage, measure the voltage
from terminal 1 to terminal 2 of the K12
relay. Nominal voltage is 120 VAC.
2. If the voltage at terminal 1 and 2
is normal and fault light is still illuminated,
remove the wire from terminal 6 of K12
relay and reset fault 1 amp. If fault lamp
can be reset, relay K12 is defective.
3. If the voltage at terminals 1 and
2 is normal and the contactor CB2 will not
close, measure the voltage from terminal
3 of K12 to TB3-1. Voltage should read
20-32 VDC, with the contactor switch S3
in the closed position. Measure the voltage from terminal 4 of K12 to TB3-1.
Voltage should read 20-32 vdc with the
contactor switch S3 in the closed position.
If no voltage, is present, replace relay K12.
6-189. ON EQUIPMENT TEST.
a. Symptom and Isolation of Malfunction. A malfunction of the underfrequency
relay K12 is usually indicated by the illumination of the UNDER FREQUENCY fault
light or by failure of the load contactor to
close with the generator output frequency
normal. To isolate the malfunction, proceed as follows:
4. Reduce frequent y below 54 Hz
(45 Hz for 50 Hz sets); relay should trip.
If not, replace relay.
b. Removal. Refer to figure 6-49 and
tag, then disconnect wiring to the underfrequency relay. Remove the four screw
assemblies securing the relay in position.
Change 3
6-147
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
NOTES:
1. REMOVE THE FOUR SCREWS AND WASHERS
SECURING THE COVER TO THE CHASSIS TO
GAIN ACCESS TO THE TEST POINTS.
2. PRECISE RELAY BOX MUST BE REMOVED
FROM GENERATOR SET TO ACCOMMODATE
REPLACEMENT OF RELAYS. TO REMOVE THE
BOX ASSEMBLY, TAG AND DISCONNECT THE
TWO ELECTRICAL PLUG CONNECTORS AT J8
AND J32, THEN REMOVE TWO SCREWS AND
WASHERS SECURING THE BOX IN POSITION.
3. REPLACE ASSEMBLY BY REVERSING ABOVE
PROCEDURES.
Figure 6-49. Precise relay box (A25) 50/60 Hz precise generator sets,
cover removed
6-148
Change 3
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
6-190. BENCH TEST.
a. Connect the under frequency relay
to the test equipment as illustrated in
figure 6-50.
WARNING
Exercise extreme care when
making tests as high voltages
present will cause injury to
personnel upon contact.
energizes. Indicated frequency should be
55 ± 1 Hertz.
d. Open all switches. Adjust input
frequency to 50 Hertz. Close switches
S1, S2, and S3. Indicator DS1 should be
energized and DS2 should be deenergized.
e. Decrease frequency until indicator
DS1 deenergizes and DS2 energizes. Indicated frequency should be 46 ±1 Hertz.
b. Energize 24VDC power supply.
Energize 120 VAC variable frequency
power supply and adjust frequency to 60
Hertz. Close switches S1 and S2. Indicator DS1 should be energized and DS2
should be deenergized.
f. If the under frequency relay does
not meet the requirements of the above
tests, replace the relay.
c. Decrease input frequency until
indicator DS1 deenergizes and DS2
g. Remover the under frequency relay
from the test equipment.
Figure 6-50. 50/60 Hertz under frequency relay (K12), test setup
Change 3
6-149
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
6-191. INSTALLATION. Refer to figure
6-49 and install the under frequency relay
in the precise relay box. Secure the relay
in position with four screw assemblies,
then refer to figure 1-21 and reconnect
wiring. Replace precise relay box and
cover.
6-192. PRECISE RELAY BOX (A25).
6-193. TEST AND REMOVAL.
a. Symptom and Isolation of Malfunction. A malfunction of the precise relay
box is usually indicated by a failure of the
under frequency relay, under voltage relay,
permissive paralleling relay, electronic
components assembly, and unequal real
load sharing when the generator set is
operated in parallel. To isolate the malfunction, refer to figure 1-20 and proceed
as follows.
WARNING
Exercise extreme care not to
touch exposed electrical connections when working inside precise
relay box with generator set
operating.
4. To isolate a malfunction of the
electronic components assembly, refer to
paragraph 6-119.
5. To isolate a malfunction in the
real load sharing circuit, measure the resistance of rheostat R28. Resistance
should be adjustable in the range of 15K
ohms ±10 percent.
b. Removal. Refer to figure 6-15, disconnect the two electrical plug connectors
at the precise relay box receptacles, then
remove the two screws and washers securing the box in position. Remove the precise
relay box.
6-194. BENCH TEST.
a. Refer to table 6-18 and perform a
continuity and resistance test of the precise
relay box.
b. Connect the precise relay box to
test equipment as illustrated in figure
6-51 and perform test specified in procedural analysis table 6-19.
6-195. DISASSEMBLY. Disassemble the
precise relay box to the extent necessary
to accomplish repair. Refer to figures
6-49 and 6-52 and disassemble in the order
of index numbers assigned. Pay particular
attention to the following.
NOTE
NOTE
Remove cover from precise relay
box to gain access to test points,
see figures 6-15 and 6-49.
1. To isolate a malfunction of the
under frequency relay, refer to paragraph
6-189.
2. To isolate a malfunction of the
under voltage relay, refer to paragraph
6-111.
3. To isolate a malfunction of the
permissive paralleling relay, refer to
paragraph 6-115.
6-150
Change 3
Remove the four screws and washers
securing the cover to the relay
chassis.
a. Tag, then disconnect harness wiring
from components.
b. Remove under voltage relay (K11),
under frequency relay (K12) and permissive
paralleling relay (16) from the chassis by
removing their attaching screw assembles
(4 each).
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Table 6-18. Precise Relay Box (A25) Continuity and Resistance Test
NOTE
Refer to paragraphs 6-110, 6-188,
and 6-114 respectively for relay
maintenance instructions.
c. Remove terminal board (TB3) and
electronic components assembly (A6) and
mounting bracket from the chassis as an
assembly by removing two screw assemblies (35, figure 6-52).
d. Remove the three screw assemblies
(7) securing the electronic components
assembly (A6) to bracket (36).
NOTE
Refer to paragraph 6-118 for assembly maintenance.
e. Remove the wire harness from the
chassis by removing eight screw assemblies and nuts.
6-196. CLEANING. Clean all components
with a lint-free cloth moistened in an
approved cleaning solvent and dry thoroughly.
Change 3
6-153
Change 3
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-0746M-35 TM 5-6115-457-34
6-154
Table 6-19.
Table 6-19.
P-9-TM-457-35
TM-07464A-35
6-155
T.O. 35C2-3-442-2
TM 5-6115-457-34
Change 3
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 6-52. Precise relay box (A25), exploded view
6-156
Change 3
T.O. 35 C2-3-442-2
P-9-TM-457-35
TM-07464A-35 TM 5-6115-457-34
Legend to figure 6-52:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Cover
Screw assembly (8)
Nut assembly (8)
Wire harness
Nut
Toggle switch (S10)
Nut
Nut
Variable resistor (R28)
Screw assembly (3)
Electronic component assembly (A6)
Screw (2)
Terminal board (TB1)
Threaded standoff (2)
Lock washer (2)
Lock washer (2)
Cable Strap
Wire
Resistor (R4, R5)
Capacitor (C 1)
Screw
Threaded standoff
6-197. INSPECTION AND TEST.
a. Harness.
1. Inspect harness wiring for defective insulation and continuity.
2, Inspect harness connectors for
damaged threads; bent, loose or missing
pins and for shorts.
b. Test rheostat (R28) for full resistance value; 0-15K ohm ± 10 percent.
c. Test switch (S10) for proper make
and break operation.
d. Inspect terminal board (TB3) for
cracks and missing hardware.
23.
24.
25.
26.
27.
28.
29,
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
6-198.
Lock washer
Washer
Terminal board assembly
Screw assembly (4)
Under voltage relay (K11)
Screw assembly (4)
Permissive paralleling relay
(K16)
Screw assembly (4)
Under frequency relay (K12)
(50/60 hertz)
Screw assembly (2)
Nut assembly (2)
Terminal board (TB3)
Screw assembly (2)
Bracket
Rivet (4)
Identification plate
Chassis assembly
REPAIR.
a. Repair or fabricate precise relay
box wire harness in accordance with figure
6-53.
b. Straighten dented or distorted sheet
metal parts using proper tools. Blend in
repaired area with a suitable abrasive
paper and touch up painted surfaces. Re stencil panel markings as necessary.
6-199. REASSEMBLY. Refer to figures
6-49 and 6-52 and reassemble the precise
relay box in reverse order of index numhers assigned. Pay particular attention
to the following.
Change 3
6-157
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 6-53. Precise relay box (A25), wire harness
(sheet 1 of 2)
6-158
Change 3
P-9-TM-457-35
T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 6-53. Precise relay box (A25), wire harness
(sheet 2 of 2)
Change 3
6-159/(6-160 blank)
P-8-627-34
T O 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
a. Install wire harness (4) in chassis
assembly (39) and secure in position with
eight screw assemblies (2) and nuts (4).
b. Assemble electronic components
assembly (11) and terminal board (34) to
bracket (36), then install the assembly in
chassis assembly (39).
c. Install under voltage relay (27),
permissive paralleling relay (29), and
underfrequency relay (31) in position using
four each, screw assemblies.
WARNING
Avoid breathing furies generated by
Unsoldering/soldering. Eye protection is required.
d. Refer to figures 6-53 and 1-21 and
connect wire harness leads to componentry.
NOTE
Solder connections shall be made
using solder, Federal Specification QQ-S-571, Sn 60.
e. Test precise relay box as outlined
in paragraph 6-194.
f. Secure cover (1) to chassis assembly
(39), using four screws and washers.
6-200. INSTALLATION. Refer to figure 6-15 and install the precise relay box
in position using two screws and washers.
Reconnect electrical plug connectors to
receptacles J8 and J32.
Section XI. PRECISE GOVERNOR CONTROL UNIT
6-201. GENERAL.
a. The precise governor control unit
(A23), figure 3-2 is utilized only on precise generator sets. The precise governor is an engine speed frequency regulating unit. It provides high control sensitivity, fast response, and minimum engine
speed frequency deviations with load
fluctuations. It senses electrical frequency and load. Load sensing and sharing
circuitry permits paralleling of more
than two generator sets on an isochronous
basis.
b. The precise governor control unit is
the device that senses the change in generator speed (frequency) and as a result,
commands actuator to move the throttle.
The governor circuits include:
1. A frequency error detection circuit to measure the exact instantaneous frequency at which the generator is operating.
A frequency reference circuit to select
desired frequency for operation.
2. A magnetic amplifier to amplify
the measured error between the outputs of
the frequency measuring and frequency
reference circuits. This error signal is
amplified to a level which is usable by the
governor actuator.
3. A transistor inverter circuit to
convert 24 vdc to approximately 1000 hertz
to power the magnetic amplifier.
4. A throttle position feedback
circuit for governor stability.
5. Provisions for accepting the load
measurement unit signals to provide
isochronous parallel operation, and
improved transient response.
Change 8
6-161
P-8-627-34
TM-07464A-35
T O 35 C2-3-442-2
TM 5-6115-457-34
6-202. ON EQUIPMENT TEST
a. Symptom and Isolation of Malfunction.
A malfunction of the governor control unit
is usually indicated by loss of frequency
control, unstable frequency, or by instability only when operating sets in parallel.
To isolate the malfunction, proceed as
follows:
WARNING
Exercise extreme care not to
touch exposed electrical connections when working inside precise
relay box with generator set
operating.
NOTE
Fold hinge cover away from precise governor control unit to gain
access to test points as shown in
figure 6-54.
1. Loss of Control. - With the set
operating under manual speed control,
measure the input voltage to the P1 connection, pins A and B (nominal 120 VAC). Also
measure input voltage to the P2 connection,
pins A(+) and B(-) (20 to 32 VDC). If the
control unit is properly energized, measure
the voltage at test points A to B and C to D
with A and D(+) (4 to 6 VDC). If either voltage is approximately 15 VDC, check for an
open circuit to the actuator coils. The
actuator coil resistance should be 10 ohms
±10%. If there is no voltage, the control
unit should be replaced. If the above readings are correct, check the circuit to the
frequency adjusting rheostat (R1) on control
cubicle from the PI connection. Pins N to
T should measure 950 ohms ±10%, pins M
to N and M to T should measure 750 ohms ±
10%. If the above checks have not indicated
the malfunction, disconnect all cables from
the control unit, rotate potentiometers R11,
6-162
Change 8
R12, R14, R15, R16, and R18 full CW.
Measure resistance between points indicated in table 6-20. Readings which do not
agree with the values given in the table
indicate a malfunctioning component in the
control unit and it should be replaced.
2. Unstable frequency. - Refer to
the alignment procedures (paragraph 6-211)
and check the adjustment of the magamp
bias gain R12, the load measurement gain
R15, the frequency gain R18, and the feedback gain R16. If the above adjustments
are correct, connect a DC voltmeter
(0 to 50 volt scale) across test points 1 and
2 of the control unit. The voltage should be
zero at rated speed and should swing as the
frequency is varied above and below rated
speed by manually forcing the actuator
linkage above and below its normal position. If the readings are correct, check
the throttle position transducer circuit by
measuring the voltage across test points 3
and 4 (+) with a DC voltmeter. Operate
the set manually with connection P2 disconnected and move the actuator manually,
the voltage across TP3 and TP4 should vary
with actuator movement. Capacitor (C1)
can cause unstable frequency and should be
checked for a short or excessive current
leakage. If the cause of this unstable frequency is not located by the above checks,
perform the resistance checks listed in
table 6-20 and observe any intermittent
readings when the adjustment potentiom eters are turned. Also check the resistance
of all pins to ground with an 100, 000 ohm
scale. All readings shall be infinite resistances. Readings other than those specified indicate replacement of the control unit.
3. Instability when operating in
parallel. Check this setting of the load
sharing potentiometers (R28). Both units
should be set at 4.6 ± 0. 25 volts with Pi-G
positive (pin A of the paralleling receptacle).
Also the frequency gain (R18) and feedback
Table 6-20.
P-9-TM-457-35
TM-07464A-35
6-163
T.O. 35 C2-3-442-2
TM 5-6115-457-34
Change 3
P-9-TM-457-35
TM-07464A-35
T.O. 35 C2-3-442-2
TM 5-6115-457-34
•Figure 6-54. Precise governor control unit (A23) adjustments and test points.
gain (R16) as set for single unit operation
are too high for parallel operation. The
gain adjustments of both units should be
reduced the same amount. If the above
adjustments do not eliminate the instability,
remove all connections and perform the
resistance checks listed in table 6-20.
Readings which do not agree with the values
in the table indicate a malfunctioning component in the control unit and it should be
replaced,
b. Remove precise governor control
unit from right hand side of lifting frame
as follows: Refer figure 3-2.
1. Remove hinge cover from top of
unit by removing two screws.
2. Tag and disconnect harness
assembly.
3. Lift unit out of retainer.
6-164
Change 3
6-203. BENCH TEST.
a. Connect the governor control unit to
test equipment as illustrated in figure 6-55
and perform test as specified in procedural
analysis table 6-21.
NOTE
Figure 1-22 (50/60 Hz sets) and
figure 1-23 (400 Hz sets) illustrates
the precise governor control unit
schematic. Refer to the appropriate figure when checking individual components for required
values.
b. Remove the precise governor control
unit from the test equipment.
6-204. DISASSEMBLY .
a. Refer to figure 6-56 and disassemble the precise governor control unit to the
extent necessary to accomplish repair. Pay
particular attention to the following.
Table 6-21.
P-9-TM-457-35
TM-07464A-35
6-165
T.O. 35C2-3-442-2
TM 5-6115-457-34
Change 3
T.O. 35C2-3-442-2
TM 5-6115-457-34
Change 3
P-9-TM-457-35
TM-07464A-35
6-166
Table 6-21.
Table 6-21.
P-9-TM-457-35
TM-07464A-35
6-167
T.O. 35C2-3-442-2
TM 5-6115-457-34
Change 3
T.O. 35 C2-3-442-2
TM 5-6115-457-34
Change 3
P-9-TM-457-35
TM-07464A-35
6-168
Table 6-21.
Table 6-21.
P-9-TM-457-35
TM-07464A-35
6-169
T.O. 35C2-3-442-2
TM 5-6115-457-34
Change 3
T.O. 35C2-3-442-2
TM 5-6115-457-34
Change 3
P-9-TM-457-35
TM-07464A-35
6-170
Table 6-21.
Table 6-21.
P-9-TM-457-35
TM-07464A-35
6-171
T.O. 35 C2-3-442-2
TM 5-6115-457-34
Change 3
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 6-55. Precise governor control unit (A23), test setup
6-172
Change 3
T.O. 35 C2-3-442-2
P-9-TM-457-35
TM -07464A -35 TM 5-6115-457-34
Remove potting from governor
control unit by performing steps 2. through
6.
1.
placed on a drain board and allowed to cool
to room temperature.
2. Remove six screws (1) and lock
washers (2) holding panel (20) to cabinet
(25).
b. Refer to figure 6-57 and disassemble
the governor printed wiring board assembly to the extent necessary to accomplish
repair. Pay particular attention to the
following:
3. Lift off panel and set across top
of cabinet at a slight angle to keep the
potentiometers out of the compound.
NOTE
4. Place the complete unit in a
temperature controlled oven large enough
to allow air to circulate completely around
unit. Set oven temperature to 170°F.
CAUTION
The flash point of the compound is
515°F. Do not unpot the unit by
placing it on a hot plate type surface or by using an open flame, as
high temperatures (hot spots )
could damage componentry.
Exercise care not to apply excessive
heat to components when unsoldering connections.
6-205. CLEANING.
Clean all components with a clean
lint-free cloth moistened with an approved
cleaning solvent and dry thoroughly.
6-206. INSPECTION.
a. Inspect electrical components and
printed wiring board in accordance with
paragraph 6-53.
NOTE
Melting usually occurs in eleven to
twelve hours.
b. Inspect wiring and electrical connectors for damage.
6-207. REPAIR.
5. To remove printed wiring board
assembly (21) from cabinet, use heavy
gloves and remove entire unit from oven,
being careful not to spill the wax from the
cabinet or allow wax to get on the panel or
potentiometers.
WARNING
Use care in handling the hot wax
as it can cause severe injury to
personnel.
6. Prior to making repairs, the
printed wiring board assembly must be
Repair printed wiring board in accordance with paragraph 6-54, step f.
6-208. REBUILD.
Refer to figure 6-58 and rebuild
precise governor control unit wiring harness.
6-209. REASSEMBLY.
a. Refer to figure 6-57 and reassemble
the precise governor printed wiring board.
Pay particular attention to the following.
Change 3
6-173
P-9-TM-457-35
TM-074644-35
T. 0. 35C2-3-442-2
TM 5-6115-457-34
Figure 6-56. Precise governor control unit (A23), exploded view
6-174
Change 3
P-8-627-34
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Legend to figure 6-56:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Screw (6)
Lockwasher (6)
Screw (16)
Lock washer (16)
Gasket
Gasket (2)
Gasket
Wiring harness
Connector (8)
10.
11.
12.
13.
14,
15.
16.
17.
18.
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Wire
Spacer
Sealing washer
NOTE
Exercise care not to apply excessive heat to components when
unsoldering connections.
b. Refer to figure 6-56 and reassemble
precise governor control unit. Pay particular attention to the following.
1. Re-pot governor control unit by
performing steps 2 through 8.
2. Place the governor cabinet in a
temperature controlled oven in order to
melt the wax.
3. Prior to installing printed wiring
board assembly in cabinet, remove it from
oven and ensure the insulation paper is
positioned next to cabinet shell.
4. Use suitable potting fixture to
locate and maintain cradle for harness.
5. To install the unit in cabinet, use
heavy gloves and slowly lower the assem bly into the cabinet.
WARNING
Use extreme care not to splash hot
wax on personnel as severe injury
can occur.
6. Take unit away from heat and let
wax cool. Place near or in front of cooling
device in order for wax to set more rapidly.
7.
is hard.
Remove potting fixture when wax
19. Identification plate
20. Panel
21. Printed wiring board
assembly
22. Gasket
23. Insulation
24. Insulation
25. Cabinet
8. Install panel (20) to cabinet (25)
and secure with screws (1) and lock washer
(2) .
c . Test the precise governor control
unit in accordance with paragraph 6-203.
6-210. INSTALLATION.
a. Install precise governor control unit
on right hand side of lifting frame as
follows:
1. Place unit into retainer.
2. Connect harness assembly.
3. Install hinge cover to top of unit
and secure with two screws.
6-211. ALIGNMENT.
a. If necessary, refer to Operator and
Organizational Maintenance Manual and
adjust precise governor actuator linkage.
b. Refer to figure 6-54 for location of
adj ustments and test points.
NOTE
Normally, operating adjustments
should be limited to desired readjustments of frequency reference
adjustment R1, and real load
sharing adjustment R28. The
following alignment procedure is
used only for initial installation
of governor or when any one of the
governor components are replaced,
or when adjustments of R7 or R28
will not correct improper operation.
Change 8
6-175
P-8-627-34
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
1. Isochronous Operation
(a) Before starting engine, rotate
frequency adjust rheostat R1, on main
generator control panel for precise generator sets to a mid-rotation position.
Legend to figure 6-57:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
6-176
Screw (2)
Nut (2)
Lock washer (2)
Washer (4)
Transformer T1
Screw (2)
Nut (2)
Lock washer (2)
Washer (4)
Filter reactor (L2)
Screw (2)
Nut (2)
Lock washer (2)
Washer (4)
Filter reactor (L1)
Resistor (R23)
Capacitor (C 7)
Resistor (R5)
Screw (2)
Nut (2)
Lock washer (2)
Washer (2)
Power transistor (2)
Screw (2)
Nut (2)
Lock washer (2)
Washer (4)
Heat sink (2)
Filter reactor (L3)
Diode (CR3)
Capacitor (C2)
Resistor (R20)
Resistor (R20)
Nut (8)
Change 8
35. Lock washer (8)
36. Washer (8)
37. Stud (8)
38. Panel assembly
39. Capacitor (C 2)
40. Rectifier (CR7, CR8, CR9,
CR10)
41. Resistor (R37)
42. Terminal (4)
43. Plate
44. Capacitor (C 5)
45. Resistor (R4 and R8)
46. Screw (2)
47. Nut (2)
48. Lock washer (2)
49. Washer (2)
50. Washer (4)
51. Washer (2)
52. Adjustable resistor (R10)
53. Magamp (SL1)
54. Capacitor (C6)
55. Screw (2)
56. Nut (2)
57. Lock washer (2)
58. Washer (2)
59. Washer (4)
60. Washer (4)
61. Resistor (R1 and R1A)
62. Wire (8)
63. Wire (3)
64. Rectifier (CR2)
65. Capacitor (C3, C4)
66. Transformer (T2)
67. Printed wiring board
P-9-TM-457-35
T.O. 35C2-3-442-2
TM-074641-35 TM 5-6115-457-34
Figure 6-57. Precise governor control unit (A23), printed wiring board assembly
Change 3
6-177
Change 3
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
6-178
Figure 6-58.
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 6-58. Precise governor control unit (A23), wiring harness diagram (Sheet 2 of 2)
Change 3
6-179
P-9-TM-457-35
TM-07464A-35
T.O. 35 C2-3-442-2
TM 5-6115-457-34
(b) Before starting engine, rotate magamp bias balance adjustment potentiometer R11, feedback null adjustment
potentiometer R14, feedback gain adjustment potentiometer R16, and frequency
gain adjust potentiometer R18 on electric
governor control unit to a mid-position
position. Then rotate load measurement
gain adjustment potentiometer R15 to a
full-rotation counterclockwise position,
and the magamp bias level adjustment potentiometer R12 to a three-quarter-rotation
counterclockwise position.
NOTE
To determine desired rotation position of a potentiometer or rheostat,
turn shaft clockwise to stop. Then
rotate shaft counterclockwise to
stop, counting the number of turns
between clockwise and counterclockwise stops. Now, rotate shaft
clockwise for a given number of
turns to obtain desired rotation
position.
(c) Start engine and observe frequenc y meter and voltmeter readings for
indication of fluctuation in either voltage or
frequency. Also listen to engine for sound
of engine hunting. If high frequency, low
amplitude engine hunting is observed, proceed to step (d) and make the necessary
adjustment; if low frequency, high amplitude engine hunting is observed, proceed
to step (e) and make the necessary adjustments. If frequency and voltage outputs
are stabilized, skip steps (d) and (e), proceed to step (f) and continue with alignment
procedures.
(d) To eliminate a high frequency,
low amplitude hunting condition, reduce
magamp bias level by rotating potentiometer (R12) in a clockwise direction, and
6-180
Change 3
reduce high feedback gain by rotating potentiometer (R16) counterclockwise,
(e) To eliminate a low frequency,
high amplitude hunting condition, reduce
frequency gain by rotating potentiometer
R18 counterclockwise When a reduction
of frequency gain does not correct the condition, increase feedback gain by rotating
potentiometer R16 clockwise, When a
reduction of frequency gain and/or an increase in feedback gain does not eliminate
slow hunting, rotate potentiometer r R1 2
more in a counterclockwise direction to
increase magnetic amplifier bias level.
Should none of the above adjustments correct and stabilize the system, increase the
capacitance (non-polarized, 50 vdc, 25 mfd
to 100 mfd electrolytic) of capacitor C1
located in the governor resistor assembly
A6 in the precise relay box for 50/60 hertz
sets or the mode II relay box for 400 hertz
sets Refer to relay box diagram figures
1-16 and 1-20. Alternately change capacitance value and repeat potentiometer R18,
R16, and R12 adjustments until the system
is stabilized, thus eliminating the low frequenc y, high amplitude hunting condition.
(f) With the engine running and
the system stabilized, insert test probes
of a 0-10 volt DC voltmeter in test jacks
3 and 4 (test jack 4 is positive). Rotate
frequency adjust rheostat R1 for a 60-hertz
(400 hertz on 400 hertz unit) reading on the
frequency meter. Then adjust potentiometer R14 for a zero voltage reading between
test jacks 3 and 4 under no load condition.
(g) Before removing the voltmeter from test jack 3 and 4, install test
probes from a similar voltmeter in test
jacks 1 and 2, (test jack 1 is positive) and
alternately adjust potentiometer R11 and the
frequency adjust rheostat to obtain a zero
voltage across test points 1 and 2, and 3
P-9-TM-457-35
T.O. 35 C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
and 4, at 60-hertz or 400 hertz with no
load. When adjustment will not provide a
zero reading across test points 1 and 2,
then adjust for a minimum reading.
(h) Connect a 0 to 10 vdc voltmeter between test jacks A and B and check
for a normal DC voltage reading of approximately 4 to 6 volts. Adjust potentiometer
R12 to obtain proper voltage readings.
(i) To achieve optimum transient
performance, adjust the load measurement
gain control potentiometer R15. Adjustment of R15 to a full clockwise rotation
position provides maximum load measurement gain.
(j) To obtain optimum performance, adjust potentiometer R18 to a maximum clockwise rotation position and potentiometer R16 to a maximum counterclockwise rotation position without causing an
oscillation to develop for any position setting of potentiometer R15. The value of
capacitor C 1 (referred to in precise mode
II relay box schematic electronic component assembly A6) will also affect transient
frequency response. Small values of capacitance will give faster transient frequency
response; however, if the capacitance of
C 1 is too small, the system will oscillate.
(k) For any position of potentiometer R18, there is an optimum position
setting for potentiometer R16. To improve
transient performance even further, rotate
potentiometer R18 in a clockwise direction.
If a hunt develops, re-adjust potentiometer
R16 to achieve stability. If, however, no
hunting condition develops, then apply and
remove the load and observe stability of
generator under such transient conditions,
while continuing to adjust potentiometer
R18 in a clockwise direction. when a potentiometer R18 has been adjusted to a point
where adjustment of potentiometer R16 will
not stability the generator, then reduce
frequency gain R18 to a stable region and
optimize generator stability and performance by adjusting potentiometer R1 6.
NOTE
For long term generator stability,
frequency gain should be reduced to
a point where the system is not on
the edge of instability.
When a steady state frequency of full load
is slightly lower than no load steady state
frequency (droop), re-adjust potentiometers
R12, R14, or R18 slightly. Rotating potentiometer R18 full clockwise for all
operating conditions will often eliminate
droop, and under certain circumstances,
adjusting potentiometer R14 for voltage
reading above zero at test jacks 3 and 4 will
also eliminate droop. A slight readjustment of the magamp bias lever potentiometer R12 will provide isochronous operation
under certain conditions.
2. Parallel Operation Alignment and
Adjustment
(a) With the generator operating
under no load, disconnect electrical connector J 17 at electric governor control
unit. Use a dc voltmeter and check for zero
voltage between pins G and J (pin G is
positive).
(b) With the DC voltmeter connect
across pins G and J of connector J17, apply
full load to generator set and adjust the real
load sharing potentiometer R12 in the precise relay box or the mode II relay box
through its full range. The dc voltmeter
should indicate between 5 and 10 volts dc.
Note and record the exact range of dc voltage available on set number one by adjusting the real load sharing potentiometer.
Change 3
6-181
P-9-TM-457-35
TM-07464A-35
T.O. 35 C2-3-442-2
TM 5-6115-457-34
(c) Repeat the procedures outlined in steps (a) and (b) on set to be connected in parallel with set number one.
(d) Adjust the real load sharing
potentiometer R28 on each generator set so
that the voltage across pins G and J in connector J17 is identical.
NOTE
Make sure during the procedure
outlined in steps (a) and (b) that
the load contactor swtich is open
so that pin G or J of one generator set connector J17 is not
connected to pins G or J of another generator set contactor
J17.
Refer to Operator and Organizational
Maintenance Manual and begin parallel operation.
(e) If the generator sets tend to
oscillate during the first attempt at parallel
operation, remove from parallel operation,
readjust real load sharing potentiometer
R28 for a lower voltage across pins G and J
in connector J17, and place generator sets
in parallel operation again. It may be nece ssary to repeat this operation several times
until the proper voltage is obtained. When
the proper voltage setting on each generator
set has been obtained, and it will be possible
to parallel isochronously with equal load
sharing during each paralleling operation.
(f) If other than equal load sharing is desired, then adjust potentiometer
R28 to obtain the proper ratio voltage desired.
NOTE
Under normal conditions, any
adjustment of potentiometer
6-182
Change 3
R28 should be made when the
generator set is not operating
in parallel. However, if a
slight readjustment of load
sharing between parallel
operating sets is necessary,
such a slight readjustment
is permissible. The same
results can usually be obtained, however, by adjusting the frequency reference
adjustment potentiometer R1.
6-211A.
ALIGNMENT PROCEDURES
PECULIAR TO OPERATION
OF 400 HZ GENERATOR SETS
IN SUPPORT OF E3A AIRCRAFT,
a. If necessary, refer to Operator and
Organizational Maintenance Manual and adjust precise governor actuator linkage.
b. Refer to figure 6-54 for location of
adjustments and test points.
1. Isochronous Operation.
(a) Before starting engine,
rotate frequency and adjust rheostat R1 on
main generator control panel for precise
generator sets to a mid-rotation position.
(b) Before starting engine,
rotate magamp bias balance potentiometer
R11, feedback null adjustment potentiometer
R14, feedback gain adjustment potentiometer]
R16, and frequency gain adjust potentiomete
R18 on precise governor control unit to a
mid-rotation position. Then rotate load
measurement gain adjustment potentiometer
R15 to a three-quarter-rotation clockwise
position.
(c) Start engine and operate at
400 hertz, no load. Observe governor actuator unit piston for hunting. If governor
actuator unit piston is hunting, adjust R18
TO 35C2-3-442-2
counter clockwise to stop hunting. If
actuator is still hunting after R18 was
adjusted, rotate R16 to stop hunting.
(h) Vary potentiometer R16
either clockwise or counterclockwise to
obtain best stability.
If moving R16
hs no effect. then set R16 at its midrotation position.
NOTE
It may require that R18 be
readjusted to a new position
and R16 rotated again to stop
hunting.
2.
Parallel Operation Alignment
and Adjustment.
(d) With engine running
and the system stabilized. insert test
probes of a 0-10 volt dc voltmeter in
test jacks 3 and 4 (test jack 4 is
positive) . Rotate frequency adjust
rheostat R1 for a 400 Hz reading on the
frequency meter. Then adjust potentiometer R14 for a zero voltage reading
between test jacks 3 and 4 under no
load condition.
(e) Insert test probes of
a 0-10 volt dc voltmeter in test jacks
A and B (test jack A is positive).
Adjust potentiometer R12 for a voltage
reading of 5.0 volts dc between test
jacks A and B.
(f) Insert test probes of
a 0-10 volts dc voltmeter in test jacks
A and B (test jack A is positive).
Adjust potentiometer R12 for a voltage
reading of 4.0 to 6.0 volts dc. Adjust
to highest voltage within range that
does not allow actuator to hunt.
(g) Note governor actuator
piston for no movement.
If necessary
Section XII.
readjust R16 and R18 potentiometers to
stop movement.
(a) Load unit with a load
bank set to obtain a load of 50 KW at
unity power factor.
(b) Connect test probes of
a 0-10 volt dc voltmeter across pins A
and B (pin A is positive) of any paralleling receptacle (J45. J46 or J47).
Adjust the real load sharing potentiometer R28 on the precise relay box to
obtain a reading of 1.5 volts dc.
(c) Place parallel/single
unit switch (S6) in the parallel position.
Ensure shorting plug is removed
then connect test probes of a 0-10
voltmeter across pins C and D of any
paralleling receptacle (J45, J46 or
J47) . Adjust reactive current sharing
potentiometer R29 on the precise relay
box to obtain a reading of 5.5 volts ac
(7.5 volts ac with 50 KVA at 0.8 power
factor) .
(d) When all alignment
procedures have been complied with.
ensure all locknuts on potentiometers
are tightened.
LOAD MEASUREMENT UNIT
6-212. GENERAL.
The load measurement unit is
utilized on both precise and utility
generator sets. The unit consists of a
three phase transformer, rectifiers,
It meaand a variable load resistor.
sures the total load on the generator
set regardless of power factor or phase
and provides a dc voltage output proportional to this load. On precise
generator sets this output signal is
applied to the load-sensing circuits in
the control unit to provide a load rate
signal to the feedback circuit, and a voltage
Change 12
6-182A/(6-182B blank)
P-9-TM-457-35
TM-07464A-35
proportional to load that is used for the
parallel system. If a dummy load kit is
utilized with the generator set the load
measurement unit is interconnected with
the kit sensing circuit.
T.O. 35C2-3-442-2
TM 5-6115-457-34
9.8 VDC proportional to load, the load
measurement unit should be replaced.
b. Removal. Refer to figure 6-59 and
remove load measurement unit by removing electrical connector and screws.
6-213. ON EQUIPMENT TEST.
6-214. TEST AND ADJUSTMENT.
a. Symptom and Isolation of Malfunction. A malfunction of the load measurement unit is not easily detected during
single unit operation unless the set is
equipped with a dummy load kit and the
automatic load removal feature is utilized.
Then a malfunction is usually indicated
by failure of the dummy load kit automatic
removal circuit. When the unit malfunctions in a generator set that is operating
in parallel, the malfunction is usually indicated by unequal load sharing. To isolate
the malfunction, proceed as follows:
1. Remove connector P16 from
load measurement unit and with generator
set operating at rated speed and voltage,
measure voltage at connector P16, pins A
to K, B to L, and C to M; voltage should
be 120 VAC nominal. Also measure voltage across connector pins G to D, G to E,
and G to F; voltage should be 5.6 VA C at
rated load.
2. If above voltages are-met, connect connector P16 to load measurement
unit. Operate generator set, controlling
speed with the manual speed control and
check load measurement unit output by removing connector P1 from the governor
control unit. Measure voltage across connector P 1 pins U(+) and S, voltage should
be 9.8 VDC with generator set operating
at rated load.
3. If input voltages are correct
and the output does not vary between 0 and
a. Connect load measurement unit to
the test equipment as illustrated in figure
6-60.
b. Test and adjust load measurement
unit as specified in table 6-22.
6-215. DISASSEMBLY.
Refer to figure 6-61 and disassemble load measurement unit in the order
of index numbers assigned. Pay particular
attention to the following.
a. Remove cover (5).
NOTE
Leave wires connected to receptacle (7).
b. Tag and unsolder wires from components, exercising care not to apply excessive heat. Unsolder diodes (19) from
transformer (24),
6-216. CLEANING.
a. Clean electrical components with
a clean lint-free cloth moistened in an
approved cleaning solvent and dry thoroughly ,
b. Clean remaining parts in an approved cleaning solvent and dry thoroughly .
Change 3
6-183
P-9-TM-457-35
TM-07464A-35
6-217.
T.O. 35C2-3-442-2
TM 5-6115-457-34
INSPECTION.
h. Inspect paint for damage.
6-218.
a. Inspect wire for defective insulation. Check each wire to connector pin for
continuity. Check connector pins for
shorts to case and surrounding pins. Inspect connector for damaged threads.
b . Check forward and reverse resistance of diodes. Measured from anode (+)
to cathode (-) value should be low, reverse
meter leads value should be infinity.
REPAIR.
a. Repair defective wiring by removing defective wire from connector and installing wire of same size and length in its
place.
b.
Chase damaged threads.
c.
Repair cracked sheet metal parts
by welding. Straighten dented or distorted
parts using suitable tools.
c. Check resistor for proper ohmic
value, resistor should be adjustable from
0 to 500 ohms.
d. Fasten loose nameplate to cover
using a suitabe adhesive.
d. Inspect transformer for burnt areas,
defective insulation, and missing terminals.
e. Remove damaged paint. Blend in
edges, prime, and paint damaged areas.
e. Inspect threads for damage.
6-219.
REASSEMBLY.
f. Inspect sheet metal parts for cracks,
dents, and distortion.
Refer to figure 6-61 and reassemble the load mea surement unit in the
reverse order of index numbers assigned.
Inspect nameplate for security and
legibility.
a. Solder diodes (19) and wires to
transformer (24).
g.
6-184
Change 3
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
proportional to load that is used for the
parallel system. If a dummy load kit is
utilized with the generator set the load
measurement unit is interconnected with
the kit sensing circuit.
b. Removal. Refer to figure 6-59 and
remove load measurement unit by removing electrical connector and screws.
6-213. ON EQUIPMENT TEST.
a. Connect load measurement unit to
the test equipment as illustrated in figure
6-60.
a. Symptom and Isolation of Malfunction. A malfunction of the load measurement unit is not easily detected during
single unit operation unless the set is
equipped with a dummy load kit and the
automatic load removal feature is utilized.
Then a malfunction is usually indicated
by failure of the dummy load kit automatic
removal circuit. When the unit malfunctions in a generator set that is operating
in parallel, the malfunction is usually indicated by unequal load sharing. To isolate
the malfunction, proceed as follows:
1. Remove connector P16 from
load measurement unit and with generator
set operating at rated speed and voltage,
measure voltage at connector P1 6, pins A
to K, B to L, and C to M; voltage should
be 120 VAC nominal. Also measure voltage across connector pins G to D, G to E,
and G to F; voltage should be 5.6 VAC at
rated load.
2. If above voltages are met, connect connector P16 to load measurement
unit. Operate gene rator set, controlling
speed with the manual speed control and
check load measurement unit output by re moving connector P1 from the governor
control unit. Measure voltage across connector P1 pins U(+) and S, voltage should
be 9.8 VDC with generator set operating
at rated load.
3. If input voltages are correct
and the output does not vary between 0 and
9.8 VDC proportional to load, the load
measurement unit should be replaced.
6-214. TEST AND ADJUSTMENT.
b. Test and adjust load measurement
unit as specified in table 6-22.
6-215. DISASSEMBLY.
Refer to figure 6-61 and disassemble load measurement unit in the order
of index numbers assigned. Pay particular
attention to the following.
a. Remove cover (5).
WARNING
Avoid breathing fumes generated by
Unsoldering/soldering. Eye protection is required.
NOTE
Leave wires connected to receptacle (7).
b. Tag and unsolder wires from components, exercising care not to apply excessive heat. Unsolder diodes (19) from
transformer (24).
6-216. CLEANING.
a. Clean electrical components with
a clean lint-free cloth moistened in an
approved cleaning solvent and dry thoroughly.
WARNING
Cleaning Solvents are f lammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protect ion required. Good general
ventilation is normally adequate.
b. Clean remaining parts in an approved cleaning solvent and dry thoroughly
●
Change 8
6-183
P-8-627-34
TM-07464A-35
6-217.
T O 35C2-3-442-2
TM 5-6115-457-34
INSPECTION.
a. Inspect wire for defective insulation. Check each wire to connector pin for
continuity. Check connector pins for
shorts to case and surrounding pins. Inspect connector for damaged threads.
b. Check forward and reverse resistance of diodes. Measured from anode (+)
to cathode (-) value should be low, reverse
meter leads value should be infinity.
c. Check resistor for proper ohmic
value, resistor should be adjustable from
0 to 500 ohms.
d. Inspect transformer for burnt areas,
defective insulation, and missing terminals.
e.
Inspect threads for damage.
f. Inspect sheet metal parts for cracks,
dents, and distortion.
g. Inspect nameplate for security and
legibility.
h.
6-218.
Inspect paint for damage.
REPAIR.
a. Repair defective wiring by removing defective wire from connector and in-
6-184
Change 8
stalling wire of same size and length in its
place.
b.
Chase damaged threads.
WARNING
Welding operations produce heat,
highly toxic fumes, injurious
radiation, metal slag and airborne particles. Welding goggles, with proper tinted lenses,
apron or jacket and welder’s
boots are required.
c.
Repair cracked sheet metal parts
by welding. Straighten dented or distorted
parts using suitable tools.
d. Fasten loose nameplate to cover
using a suitabe adhesive.
e . Remove damaged paint. Blend in
edges, prime, and paint damaged areas.
6-219.
REASSEMBLY.
Refer to figure 6-61 and reassemble the load measurement unit in the
reverse order of index numbers assigned.
WARNING
Avoid breathing fumes generated by
unsoldering/soldering. Eye protection is required.
a. Solder diodes (19) and wires to
transformer (24).
P-9-TM-457-35
T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 6-60. Load measurement unit (LMU), test setup
Change 3
6-185
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 6-61. Load measurement unit, exploded view
6-186
Change 3
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Legend to figure 6-61:
1.
2.
3.
4.
5.
6.
6A.
7.
8.
9.
10.
11.
12.
Nameplate
Nut (4)
Lock washer (4)
Washer (4)
Cover
Screw (4)
Washer (4)
Receptacle (J16)
Screw (2)
Nut (2)
Lock washer (2)
Washer (2)
Bracket
b. Prior to installing cover (5) test and
adjust load measurement unit as specified
in paragraph 6-214.
c. Install cover after test.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Screw
Nut
Lock washer
Washer (2)
Washer (2)
Adjustable resistor (R1)
Diode (CR1 through CR6)
Nut (4)
Lock washer (4)
Tube (4)
Washer (4)
Transformer (T1)
Bracket
6-220. INSTALLATION.
Refer to figure 6-59 and install
load measurement unit on bracket and secure with screws. Connect electrical’
connector to unit.
Change 3
6-187
Table 6-22.
All data on pages 6-189 through 6-220,
including figures 6-66 through 6-75 deleted.
T.O. 35C2-3-442-2
TM 5-6115-457-34
Change 3
P-9-TM-457-35
TM-07464A-35
6-188
P-9-TM-457-35 T.O. 35 C2-3-442-2
TM-07464A-35 TM 5-611 5-457-34
CHAPTER 7
GENE RATOR ASSEMBLY REPAIR INSTRUCTIONS
7-1. GENERAL.
The generator is a brushless type
with a rotating exciter. The armature of
the exciter, the field of the generator and
the rectifier assembly are mounted on the
same rot sting shaft. The field of the exciter and armature of the generator are
stationary. The output of the generator
armature is kept at a predetermined constant value by the generator set output. In
order to build up the voltage of a generator,
the residual magnetism of its pole pieces is
generally relied upon to produce a small
initial voltage which increases as the generator comes up to speed. If this is not
sufficient, the exciter regulator flashes the
field. This voltage is fed from the exciter
armature to the bridge rectifier assembly,
the dc output of which is coupled to the generator field rotating on the same shaft with
the exciter armature and rectifier assembly. The generator field induces an ac
voltage in the stationary armature windings.
WARNING
Stay clear of generator
output leads.
3. Remove electrical connector P61
from right side of generator endbell.
4. Connect a variable dc voltage supply (0-10 volt, 15 amperes) in series with
a 0-10 dc ammeter to connector J61 pin C
(positive) and pin B (negative). Set variable
voltage supply to zero.
5. Start generator set and operate
engine at rated speed, 1800 RPM, for
50/60 hertz generator sets or 2000 RPM
for 400 hertz generator sets.
6. Adjust variable voltage supply
until normal generator output voltage is
obtained (120/208 or 240/416). Test dc
ammeter should indicate 3 to 3.5 amperes
for 50/60 hertz generator sets and 6.25 to
6.75 amperes for 400 hertz generator sets.
7-2. ON EQUIPMENT TEST.
a. Symptom and Isolation of Malfunction. A malfunction of the generator is
usually indicated by either low output
voltage or no voltage output. To isolate the
malfunction proceed as follows:
7. Remove external power supply
and shut down generator set.
8. If above requirements are met,
refer to paragraph 6-76 and test the exciter
regulator. If requirements are not met,
proceed as indicated below.
1. Disconnect generator set air
intake doors, below control cubicle, by removing fourteen screws, washers, and nuts.
NOTE
2. Disconnect generator set air inlet
louver and screen assembly, by removing
twenty screws, forty washers and sixteen
nuts.
Generator temperature should
be approximately 77° F during
resistance test.
Change 7 7-1
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
9. Check resistance between connector J61 pins B and C using a Wheatstone
Bridge or other suitable low resistance
measuring device. Resistance should be
1.23 ohms ±10 percent for 50/60 hertz
generator sets and 1.51 ohms ±10 percent
for 400 hertz generator sets.
10. Check insulation resistance of
exciter stator by electrically bonding connector J61 pins B and C together. Connect
lead from pins to a 500 volt megger and
connect other megger lead to frame. Resistance reading should be a minimum of
50K ohms.
NOTE
Interconnecting wiring information
is contained in Operator and Organizational Maintenance Manual.
11. Remove plastic shield from reconnection panel. Remove voltage change
over board. Disconnect electrical connector
P10 from mode I or mode II relay box connector J10, and electrical connector P13
from exciter regulator connector J13. Check
resistance between generator leads T1-T4,
T2-T5, T3-T6, T7-T10, T8-T11, and
T9-T12, using a Kelvin Bridge or other
suitable low resistance measuring device.
Resistance should be 0.00974 ohm ±10 percent for 50/60 hertz generator sets and
0.00490 ohm ±10 percent for 400 hertz
generator sets.
12. Check insulation resistance of
main stator by electrically bonding all
twelve leads (T1 thru T12) together. Connect a lead from the twelve generator leads
to a 500 volt megger and connect other megger lead to frame. Resistance reading
should be a minimum of 50K ohms. Connect
electrical connector P10 to J10 on mode I or
mode II relay box and electrical connector
P13 to J13 on exciter regulator. Install
voltage change over board and plastic shield
over the reconnection board.
7-2
NOTE
Figure 1-28 is the generator assembly simplified schematic.
13. Disconnect end bell and exciter
stator assembly (61, figure 7-1) from generator by removing screws (59) and lock
washer (60). Tag and disconnect six diode
leads from rectifier assembly (12) and test
each diode for an open or short.
14. Tag and disconnect two main
rotor leads from rectifier assembly. Check
resistance between two stator leads using a
Kelvin Bridge or other suitable low resistance measuring device. Resistance should
be 0.834 ohm ±10 percent for 50/60 hertz
generator sets and 0.703 ohms ±10 percent
for 400 hertz generator sets.
15. Check insulation resistance of
main rotor by electrically bonding the two
leads together. Connect leads to a 500 volt
megger and connect other megger lead to
rotor shaft. Resistance reading should be
a minimum of 50K ohms.
16. Tag and disconnect three exciter
rotor leads from rectifier assembly. Check
resistance between exciter rotor leads
R1-R2 and R1-R3, using a Kelvin Bridge or
other suitable low resistance measuring
device. Resistance should be 0.0772 ohm
±10 percent.
17. Check insulation resistance of
exciter rotor by electrically bonding the
three leads together. Connect leads to a
500 volt megger and connect other megger
lead to rotor shaft. Resistance reading
should be a minimum of 50K ohms.
18. Connect main stator, exciter
rotor, and diode leads to rectifier assembly.
Install endbell and exciter stator assembly
(61). Connect electrical connector P61 to
electrical connector J61 on generator endbell. Install generator air inlet louver and
P-9-TM-457-35
TM-07464A-35
T. O. 35C2-3-442-2
TM 5-6115-457-34
Figure 7-1. Generator assembly, exploded view
(sheet 1 of 2)
7-3
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 7-1.
Generator assembly, exploded view
(sheet 2 of 2)
screen assembly and secure with screws,
washers, and nuts. Install generator set
air intake doors and secure with screws,
washers, and nuts.
b. REMOVAL. Remove the generator
as specified in paragraph 2-7.
7-4
7-3. DISASSEMBLY.
Refer to figure 7-1 and disassemble
generator in the order of index numbers
assigned. Pay particular attention to the
following:
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Legend to figure 7-1:
1. Main rotor and shaft
assembly
2. Screw (8)
3. Clip locks 4)
4. Retainer
5. Shaft coupling (3)
6. Fan
7. Snap ring
8. Bearing
9. Nut (5)
10. Lock washer (5)
11. Setscrew
12. Rectifier assembly
13. Diode lead (6)
14. Nut (3)
15. Lock washer (3)
16. Bolt (3)
17. Nut (2)
18. Lock washer (2)
19. Screw (2)
20. Washer (2)
21. Nut (6)
22. Lock washer (6)
23. Diode (6)
24. Rivet (6)
25. Heatsink (2)
26. Rivet (4)
27. Washer (4)
28. Plate
29. Hub
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45,
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
Insulator
Setscrew
Spacer
Exciter rotor assembly
Key
Hub
Key
Main rotor subassembly
Key
Screw (AR*)
Lock washer (AR*)
Balance weight (AR*)
Shaft
Main stator and frame
assembly
Nut (2)
Lock washer (2)
Screw (2)
Screen
Screw (4)
Lock washer (4)
Clip (2)
Screen
Screw (4)
Lock washer (4)
Cover
Screw (4)
Lock washer (4)
Clip (2)
Screen
59. Screw (6)
60. Lock washer (6)
61. End bell and exciter
stator assembly
62. Screw (4)
63. Lock washer (4)
64. Connector
65. Screw (6)
66. Lock washer (6)
67. Washer (6)
68. Exciter stator
assembly
69. End bell
70. Nut (4)
71. Lock washer (4)
72. Washer (4)
73. clamp
74. clamp
75. c lamp
76. Stud
77. Leads (12)
78. Setscrew (2)
79. Pin (2)
80. Main stator assembly
81. Lifting eye bolt (2)
82. Nut (2)
83. Screw (4)
84. Name plate
85. Insulation bushing
86. Main stator frame
(AR*) As Required
a. Before disassembly, insure that
shipping block (refer to figure 2-1) is installed on main stator and frame assembly
(43) and fan (6) is secure to shaft couplings
(5).
WARNING
Insure that generator is properly
blocked to prevent injury to personnel during disassembly.
b. Attach a suitable cable hook and
lifting device to generators lifting eye (81).
Position generator in a vertical position
resting generator end bell and exciter stator assembly (61) on wooden blocks. Position two each twelve inch by twelve inch
wooden blocks under generator mounting
brackets on frame assembly (85) to prevent generator from tipping over. Remove
lifting device.
Change 8
7-5
P-8-627-34
T O 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
c. Remove shipping block. Bend down
corners of clip locks (3) and using a suitable
tool hold shaft couplings (5) and remove two
screws (2) 180 degrees apart. Install lifting fixture (figure 2-1, view I) and secure
with two (0.500-20 x 3.00) screws to main
rotor and shaft assembly (l). Install lifting eyebolt (81) in lifting fixture. Using a
cable hook and lifting device, lift main rotor
and shaft assembly (1) from main stator and
frame assembly (43).
d. Place main rotor and shaft assembly
(1) on a bench resting the main rotor subassembly (37) on cushion material, to prevent damage. Allow fan (6) and shaft
coupling (5) to hang over side of bench.
e. Remove lifting eyes from main rotor
and shaft assembly (l).
f. Remove screws (2), clip locks (3),
retainer (4), shaft couplings (5), and fan (6).
Disconnect fan (6) from shaft couplings (5)
by removing shipping screws and nuts.
CAUTION
Do not remove bearing (8) unless
proven defective at time of inspection or further disassembly
is required.
Remove snap ring (7) and using a
suitable puller, remove bearing (8) from
shaft (42).
g.
h. Tag and disconnect electrical leads
from rectifier assembly (12) by removing
nuts (9) and lock washers (10). Remove
setscrew (11) and remove rectifier assembly (12) from shaft (42).
NOTE
Do not disassembly rectifier assembly unless proven defective at time
of inspection.
7-6
Change 8
Disassembly of rectifier assembly
(12) as follows:
1. Disconnect diode leads (13).
2. Remove diodes (23) from heat
sinks (25).
i.
WARNING
Avoid breathing fumes generated by
unsoldering/soldering. Eye protection is required.
3. Unsolder leads (13) from diodes
(23) using suitable soldering equipment.
4. Remove heat sinks (25) from
plate (28) by removing rivet (24).
5. Separate insulator (30), hub (29),
and plate (28).
j. Remove setscrew (31) and using a
suitable puller, remove spacer (32), exciter
rotor assembly (33), and key (34) from
shaft (42).
CAUTION
Do not remove main rotor subassembly (37) from shaft (42)
unless found defective at
inspection.
k. Using a suitable puller, remove hub
(35) and key (36) from shaft (42).
1. Using a suitable press, press shaft
(42) from main rotor subassembly (37) and
remove key (38).
m. Turn main stator and frame assembly (43) over and position frame assembly
on wooden blocks with end bell on top. Block
assembly to prevent tipping.
n. Remove screens (47, 51, and 58) and
cover (54).
o. Remove end bell and exciter stator
assembly (61).
p. Lift connector (64) from side of end
bell (69), tag and unsolder exciter stator
(68) leads from connector (64). Remove
exciter stator assembly (68) from end bell
assembly.
T O 35C2-3-442-2
P-8-627-34
TM-07464A-35 TM 5-6115-457-34
CAUTION
Remove main stator assembly (80)
only if found defective at time of
inspection.
q. Remove clamps (73, 74, and 75).
WARNING
Drilling operations create metal chips
which may enter the eye. Eye protection is required.
r . Remove two setscrews (78) and using
0.1250 inch drill, drill a hole 0.375 inch
deep in each pin (79). Using an easy out
tool remove pins and remove main stator
assembly (80) from main stator frame (86)
using a suitable puller.
7-4. CLEANING.
WARNING
Compressed air used for cleaning and
drying purposes can create airborne
particles that may enter the eyes.
Pressure shall not exceed 30 psig.
Eye protection is required.
a. Use a clean cloth and low-pressure
compressed air (10-15 pounds pressure)
and remove dust and dirt fro m windings and
frame.
b. Use a clean lint-free cloth moistened
with an approved cleaning solvent to remove
heavy deposits from windings and dry
thoroughly.
c. Clean rectifier assembly with a clean
lint-free cloth moistened with an approved
cleaning solvent and dry thoroughly.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protec t ion required. Good general
ventilation is normally adequate.
d. Clean all metal parts with an
approved cleaning solvent and dry
thoroughly.
Appropriate glass head blasting
may be used toremove paint and
corrosion as necessary. In
accordance with TO 1-1-2.
7-5. INSPECTION.
a. Inspect generator frames for cracks
and burred mating surfaces.
b. Inspect generator frames for cracked
welds and distortion.
c. Inspect shaft couplings for distortion
and elongated holes.
d. Inspect shaft for nicks and scratches.
e. Inspect fan for distortion, elongated
holes, cracked welds or chipped blades.
f. Inspect screens for distortion and
bent corners.
g. Inspect nuts, bolts, and screws for
damaged threads and heads.
h. Rotate bearing and check for freedom of movement, flat spots, binding, and
signs of overheating. Measure bearing
inside diameter, diameter should be
+0. 0000
inches. Measure bearing
2.7559 -0.0008
outside diameter, diameter should be
+0. 0000
inches.
5.9005
-0.0008
i. Measure shaft bearing contact surface, shaft should be 2.7565 to 2.7560 inches.
j . Measure end bell bearing contact,
end bell should be 5.9062 to 5.9055 inches.
NOTE
Generator windings temperature
should be approximately 77° F during resistance checks. Resistance
checks should be made using a
Kelvin Bridge for resistance values
below one ohm, and a Whetstone
Bridge for values above one ohm.
Other suitable low resistance type
measuring devices may be used.
Resistance values of windings are to
be within a tolerance of ± 10 percent.
k. Check main stator resistance values
Change 9
7-7
T O 35C2-3-442-2
P-8-627-34
TM 5-6115-457-34
TM-07464A-35
between leads: T1-T4, T2-T5, T3-T6,
T7-T10, T8-T11, and T9-T12. Resistance
should be 0.00974 ohm for 50/60 hertz
generator sets and 0.00490 ohm for
400 hertz generator sets.
1. Check main rotor resistance value
between leads R4 and R5. Resistance
should be 0.834 ohm for 50/60 hertz
generator sets and 0.750 ohm for 400 hertz
generator sets.
m. Check exciter rotor resistance
values between leads R1-R2 and R1-R3.
Resistance should be 0.0772 ohms.
1. Disconnect diodes from the rectifier assembly and test each diode separately
using a suitable multimeter
2. Connect the multimeter across
the diode, meter positive lead on the anode
(back end of arrow) and negative meter lead
on the cathode (tip of the arrow). A low
resistance should be indicated.
3. Reverse multimeter leads, a
high resistance (several K ohms) should be
indicated,
t. Inspect paint for damage.
7-6. REPAIR OR REBUILD.
n. Check exciter stator resistance
value between leads F1 and F2. Resistance
should be 1.23 ohms for 50/60 hertz generator sets and 1.51 ohms for 400 hertz
generator sets.
NOTE
Generator windings insulation
resistance checks should be made
using a 500 volt megger. Resistance readings should be a minimum of 50K ohms.
o. Check insulation resistance of main
stator windings by electrically bonding all
twelve leads together and connecting a
megger between leads and stator frame.
p.
rotor
leads
tween
Check insulation resistance of main
winding by electrically bonding rotor
together and connect a megger beleads and rotor frame or rotor shaft.
q. Check insulation resistance of exciter
rotor winding by electrically bonding the
three rotor leads together and connecting a
megger between leads and rotor frame or
rotor shaft.
r. Check insulation resistance of exciter
stator winding by electrically bonding statol
leads together and connecting a megger
between leads and stator frame.
s. Inspect rectifier assembly as follows:
7-8
Change 9
Welding operations produce heat,
highly toxic fumes, injurious
radiation, metal slag and airborne particles. Welding goggles, with proper tinted lenses,
apron or jacket and welder’s
boots are required.
a. Repair cracks by welding as long as
it does not distort or empair strength of
part.
b. Remove burrs or nicks using a
suitable file or stone.
c. Straighten dented or distorted sheet
metal parts using suitable tools.
d. Repair or rebuild main stator
assembly as specified in figure 7-2 for
50/60 hertz generators or figure 7-3 for
400 hertz generators.
e. Repair or rebuild main rotor assembly as speciin figure 7-4 for 50/60 hertz generators or figure 7-5
for 400 hertz generators.
NOTE
Apply 6 to 12 VDC to rotor leads.
Pass a compass around the diameter of
the rotor noting which pole of the
compass pointer is attracted to each of
the wound poles. If the windings are
correctly connected, all wound poles
will attract the same compass pole.
fied
f. Repair or rebuild exciter rotor assembly as
specified in figure 7-6 for 50/60 hertz generators or figure 7-7 for 400 hertz generators.
g. Repair or rebuild exciter stator assembly as
specified in figure 7-8 for 50/60 hertz generators or figure 7-9 for 400 hertz generators.
h. Remove damaged paint with a suitable scraper.
Blend in edges, prime, and paint damaged areas.
P-86-27-34
TM-07464A-35
7-7. REASSEMBLY.
Refer to figure 7-1 and reassemble
generator in the reverse sequence of index
T O 35C2-3-442-2
TM 5-6115-457-34
numbers assigned. Pay particular attention to the following.
Change 9
7-8A/(7-8B Blank)
Figure 7-2.
P-9-TM-457-35
TM-07464A-35
T. O. 35C2-3-442-2
TM 5-6115-457-34
7-9
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
NOTES:
1. COIL DATA:
A. WIRE SIZE: . 064 DIA (#14 GA) CLASS 155, TYPE L2.
B. NUMBER OF WIRES PER TURN: 10
c . NUMBER OF TURNS PER COIL: 3
D. NUMBER OF WIRES PER COIL: 30
E. COIL GROUPING: 12 GROUPS OF 6 COILS.
F. COIL SPAN: SLOTS 1 AND 13.
2. STATOR WINDING PROCEDURE:
A. WIND COILS TO PROPER SHAPE, SPECIFIED DIMENSIONS AND NUMBER OF TURNS.
B. HOLD COILS TOGETHER WITH TAPE, INDEX 9.
c . APPLY SLEEVING, INDEX 11, AND INDEX 8, (LOOSE).
D. SELECT AN ARBITRARY SLOT ON CORE, INDEX 1, AND INSERT FIRST COIL GROUP WITH START
LEAD IN THE BOTTOM OF SLOT NO. 1 AND THE ENDING LEAD IN THE TOP OF SLOT NO. 13.
(COIL SPAN 1 AND 13).
E. INSERT THE NEXT COIL GROUP PER ABOVE GROUPING SEQUENCE. INSERT PHASE INSULATION,
INDEX 10, DURING PLACING OF COILS. REPEAT SEQUENCE UNTIL WINDING IS COMPLETE.
F. MAKE PHASE CONNECTION PER CONNECTION DIAGRAM (HOMOGENEOUS WELD).
G. CONNECT LEADS, INDEX 6 AND 7 INDIVIDUALLY AND ISOLATED FROM EACH OTHER WITH
INDEX 8 PER CONNECTION TABLE (HOMOGENEOUS WELD WIRE ENDS).
H. APPLY SLEEVING, INDEX 8, OVER LEAD, INDEX 6 AND 7, CONNECTIONS AND PHASE CONNECTIONS.
J. WRAP WINDING WITH TAPE, INDEX 9.
3. VARNISH AS FOLLOWS:
STEP 1: PREBAKING PUT INTO OVEN AT 110° C(230° F) HOLD AT TEMPERATURE FOR 4 HOURS. COOL TO
APPROXIMATELY 50° C(122° F).
STEP 2: DIPPING IMMERSE IN VARNISH, MIL-1-24092, UNTIL BUBBLING CEASES. VISCOSITY SHALL BE
HELD TO 60 ZAHN SECONDS USING NO. 2 CUP. THIN WITH SOLVENT, MIL-N-15178,
TYPE A/B.
STEP 3. DRAINING DRAIN AND AIR DRY FOR 1 HOUR. ROTATE WOUND APPARATUS TO PREVENT POCKETING
THE VARNISH.
STEP 4: WIPING AFTER DRAINING BUT BEFORE BAKING, THE METAL SURFACES OF THE ARMATURE, THE
BORE OF THE STATOR AND THE POLE FACES OF THE FIELD STRUCTURE SHALL BE
WIPED WITH A CLOTH MOISTENED WITH SOLVENT, MIL-N-15178, TYPE A/B.
STEP 5: BAKING BAKE IN CIRCULATING TYPE, FORCED EXHAUST, BAKING OVEN AT TEMPERATURE OF
165° C(329 F),
STEP 6: COOLING REMOVE FROM OVEN AND COOL TO APPROXIMATELY 50° C(122° F).
STEP 7: SECOND TREATMENT (DIP IN OPPOSITE DIRECTION) - REPEAT STEPS 2 (IMMERSE FOR 1
MINUTE)> 3, 4, 5, AND 6,
STEP 8: THIRD TREATMENT (DIP IN ORIGINAL DIRECTION) - REPEAT STEPS 2 (IMMERSE FOR 1
MINUTE), 3, 4, 3, AND 6.
4. STAMP PART NUMBER AS SHOWN BELOW PER MIL-STD-130, 0.12 MIN HEIGHT, USING WHITE
ENAMEL PAINT.
5. AFTER REWINDING, PERFORM INSPECTION SPECIFIED IN 7-5, STEPS K AND 0.
Figure 7-2.
7-10
50/00 Hertz generator, main stator rewind data (sheet 2 of 2)
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Legend to figure 7-2:
1.
2.
3.
4.
5.
6.
7.
Stator core
Magnet wire 0.064 DIA (#14)
Slot cell insulation (72)
Center spacer 0.032 thick
Wedge (72)
Lead (6)
Lead (6)
NOTE
8.
9.
10.
11.
12.
13.
Insulation sleeving 0.625 ID
Untreated glass tape 0.010 x 0.75
Phase insulation
Insulation sleeving 0.330 ID
Varnish
Insulation slot cell (72)
Table 7-1. Generator Output Lead Lengths
Figure 1-28 is the generator assembly simplified schematic
diagram.
a. Heat main stator frame (86) in a
suitable oven to 200°F for ease of installing main stator assembly (80).
b. Place heated main stator frame
assembly (86) in a vertical position, resting exciter end on wooden blocks.
CAUTION
Exercise care when installing main
stator assembly (80) into main
stator frame (86) to prevent damage
to windings.
c. Position main stator assembly (80)
so that pin (79) holes are aligned with holes
in main stator frame (86). Start leads (77)
through insulation bushing (85). Pull leads
and slide main stator assembly (80) into
main stator frame (86) until pin (79) holes
are aligned.
d. Install pin (79) and setscrew (78)
tighten to 5 foot-pound torque.
e. Cut output leads (77) to lengths
specified in table 7-1. Strip insulation
back 0.62 inches and install terminal lugs
on leads (77).
f. Position clamp (75) on generator
and install generator output leads
in the following sequence starting at
exciter end: T12, T11, TI0, T9, T8, and
T7. Install clamp (74) and install following
output leads starting at exciter end: T6,
T5, T4, T3, T2, and T1. Install clamp
(73) and tighten nuts (70) finger tight.
Change 8
7-11
T O 35C2-3-442-2
TM 5-6115-457-34
P-8-627-34
TM-07464A-35
Figure 7-3. 400 Hertz generator, main stator rewind data
(sheet 1 of 2)
7-12
Change 8
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
NOTES:
1. COIL DATA
A. WIRE SIZE:0.051 DIA (#16 GA) CLASS 155, TYPE L2.
B. NUMBER OF WIRES PER TURN: 20
c . NUMBER OF TURNS PER COIL: 1
D. NUMBER OF. WIRES PER COIL: 20
E. COIL GROUPING: 36 GROUPS OF 2 COILS
36 GROUPS OF 1 COIL
F. COIL SPAN: SLOTS 1 & 4
2. STATOR WINDING PROCEDURE:
A. WIND COILS TO PROPER SHAPE, SPECIFIED DIMENSIONS AND NUMBER OF TURNS.
B. HOLD COILS TOGETHER WITH TAPE, INDEX NO. 9
c . APPLY SLEEVING, INDEX NO. 11 & INDEX NO. 8( LOOSE).
D. SELECT AN ARBITRARY SLOT ON CORE, INDEX NO. 1, AND INSERT FIRST COIL GROUP WITH
START LEAD IN THE BOTTOM OF SLOT NO. 1 AND THE ENDING LEAD IN THE TOP OF SLOT
NO. 4, (COIL SPAN 1 & 4).
E. INSERT THE NEXT COIL GROUP PER ABOVE GROUPING SEQUENCE. INSERT PHASE INSULATION,
INDEX NO. 10, DURING PLACING OF COILS. REPEAT SEQUENCE UNTIL WINDING IS COMPLETE.
F. MAKE PHASE CONNECTION PER CONNECTION DIAGRAM, HOMOGENEOUS WELD.
G. CONNECT LEADS, INDEX NO. 6 TO T1, T2, T3, T7, T8, T9 AND LEADS, INDEX NO. 7 TO T4, T5,
T6, TI0, T11, T12" PER CONNECTION DIAGRAM & TABLE, HOMOGENEOUS WELD.
H. APPLY SLEEVING, INDEX NO. 8 OVER LEAD, INDEX NO. 6 & 7, CONNECTIONS AND PHASE
CONNECTIONS.
J. WRAP WINDING WITH TAPE, INDEX NO. 9.
3. VARNISH DATA SPECIFIED IN FIGURE 7-2 NOTE 3.
4. STAMP PART NUMBER AS SHOWN BELOW PER MIL-STD-130, 0.12 MIN HEIGHT, USING WHITE ENAMEL
PAINT.
30554 ASSY 70-4521
MFG (MFG CODE)
5. AFTER REWINDING, PERFORM INSPECTION SPECIFIED IN PARAGRAPH 7-5. STEPS K AND O.
Figure 7-3. 400 Hertz generator, main stator rewind data
(sheet 2 of 2)
Legend to figure 7-3:
1.
2.
3.
4.
5.
6.
7.
Stator core
Magnet wire 0.051 DIA (#16)
Slot cell insulation (108)
Center spacer 0.032 thick
Wedge (108)
Lead (6)
Lead (6)
8.
9.
10.
11.
12.
13.
Insulation sleeving 0.625 ID
Untreated glass tape 0.010 x 0.75
Phase insulation
Insulation sleeving 0.330 ID
Varnish
Slot cell insulation (108)
7-13
P-9-TM-457-35
TM-07464A-35
7-14
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 7-4.
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
NOTES:
PRESS FIT SHAFT, INDEX 1, INTO CORE, INDEX 2, TO SHOULDER ON SHAFT INDEX 1.
1.
2.
INSULATING:
A. APPLY EPOXY, INDEX 14, TO POLE BOTTOM, POLE SIDES AND POLE ENDS.
B. INSTALL INSULATION, INDEX 5, ON BOTTOM POLE SIDES. INSTALL INSULATION, INDEX 4,
ON TOP POLE SIDES. INSTALL INSULATION, INDEX 6, ON POLE ENDS. INSTALL INSULATION,
INDEX 7, ON POLE SIDES.
3. WINDING:
A. ADJUST WIRE TENSION TO 70 LBS.
B. APPLY SLEEVE, INDEX 13, TO START LEAD OF EACH COIL.
c . WIND THE FIRST LAYER WITH 10 TURNS TO FILL THE WINDING SPACE. FORM THE COIL SIDES
WITH A FIBRE BLOCK TO OBTAIN FLAT AND TIGHT WINDING. DO NOT FORM COIL ENDS. APPLY
EPOXY, INDEX 14.
D. CONTINUE WINDING COMPLETE COIL AS DESCRIBED IN WINDING NOTE 3B, MAKING SURE TO
APPLY EPOXY, INDEX 14, TO COVER ALL TURNS AND TO FILL ALL VOIDS THROUGH THE ENTIRE
WINDING. THIS WILL REQUIRE BRUSHING EPOXY ON ALL LAYERS. FORM COIL SIDES WHILE
WINDING TO PRODUCE FLAT SIDES. WIND EACH COIL WITH 160 TURNS, 10 TURNS PER LAYER,
4 COILS.
E. APPLY SLEEVING, INDEX 13, TO ENDING LEAD OF EACH COIL. SELECT START LEAD 0F
ARBITRARY COIL AND CONNECT COILS IN SERIES, HOMOGENOUS WELD, AND USE PARALLEL
SPLICE, INDEX 16.
F. CONNECT LEADS, INDEX 12, TO REMAINING TWO LEADS, SOLDER
USING SOLDER, INDEX 17.
4.
BAKE COMPLETED ROTOR FOR A MIN. OF 24 HOURS AT 325” F to 35° F.
5. HEAT HUB, INDEX 3, TO 400” F THEN SHRINK FIT ON SHAFT, INDEX 1, TO SHOULDER.
6. STAMP PART NUMBER AS SHOWN BELOW PER MIL-STD-130, 0.12 MIN HEIGT. USING WHITE
ENAMEL PAINT.
30554 ASSY 70-4509
MFG (MFG CODE)
7. AFTER REWINDING, PERFORM INSPECTION SPECIFIED IN PARAGRAPH 7-5, STEPS I AND P.
Figure 7-4.
50/60 Hertz generator, main rotor rewind data
(sheet 2 of 2)
Legend to figure 7-4:
1.
2.
3.
4.
5.
6.
7.
Shaft
Rotor core
Drive hub coupling
Pole insulation (8)
Pole insulation (8)
Pole insulation (8)
Pole insulation (8)
8. Key
9. Key
10. Magnet wire HPT
0.085 X 0.200
11. Pin (16)
12. Lead (2)
Form an appropriate five inch loop in outputs leads between insulation bushing (85)
and clamps. Make sure leads are in
proper position and tighten nuts (70).
WARNING
Avoid breathing fumes generated by
unsoldering/soldering. Eye protection is required.
g. Insert exciter stator assembly (68)
13. Insulation sleeving
0.234 ID
14. Epoxy compound
15. Insulation sleeving
16. Splice (3)
17. Solder
leads in connector (64) opening. Install
exciter stator assembly into end bell (69),
pulling leads through opening as exciter
stator is installed. Cut exciter stator
assembly leads to permit connection to
connector (64), when connector is
approximately one inch from end bell (69).
Strip lead insulation back approximately
0.375 inch and solder lead F1 to connector
pin C and lead F2 to connector pin B.
Install connector (64) with key on top.
Change 8
7-15
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Figure 7-5. 400 Hertz generator, main rot or rewind data
(sheet 1 of 2)
7-16
Change 8
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
NOTES:
1. IF HUB WAS REMOVED, HEAT HUB, INDEX 3, TO 450° F, THEN SHRINK-FIT ON SHAFT, INDEX 1, TO SHOULDER.
2. COIL DATA:
A. WIRE SIZE: 0.040 DIA (#18 GA) CLASS 155, TYPE L2.
B. NO. OF WIRES PER TURN: 16
C. NO. OF TURNS PER COIL: 29
D. COIL GROUPING: 1 GROUP OF 12 COILS.
3. WINDING PROCEDURE:
A. WIND COILS TO PROPER SHAPE, SPECIFIED DIMENSIONS AND NUMBER OF TURNS.
B. HOLD COILS TOGETHER WITH TAPE, INDEX 9.
C. APPLY INSULATION SLEEVING, INDEX 8. AND INDEX 13 (LOOSE).
D. SELECT AN ARBITRARY SLOT ON CORE, INDEX 2, AND INSERT FIRST COIL WITH START LEAD IN THE BOTTOM
OF SLOT NO. 1 AND THE ENDING LEAD IN THE BOTTOM OF SLOT NO. 2.
E. REPEAT SEQUENCE UNTIL WINDING IS COMPLETE.
WARNING
WELDING OPERATIONS PRODUCE HEAT, HIGHLY TOXIC FUMES, INJURIOUS RADIATION, METAL SLAG AND AIRBORN PARTICLES. WELDING GOGGLES, WITH PROPER
TINTED LENSES, APRON OR JACKET AND WELDER’S BOOTS ARE REQUIRED.
F. CONNECT ENDING LEAD OF ARBITRARY COIL TO STARTING LEAD OF ADJACENT COIL. CONTINUE CONNECTING COIL ENDING LEAD TO ADJACENT COIL STARTING LEAD FOR ALL COILS UNTIL ONLY TWO LEADS
REMAIN. HOMOGENEOUS WELD ALL CONNECTIONS.
G. CONNECT LEADS, INDEX 7, TO REMAINING TWO COIL LEADS AND HOMOGENEOUS WELD.
H. WRAP WINDING WITH TAPE, INDEX 9.
J. INSTALL RETAINER. INDEX 10. USING TAPE. INDEX 12.
4. VARNISH AS FOLLOWS:
STEP 1:
PREBAKING PUT INTO OVEN AT 110” C (230° F). HOLD AT TEMPERATURE FOR 4 HOURS. COOL TO APPROXIMATELY
50°c (122° F).
STEP 2:
DIPPING
IMMERSE IN VARNISH. 70-4560, UNTIL BUBBLING CEASES. VISCOSITY SHALL BE HELD 20 ZAHN SECONDS USING A NO. 2 CUP. THIN WITH SOLVENT, MIL-N-15178, TYPE A/B TO MAINTAIN VISCOSITY.
STEP 3:
DRAINING DRAIN AND AIR DRY FOR 1 HOUR. ROTATE WOUND APPARATUS TO PREVENT POCKETING THE
VARNISH.
WIPING
STEP 4.
AFTER DRAINING BUT BEFORE BAKING, THE METAL SURFACES OF THE ARMATURE, THE BORE OF
THE ROTOR AND THE POLE FACES SHALL BE WIPED WITH A CLOTH MOISTENED WITH SOLVENT,
MIL-M-15178. TYPE A/B.
STEP 5:
B A K I N G
PUT INTO A CIRCULATING TYPE, FORCED EXHAUST, BAKING OVEN AT TEMPERATURE OF 80°C (176” F)
FOR 3 HOURS, INCREASE TEMPERATURE TO 165°C (329” F) AND CONTINUE TO BAKE AN ADDITIONAL
7 HOURS.
STEP 6:
COOLING REMOVE FROM OVEN AND COOL TO APPROXIMATELY 50°C (122” F).
STEP 7:
SECOND TREATMENT (DIP IN OPPOSITE DIRECTION) - REPEAT STEPS 2 (IMMERSE FOR 1 MINUTE) 3,4,
5, AND 6.
STEP 8:
THIRD TREATMENT (DIP IN ORIGINAL DIRECTION) - REPEAT STEPS 2 (IMMERSE FOR 1 MINUTE) 3,4,
5. AND 6.
5. STAMP PART NUMBER AS SHOWN BELOW PER MIL-STD-130, 0.12 MIN HEIGHT, USING WHITE ENAMEL PAINT
30554 ASSY 70-4518
MFG (MFG CODE)
6. AFTER REWINDING, PERFORM INSPECTION SPECIFIED IN PARAGRAPH 7-5, STEPS I AND P.
Figure 7-5. 400 Hertz generator, main rotor rewind data
(sheet 2 of 2)
Legend to figure 7-5:
1.
2.
3.
4.
5.
Shaft
Rotor core
Drive hub coupling
Key
Magnet wire
0.40 DIA (#18)
6. Slot cell insulation (24)
7. Lead (2)
8. Insulation sleeving
0.294 ID
9. Untreated glass tape
0.010X0.75
10. Retainer (2)
11. Insulation
wedge (24)
12. Banding tape
13. Insulation sleeving
0.330 ID
14. Varnish
15. Yellow locking
compound GRB
16. Screw
17. Cable clamp (2)
Change 7 7-17
P-9-TM-457-35
TM-07464A-35
7-18
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 7-6.
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
NOTES:
1. COIL DATA:
A. WIRE SIZE: 0.040 DIA (#18 GA) CLASS 155, TYPE L2.
B. NUMBER OF WIRES PER TURN: 6
c . NUMBER OF TURNS PER COIL: 3
D. NUMBER OF WIRES PER COIL: 18
E, COIL GROUPING: 18 GROUPS OF 2 COILS.
F. COIL SPAN: SLOTS 1 & 6.
2. ROTOR WINDING PROCEDURE :
A. WIND COILS TO PROPER SHAPE, SPECIFIED DIMENSIONS AND NUMBER OF TURNS.
B. HOLD COILS TOGETHER WITH TAPE, INDEX 6.
C. APPLY SLEEVING,INDEX NO. 14 & INDEX 10 (LOOSE).
D. SELECT AN ARBITRARY SLOT ON CORE, INDEX 1, AND INSERT FIRST COIL GROUP WITH START
LEAD IN THE BOTTOM OF SLOT NO. 1 AND THE ENDING LEAD IN THE TOP OF SLOT NO. 6.
(COIL SPAN 1 & 6).
E. INSERT THE NEXT COIL GROUP PER ABOVE GROUPING SEQUENCE . INSERT PHASE INSULATION,
INDEX 15, DURING PLACING OF COILS. REPEAT SEQUENCE UNTIL WINDING IS COMPLETE.
F. MAKE PHASE CONNECTION AND CONNECT LEADS, INDEX 3 PER CONNECTION DIAGRAM, (HOMOGENEOUS WELD) .
G. APPLY SLEEVING, INDEX 10, OVER LEAD, INDEX 3 CONNECTIONS AND PHASE CONNECTION.
H. WRAP WINDING WITH TAPE, INDEX 6.
J. VARNISH, REFER TO FIGURE 7-5 NOTE 4.
3. CUT LEADS, INDEX 3, AND INSTALL TERMINALS, INDEX 4, & WIRE MARKERS, INDEX 11, 12, & 13,
TO DIMENSIONS SHOWN. CRIMPING OF TERMINALS TO MEET THE REQUIREMENTS & TESTS OF
MIL-T-7928. HEAT WIRE MARKERS, INDEX 11, 12 &13 TO 20°C FOR 5 SECONDS.
4. STAMP PART NUMBER AS SHOWN BELOW PER MIL-STD-130, 0.12 MIN HEIGHT, USING WHITE ENAMEL
PAINT.
30554 ASSY 70-4511
MFG (ADD MFG CODE)
5. AFTER REWINDING, PREFORM INSPECTION SPECIFIED IN PARAGRAPH 7-5, STEPS M AND Q.
Figure 7-6. 50/60 Hertz generator, exciter rotor rewind data
(sheet 2 of 2)
Legend to figure 7-6:
1.
2.
3.
4.
5.
6.
7.
8.
Rotor core
Insulation (2)
Lead (3)
Terminal lug (3)
Magnet wire 0.040 DIA (#18)
Untreated glass tape 0.010 x 0.75
Slot cell insulation (36)
Center spacer 0.032 THK
h. Install end bell and exciter stator
assembly (61 ) on main stator and frame
assembly (43) with connector (64)
positioned at three o’clock looking from
rear of generator.
i. Install key (38) on shaft (42) and
using a suitable press, press shaft (42) into
9.
10.
11.
12.
13.
14.
15.
16.
Wedge (36)
Insulation sleeving 0.330 ID
Wire marker
Wire marker
Wire marker
Insulation sleeving 0.06 ID
Phase insulation
Varnish
main rotor subassembly (37) until main
rotor subassembly (37) is against shoulder
on shaft (42).
j. Install key (36) on shaft (42). Heat
hub (35) in a suitable oven to 450°F and
install hub (35) on shaft (42) until it bottoms
on shaft shoulder.
7-19
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
NOTES:
1. COIL DATA:
A. WIRE SIZE: 0.040 DIA (#18 GA), CLASS 155, TYPE L2.
B. NUMBER OF WIRES PER TURN: 6
c. NUMBER OF TURNS PER COIL: 3
D. NUMBER OF WIRES PER COIL: 18
E. COIL GROUPING: 18 GROUPS OF 2 COILS
F. COIL SPAN: SPAN 1 AND 6.
2. ROTOR WINDING PROCEDURE :
A. WIND COILS TO PROPER SHAPE, SPECIFIED DIMENSIONS AND NUMBER OF TURNS.
B. HOLD COILS TOGETHER WITH TAPE, INDEX 6.
C. APPLY INSULATION SLEEVING. INDEX 14 AND 10 (LOOSE}.
D. SELECT AN ARBITRARY SLOT ON CORE, INDEX 1, AND INSERT FIRST COIL GROUP WITH
START LEAD IN THE BOTTOM OF SLOT NO. 1 AND ‘hi E ENDING LEAD IN THE TOP OF SLOT
NO. 6 (COIL SPAN 1 AND 6).
E. INSERT THE NEXT COIL GROUP PER GROUPING SEQUENCE. INSERT PHASE INSULATION,
INDEX 15, DURING PLACING OF COILS. REPEAT SEQUENCE UNTIL WINDING IS COMPLETE.
F. MAKE PHASE CONNECTION AND CONNECT LEADS, INDEX 3, PER CONNECTION DIAGRAM,
(HOMOGENEOUS WELD).
APPLY SLEEVING, INDEX 10, OVER LEADS, INDEX 3, CONNECTIONS AND PHASE CONNECTION.
H. WRAP WINDING WITH TAPE, INDEX 6.
J. VARNISH. REFER TO FIGURE 7-5 NOTE 4.
3. CUT LEADS, INDEX 3, AND INSTALL TERMINALS, INDEX 4, AND WIRE MARKERS, INDEX 11, 12,
AND 13, TO DIMENSIONS SHOWN. CRIMPING OF TERMINALS TO MEET THE REQUIREMENTS AND
TESTS OF MIL-T-7928. HEAT WIRE MARKERS, INDEX 11, 12, AND 13, TO 200’ F FOR 5 SECONDS.
4. STAMP PART NUMBER AS SHOWN BELOW PER MIL-STD-130, 0.12 MIN HEIGHT, USING WHITE
ENAMEL PAINT
30554 ASSY 70-4519
MFG (MFG CODE)
5. AFTER REWINDING, PERFORM INSPECTION SPECIFIED IN PARAGRAPH 7-5, STEPS M AND Q,
Figure 7-7. 400 Hertz generator, exciter rotor rewind data
7-20
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Legend to figure 7-7:
1.
2.
3.
4.
5.
6.
Rotor core
Insulation (2)
Lead (3)
Terminal lug (3)
Magnet wire 0.040 DIA (#18)
Untreated glass tape
0.010 x 0.75
7. Slot cell insulation
8. Center spacer
0.032 thick
9. Wedge (36)
10. Insulation sleeving
0.330 ID
11. Wire marker
k. Install key (34) and exciter
rotor assembly (33) on shaft (42). Using
a suitable press, press spacer (32) into
place.
1. Assemble rectifier assembly (12)
and position on shaft (42). Align setscrew
(11) hole with hole in shaft (42).
m. Install setscrew (11 and 31) and
tighten to 20 foot-pounds torque.
WARNING
Varnish, Insulating, is flammable and
extremely toxic. Avoid eye and skin
contact or breathing of vapors. Good
general ventilation is normally adequate.
n. Apply insulation sleeving to main
rotor subassembly (37) leads R4 and R5.
Position lead R5 at three o’clock and lead
R4 at nine o’clock on shaft (42) looking from
bearing end of shaft. Tape leads to shaft at
two evenly spaced positions between the
main rotor subassembly (37) and exciter
rotor assembly (33). Brush coat tape with
varnish. Position leads R4 and R5 through
two holes provided in exciter rotor assembly (33) and insulator (30). Cut leads long
enough to connect a rectifier assembly (12).
Strip lead insulation back 0.375 inch and
install terminal lugs on leads. Connect
leads R4 and R5 to rectifier assembly.
o. Position leads Rl, R2, and R3 from
exciter rotor assembly (33) through insulator (30) holes and cut leads long enough to
connect to rectifier assembly (12). Strip
12. Wire marker
13. Wire marker
14. Insulation sleeving
O. 106 ID
15. Phase insulation
16. Varnish
lead insulation back 0.375 inch and install
terminal lugs and connect leads R1, R2, and
R3 to rectifier assembly (12).
p. Using a suitable press, press bearing (8) against shoulder on shaft (42). Install snap ring (7) on shaft (42).
q. Place assembled shaft in a suitable
dynamic balancing machine. Balance
assembled shaft in two planes. Rotate
shaft at 600 to 800 RPM and balance shaft
on 50/60 hertz generators to 3.5 inch-ounce
and on 400 hertz generators to 10 inch-ounce
using blance weights (41). To install balance weight, place weight in proper position
on rotor and transfer two drill 0.2570 inch
holes, one inch deep for each weight. Tap
hole for 5/16 - 18 UNC - 2B thread.
Secure weights with screws (39) and lock
washer (40). Trim balance to 0.5 inchounce by removing metal from steel core of
main rotor subassembly (37).
r . Place rotor and shaft assembly (1) on
a bench resting main rotor subassembly (37)
on a cushion material to prevent damage.
Allow hub (35) to hang over side of bench.
NOTE
Securing fan to shaft couplings is
only to protect fan from damage
and for ease of handling.
s. Position fan (6) on shaft couplings (5)
and secure fan to shaft couplings with two
suitable screws and nuts 180 degrees apart.
Install fan (6), shaft couplings (5), retainer
Change 8
7-21
T O 35C2-3-442-2
TM 5-6115-457-34
P-8-627-34
TM-07464A-35
NOTES:
1. COIL DATA:
A. WIRE SIZE: 0.057 DIA (#15GA), CLASS 155, TYPE L2.
B. NUMBER OF POLES: 6
c . NUMBER OF TURNS PER COIL: 85
2. STATOR WINDING PROCEDURE:
A. INSULATE STATOR CORE, INDEX 1, COMPLETE USING INSULATION PLATE, INDEX 3, AND
SLOT CELL INSULATION, INDEX 4 AND INDEX 9.
B. WIND STATOR COMPLETE, 6 COILS CONNECTED IN SERIES.
c . CONNECT LEADS, INDEX 5, TO COILS, SEE DETAIL A, HOMOGENEOUS WELD.
D. APPLY SLEEVING, INDEX 6.
E. TIE LEADS AND ENDLOOPS WITH TAPE, INDEX 7.
3. VARNISH, REFER TO FIGURE 7-2 NOTE 3.
4. STAMP PART NUMBER AS SHOWN BELOW PER MIL-STD-130, 0.12 MIN HEIGHT, USING WHITE
ENAMEL PAINT
30554 ASSY 70-4514
MFG (MFG CODE)
5. AFTER REWINDING, PERFORM INSPECTION SPECIFIED IN PARAGRAPH 7-5, STEPS N AND R.
Figure 7-8. 50/60 Hertz generator, exciter stator rewind data
Legend to figure 7-8:
1. Stator core
2. Magnet wire
0.057 DIA (#15)
3. Insulation plate (6)
7-22
Change 8
4. Slot cell insulation (6)
5. Lead (2)
6. Insulation sleeving
0.330 ID
7. Untreated glass tape
0.010X0.75
8. Varnish
9. Slot cell insulation (6)
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
NOTES:
1. COIL DATA:
A. WIRE SIZE:0.057DIA (#15GA), CLASS 155, TYPE L2.
B. NUMBER OF POLES: 6
C. NUMBER OF TURNS PER COIL: 85
2. STATOR WINDING PROCEDURE:
A. INSULATE STATOR CORE, INDEX 1, COMPLETE USING INSULATION PLATE, INDEX 3 AND
SLOT CELL INSULATION INDEX 4 AND INDEX 9.
B. WIND STATOR COMPLETE, 6 COILS CONNECTED IN SERIES.
c . CONNECT LEADS, INDEX 5, TO COILS, SEE DETAIL A, HOMOGENEOUS WELD.
D. APPLY SLEEVING. INDEX 6.
E. TIE LEADS AND ENDLOOPS WITH TAPE, INDEX 7.
3. VARNISH, REFER TO FIGURE 7-2 NOTE 3.
4. STAMP PART NUMBER AS SHOWN BELOW PER MIL-STD-130, 0.12 MIN HEIGHT, USING
WHITE ENAMEL PAINT
30554 ASSY 70-4522
MFG (MFG CODE)
5. AFTER REWINDING, PERFORM INSPECTION SPECIFIED IN PARAGRAPH 7-5, STEPS N AND R.
Figure 7-9. 400 Hertz generator , exciter stator rewind data
Legend to figure 7-9:
1. Stator core
2. Magnet wire
0.057 DIA (#15)
3. Insulation plate (6)
4. Slot cell insulation (6)
5. Lead (2)
6. Insulation sleeving
7. Untreated glass tape
0.010 x 0.75
8. Varnish
9. Slot cell insulation (6)
7-23
P-9-TM-457-35 T. O. 35C2-3-442-2
TM-07464A-35
TM 5-6115-457-34
(4), and clip locks (3) on shaft (42)
and secure with screws (2), leaving two
screws (2) 180 degrees apart out. Tighten
screws to 50 foot-pounds torque. Insert
two suitable lifting eyebolts into shaft hub.
t. Using a suitable lifting device and
cable hook, position main stator and frame
assembly (43) in a vertical position resting
the end bell (67) on wooden blocks. Place
blocks under the generator mounting plates
(84) to prevent generator from tipping over.
CAUTION
This test is applicable to new or
rewound components only.
a. Isolate the generator and exciter
armature and field windings from all
external circuits including rotating rectifiers. Be sure generator frame and test
apparatus are properly grounded to an
external ground (in addition to unit frame).
Connect one end of each armature winding
together to form a single circuit for testing.
CAUTION
Exercise extreme care when installing main rotor and shaft assembly
into main stator and frame assembly to prevent damage to windings.
u. Connect suitable lifting device to
lifting eyebolts in main rotor and shaft
assembly (1) into main stator and frame
assembly (43). Remove lifting device and
lifting eyebolts. Install two remaining
screws (2) and tighten screws to 50 footpounds torque. Bend up all corners of clip
locks (3) to prevent screws from turning.
v. Connect a suitable block across
engine mounting end of generator to hold
main rotor and shaft assembly in center
position and to prevent assembly from
sliding out of frame when moving generator.
w. Lower generator to horizontal position. Place tag on generator stating fan is
mounted to shaft coupling with shipping
screws and nuts only. Remove screws and
nuts prior to installation.
7-8.
HIGH POTENTIAL TEST.
Perform the high potential test as
follows:
7-24
CAUTION
Ground generator and exciter field
windings securely when testing
generator armature windings.
b. Connect the high voltage lead from
the test apparatus to the generator armature winding. Bring the voltage up to
1480 volts in not less than 10 seconds nor
more than 30 seconds. Apply this voltage
for one minute then gradually reduce to
zero in not less than 5 seconds. Ground
high voltage lead before removing to discharge winding.
CAUTION
Ground generator armature and
exciter windings securely when
testing generator field windings,
Ground generator field and generator armature windings securely
when testing exciter windings.
c. Repeat step b. for the generator field
and exciter windings, except that the maximum voltage shall be between 1500 to
3500 volts.
d. Electrical windings shall be able to
withstand the following 60 hertz voltages
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
applied for one minute between the windings 7-9. INSTALLATION.
and ground.
Generator armature windings -1480 volts
Generator field and exciter windings 1500 to 3500 Volta
Install the generator as specified
in paragraph 2-7.
Change 1
7-25/(7-26 blank)
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
CHAPTER 8
ENGINE GROUP REPAIR INSTRUCTIONS
Section I. ENGINE COMPONENTS
8-1.
7.
GENERAL.
The engine is a six cylinder, 4 cycle,
turbo charged, overhead valve diesel. Components covered in this chapter, in addition
to the basic engine, are those which are
mounted on the engine block.
Lubricating oil filters
8. Secondary fuel filter and relief
valve
9. Breather assembly
10. Hydraulic filter (precise sets
8-2.
REMOVAL.
Refer to paragraph 2-8 and remove
the engine group.
8-3.
DISASSEMBLY.
a. Tag and remove all hydraulic and
fuel lines from engine. Cap lines and plug
all openings.
b. Refer to Operator and Organizational
Maintenance Manual and remove the following.
only)
11. Atomizer tube, atomizer and
bushing.
c. Remove oil pan shutoff cock.
d. Remove four screws and lockwashers
securing two flywheel housing supports.
e. Remove components and disassemble
engine as specified in subsequent sections
of this chapter.
8-4.
REASSEMBLY.
1. Alternator and fan drive belts
2. Alternator assembly
a. Replace components and reassemble
engine as specified in subsequent sections
of this chapter.
3. Fuel day tank
4. Manual speed controls
5. Fuel filter and pump assembly,
threaded spacers and adapter.
6. Starter motor
b. Install two flywheel housing supports and secure with four screws and
lockwashers.
c. Install oil pan shutoff cock.
d. Refer to Operator and Organizational
Maintenance Manual and install the following.
Change 8
8-1
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
1. Atomizer tube, atomizer and
bushing.
10. Alternator assembly.
11. Alternator and fan drive belts.
2.
Hydraulic filter (precise sets
only).
e. Connect all hydraulic and fuel lines
to engine.
3. Breather assembly.
4. Secondary fuel filter and relief
valve.
5,
Lubricating oil filters.
f. Refer to Operator and Organizational
Maintenance Manual and adjust fan and
alternator belts, valve lash, and utility
governor linkage. Service the engine and
components.
8-5.
6. Starter motor.
INSTALLATION.
NOTE
7. Fuel filter and pump assembly,
threaded spacers and adapter.
If a complete overhaul or any major
repair has been performed on the
engine, refer to Section XXXI for
engine test after overhaul.
8. Manual speed controls.
Refer to paragraph 2-8 and install
the engine group.
9. Fuel day tank
Section II. ENGINE HARNESS GROUP
8-6.
GENERAL.
The engine wiring harness provides
for electrical interconnection between the
engine accessories and mode I or mode II
relay box. The harness is connected to
connector J5 of the mode I or mode H relay
box (A27), J14 of high coolant temperature
switch, J33 of day tank float switch, J35 of
air cleaner indicator switch, J36 of day tank
solenoid valve, J37 of speed switch, J38 of
ether starting aid primer, J39 of DC control circuit breaker, J42 of low oil pressure
switch, J43 of alternator, two oil pressure transmitters, collant temperature
transmitter, fuel level transmitter, fuel
transfer pumps, engine shutdown solenoid
valve, starter, and starter solenoid.
Maintenance Manual and remove the engine
wiring harness.
8-8.
a. Clean wires with a clean lint free
cloth.
WARNING
Compressed air used for cleaning and
drying purposes can create airborne
particles that may enter the eyes.
Pressure shall not exceed 30 psig.
Eye protection is required.
b. Remove dirt from connector pins
using low pressure compressed air.
8-9.
8-7.
INSPECTION.
REMOVAL.
Refer to Operator and Organizational
8-2
CLEANING.
Change 8
a. Inspect wiring for defective insulation, continuity, and proper connection.
P-9-TM-457-35
TM-07464A-35
b. Inspect electrical connectors for
damaged threads; bent, loose, or missing
pins; and for shorts to case and surrounding pins.
8-10.
T. O. 35C2-3-442-2
TM 5-6115-457-34
REBUILD.
Refer to figure 8-1 and rebuild
engine wiring harness.
c. Inspect terminal lugs for security
and condition.
8-11.
d. Check each wire for continuity,
refer to figure 8-1.
Refer to Operator and Organizational
Maintenance Manual and install the engine
wire harness.
INSTALLATION.
8-3
P-9-TM-457-35
TM-07464A-35
8-4
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 8-1.
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Figure 8-1. Engine wire harness (sheet 2 of 2)
Change 8
8-5
T O 35C2-3-442-2
P-8-627-34
TM-07464A-35 TM 5-6115-457-34
Section III. ALTERNATOR
8-12.
CAUTION
GENERAL.
The alternator is a 24 volt, negative
ground system incorporating a voltage regulator and voltage protector. It is driven by
the fan pulley via the alternator drive belt.
The alternator provides power for charging
the batteries and operation of direct current
components of the generator set.
8-13.
REMOVAL.
Refer to Operator and Organizational
Maintenance Manual, and remove the
alternator.
8-14.
DISASSEMBLY.
Refer to figure 8-2, and disassemble
alternator in the order of index numbers
assigned. Pay particular attention to the
following:
NOTE
Tag electrical leads before removing to facilitate reassembly.
CAUTION
To prevent damage to stator windings or laminations, do not insert
sharp tools between stator and
housing.
a. When removing front and rear bearings (47 and 49) from rotor assembly shaft
(42), make sure puller contacts inner
bearing race only.
NOTE
Remove retaining ring in front
housing. Refer to figure 8-2
view A and B.
8-6
Change 8
To prevent overheating and possible
damage to rectifier diodes (37 and
38) when unsoldering, grasp diode
connection terminal with long nose
pliers, between soldering iron and
diode.
b. To prevent rotor shaft assembly (51)
from turning when removing nut (40), wrap
an oversize belt around pulley. Clamp
pulley in vise while removing rotor shaft
from pulley.
8-15.
CLEANING.
CAUTION
Do not immerse alternator assembly in cleaning solvent of any kind.
Do not clean isolation diodes (22)
with cleaning solvent. The diodes
are coated with a special corrosion
resistant paint.
WARNING
Dry cleaning solvent, P-D-680,
Type II, is flammable and moderately toxic to the skin, eyes
and respiratory tract. Skin,
eye and respiratory protection
is required.
a . Clean parts with a soft bristle
brush moistened with cleaning solvent,
Federal Specification P-D-680, Type 11.
WARNING
Compressed air used for cleaning and
drying purposes can create airborne
particles that may enter the eyes.
Pressure shall not exceed 30 psig.
Eye protection is required.
b. Dry parts with filtered low pressure
compressed air or a clean lint-free
cloth .
P-9-TM-457-35
TM-07464A-35
8-16.
INSPECTION.
a. Inspect brush assembly (29, figure
8-2) for excessive wear, replace brush
assembly if 3/16 of an inch or less extends
beyond bottom of holder.
b. Check brush assembly (29) spring
tension with suitable spring scale. Spring
tension should be 4 to 6 ounces.
c. Test rectifier diodes (37 and 38) in
heat sinks connecting one of multimeter
leads to the heat sink and the other multimeter lead to the diode stem, and note the
reading. Then reverse the multimeter lead
connections, and note the reading. If both
readings are very low, of if both readings
are very high, the diode is defective. A
good diode will give one low reading and one
high reading.
d. Test isolation diode assembly (22)
by connecting one of the multimeter test
leads to the output terminal stud of the
diode, the other to the exposed metal area
on heat sink, and note reading. Then reverse the lead connections and note the
reading. If both readings are very low, or
if both readings are very high, the diode is
defective. A good diode will give one low
reading and one high reading.
e. Test stator assembly (39) for grounds
and opens as follows:
T.O. 35C2-3-442-2
TM 5-6115-457-34
1. Connect the multimeter to two
pairs of stator leads. Use a multimeter
and set to the lowest range scale on the
multimeter. If either reading is very high
(infinite) the stator winding is open.
2. To test the stator for grounds,
connect the multimeter from any stator lead
to the ground screw or the shell, and note
the reading. Then reverse the multimeter
lead connections, and note the reading. If
both readings are very low, the stator is
grounded.
f. Test rotor assembly (51) or grounded
slip ring, using a multimeter. No circuit
from either slip ring to shaft is correct
condition.
g. Perform resistance check on rotor
assembly (51) windings using a multimeter.
Resistance should be between 11 to 14 ohms.
h. Test voltage regulator (25) by connecting multimeter leads to regulator leads
as follows: (See figure 8-3).
1. Multimeter lead (+) to regulator
lead yellow, multimeter lead (-) to regulator lead red. Multimeter should indicate
300 to 350 ohms.
2. Multimeter lead (+) to regulator
lead red, multimeter lead (-) to regulator
lead yellow, multimeter should indicate
open circuit.
NOTE
These tests may be made with the
stator leads disconnected from the
diodes, or with the stator leads connected to the diodes provided all the
diodes are in good condition. Scrape
enough insulation from the leads to
insure good contact with the test
prods.
3. If above readings are not obtained,
replace regulator.
i. Inspect fan (43) for cracked or broken
fins. Check fan bore for wear.
j . Inspect pulley (42) for worn drive
surfaces and condition of key groove. Check
pulley bore for wear.
8-7
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 8-2. Alternator assembly, exploded view (sheet 1 of 2)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Cap
Fuse (40 amp)
Screw (5)
Nut
Washer
Connector (red)
Connector (yellow)
Nut (2)
Washer (2)
Connector (black)
Connector (black)
Nut
Receptacle
Gasket
Cover and connector
assembly
16. Circuit protector
17. Screw (8)
18. Housing shield
assembly
8-8
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
Nut (2)
Washer (2)
Sleeve (2)
Isolation diode
assembly
Screw (3)
Voltage
adjust
rheostat
Voltage regulator
Cable
Screw (2)
Cover
Brush assembly
Nut (4)
Bolt (4)
Nut (4)
Washer (8)
Rear housing
Sleeve (4)
36. Washer (4)
37. Rectifier diode
assembly
(positive)
Rectifier
diode
38.
assembly
(negative)
39. Stator assembly
40. Nut
41. Lock washer
42. Pulley
43. Fan
44. Key
45. Spacer
46. Retaining ring
47. Rear bearing
48. Retaining ring
49. Front bearing
50. Front bearing
51. Rotor assembly
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 8-2. Alternator assembly, exploded view (sheet 2 of 2)
k. Inspect front bearing cavity for
evidence of wear. Check condition of retainer recess.
8-17. REPAIR.
CAUTION
1. Check slip rings for pitting, roughness or burned spots. If surface is worn
beyond repair, replace entire rotor
assembly (42).
m. Inspect rotor shaft for key slot
wear, worn bearing surfaces, scuff marks
on pole fingers, and condition of threads on
pulley nut.
n. Inspect bearings (47 and 49) for
scored, pitted, scratched, cracked or
chipped races.
Do not attempt to turn slip ring
in a lathe.
a. Slip rings may be cleaned up by
cleaning contacting surfaces with a fine
crocus cloth. Carefully wipe dust and
residue away after cleaning.
b. Repair minor thread damage on
rotor shaft using a suitable thread chaser.
8-9
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
c. Spin rotor by hand and check freedom
of rotation.
d. Tighten pulley nut (40) from 35 to
50 foot pounds torque.
8-19.
TEST AND ADJUSTMENT.
a. Voltage Regulator Setting Test.
1. Equipment required
(a) Variable speed drive (2000
to 3000 RPM).
Figure 8-3. Voltage regulator
excitation circuit test
(b) Resistor (1/4 ohm 500 watt).
(c) DC voltmeter (0 to 50 volt
scale).
8-18.
REASSEMBLY.
(d) Two 12 volt batteries.
Refer to figure 8-2 and reassemble
alternator in the reverse order of index
numbers assigned. Pay particular attention to the following:
NOTE
Refer to schematic wiring diagram
figure 8-4 when connecting electrical
leads.
(e) Jumper 12 inches long, No.
8 wire with two alligator clips.
(f) Mating plug for alternator
receptacle, to be wired as shown in figure
8-4.
2. Connect circuit as shown in figure 8-5.
CAUTION
CAUTION
To prevent overheating and possible
damage to rectifier (37 and 38) diodes
when soldering, grasp diode connection terminal with long nose pliers
between soldering iron and diode.
Alternator must be driven in direction of arrow on rear cover (15, figure 8-2).
a. When installing rear and front bearings (47 and 49) on shaft, use hollow sleeve
the same diameter of inner races and press
bearings on rotor assembly shaft (51). Install
front bearing retainer (48, VIEW c).
b. Tighten through bolts (31) evenly.
8-10
3. Connect alternator to variable
speed drive by means of a suitable belt and
pulley combination.
4. Run alternator up to a speed between 2000 to 3000 RPM. Connect jumper
wire across 1/4 ohm resistor. Run alternator under these conditions for a warm up
period of at least 10 minutes.
P-9-TM-457-35
T.O. 35C2-3-442-2
TM -07464A-35 TM 5-6115-457-34
5. Remove jumper from across 1/4
ohm resistor and record voltage reading.
Nominal voltage should be 28 ± 3 volts at
75 °F ambient. If nominal voltage is not indicated, adjust voltage adjust rheostat
(19, figure 8-2) on voltage regulator, which
is accessible through rear cover (8) of
alternator, Increase voltage by rotating in
a clockwise direction.
(b) Ammeter (0 to 50 ampere
scale).
(c) Jumper lead and 1/4 ohm
resistor not used in this test.
2. Connect circuit as shown in figure 8-6.
CAUTION
6. If nominal voltage can not be
obtained, shut down alternator test. Replace voltage regulator and repeat test.
Alternator must be driven in direction of arrow (shown on rear cover
15, figure 8-2).
b. Alternator Output Test.
1. Equipment required in addition
to equipment listed in step a.
(a) Carbon pile (0 to 600 ampere
load capacity).
NOTE
Make sure drive belt has a midway
deflection of 9/16 to 13/16 of an
inch.
Figure 8-4. Alternator schematic and wiring diagram (sheet 1 of 2)
8-11
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
NOTE :
1. THESE TWO LEADS MAYBE CONNECTED
TO ANY DIODE ON A RECTIFIER ASSEMBLY
PROVIDING ONE DIODE IS ON THE POSITIVE
HEATSINK AND THE OTHER DIODE IS ON THE
NEGATIVE HEATSINK. THE SAME APPLIES TO
THE OTHER TWO SETS OF LEADS.
2. POSITIVE RECTIFIER ASSEMBLY CAN BE
IDENTIFIED BY RED LETTERING ON UNDERSIDE
OF THE THREE DIODES.
Figure 8-4. Alternator schematic and wiring diagram (sheet 2 of 2)
8-12
P-8-627-34
TM-07464A-35
Figure 8-5. Voltage regulator
setting test
3. Run alternator up to a speed of
approximately 1500 RPM. Adjust carbon
pile by slowly applying load across battery
until test ammeter indicates a 10 ampere
charging current. Allow alternator to run
at this speed for at least 5 minutes to stabilize component temperatures.
4. Increase variable drive speed to
2500 RPM. Increase carbon pile load on
battery causing alternator to deliver its
maximum current capacity indicated on test
ammeter.
Figure 8-6. Alternator output test
6. Shut down alternator and disconnect carbon pile from across batteries immediately to prevent discharging batteries.
7. Nominal output current should be
20 to 25 amperes at 75° F ambient. This
current output of 20 to 25 amperes should be
obtained with test voltmeter indicating 26 to
30 volts.
8. If nominal current of 20 to 25
amperes can not be obtained, check drive
belt for proper tension. If drive belt has a
midway deflection of 9/16 to 13/16 of an
inch, then disassemble alternator and inspect (para 8-16).
8-20.
5. Record maximum current obtained. Record voltmeter reading at maximum current condition.
T.O. 35C2-3-442-2
TM 5-6115-457-34
INSTALLATION
Refer to Operator and Organizational
Maintenance Manual, and install the
alternator.
Change 8 8-13
P-8-627-34
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Section IV. STARTING MOTOR
8-21. GENERAL.
The starting motor is mounted to the
flywheel housing. It consists of a frame
and field assembly, armature head assembly, intermediate housing assembly, brush
assembly starter drive, pinion housing
assembly, and a solenoid switch. The
starting motor is a heavy-duty type that is
completely sealed with gaskets, preformed
packings and an oil seal. The solenoid is
mounted on the outside of the frame with the
solenoid plunger and pinion engagement
mechanism totally enclosed. The starting
motor converts electric al energy from the
batteries into mechanical energy to turn the
engine over for starting.
8-22. REMOVAL.
Refer to Operator and Organizational
Maintenance Manual, and remove the starting motor.
8-23. DISASSEMBLY.
Refer to figure 8-7 and disassemble
starting motor in the order of index numbers
assigned. Pay particular attention to the
following:
a. B efore separating the intermediate
housing (34) and pinion housing (2), scribe
or center punch locating marks to insure
proper reassembly.
b. Bearings (3, 36, and 49) are press
fitted.
c. Scribe or center punch locating mark
before separating head assembly (48) and
frame on field assembly (53).
8-14 Change 8
8-24. CLEANING .
CAUTION
To prevent damage to brushes, do
not allow dry cleaning solvent to come
in contact with brushes.
a. Clean brushes with a clean, dry
cloth only.
b. Clean electrical components with a
clean lint free cloth moistened with an
approved cleaning solvent and dry thoroughly.
c. Clean metal parts with a clean cloth
moistened with an approved cleaning solvent
and dry thoroughly.
WARNING
Compressed air used for cleaning and
drying purposes can create airborne
particles that may enter the eyes.
Pressure shall not exceed 30 psig.
Eye protection is required.
CAUTION
Do not use emery cloth to clean
commutator.
d. Remove loose particles from armature with compressed air and wipe with a
clean lint free cloth moistened with dry
cleaning solvent. Clean commutator lightly
with No. 00 sandpaper and remove all traces
of dust using low-pressure compressed air.
8-25.
INSPECTION.
a. Refer to table 1-1 and inspect parts
for dimensional tolerances.
b. Inspect housings and commutator end
head, pinion teeth and splines for scratches,
burrs, nicks and cracks.
c. Inspect bearings for discoloration,
rough spots, score marks, scratches and
nicks.
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
NOTE
d. Inspect threaded parts for thread
damage.
e. Inspect commutator on armature
(40, figure 8-7) for rough spots, discoloration, pitting, scoring, and high mica.
f. Inspect armature shaft (40) for pitting, scoring, or excessive wear. Inspect
starter drive (27) for broken teeth on pinion.
Check to see that starter drive (27) clutch
assembly moves on armature shaft (40) to
see if splines fit properly.
g. Inspect solenoid switch (19) parts.
Check condition of moving core and sealing
boot. Check connector (17) and terminal
studs to see if they are burned, eroded, or
pitted excessively.
Armature must be replaced if commutator diameter is not within
limits specified in table 1-1 after
repair.
e. Repair commutator on armature
(40, figure 8-7) by turning it down using a
suitable lathe. Take light cuts until all defects are removed. Remove all burrs by
holding No. 00 sandpaper lightly against
commutator. Undercut mica to a depth of
1/32 of an inch using a suitable mica undercutter.
f. Replace parts that are not within dimensional tolerances specified in table 1-1.
8-27.
h. Using a suitable spring scale, check
brush springs (58) tension, Tens ion should
be 50 to 60 ounces.
i. Refer to Appendix A for Electric
Motor and Generator Repair Manual, and
check armature and field coils for shorts,
open circuits, and grounds. Check armature for shorts using a suitable growler.
8-26. REPAIR.
a. Refer to Appendix A for Electric
Motor and Generator Repair Manual for
general repair instructions.
REASSEMBLY .
Refer to figure 8-7 and reassemble
starting motor in the reverse order of index
numbers assigned. Pay particular attention
to the following:
a. When installing new bearings (3, 36
and 49), always use proper bearing arbor
to obtain a proper fit. Remove wick from
pinion housing (2), intermediate housing
(34), and head assembly (48) reservoirs
before installing a new bearings (3) (36),
and (49). After new bearing installation,
saturate felt wicks with SAE 10 oil, install
wicks in reservoirs and fill reservoirs
with SAE 10 oil.
b. Remove minor nicks and burrs from
housings, commutator end head, pinion
teeth and splines using a suitable hone.
b. Lubricate packings (5 and 37)
with a film of light grease MIL-G-23827 to
prevent damage during reassembly.
c. Replace discolored, spotted or
scored bearings. Remove minor nicks and
scratches from bearings using crocus cloth
dipped in an approved cleaning solvent.
c. Lubricate armature (40) bearing surfaces on shaft with SAE 10 oil. Lubricate
shaft and splines under starter drive (27)
with grease that conforms to Military
Specification MIL-G-23827.
d. Repair minor thread damage using a
suitable thread chaser.
d. Install armature (40) and seat
brushes (56) as follows:
Change 1
8-15
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 8-7. Starter motor, exploded view
8-16
Change 1
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Legend to figure 8-7:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17,
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Screw (6)
Pinion housing
Bearing
Plug (6)
Packing
Thrust washer
P lug
Gasket
Nut
Screw
Clip
Nut
Lock washer
Lead assembly
Nut
Lock washer
Connector
Bolt (4)
Solenoid switch
Pin
Deleted
Deleted
Deleted
Yoke cover
Deleted
Pin
Starter drive
Deleted
Deleted
30.
31.
32.
33.
34.
35.
36.
37.
38,
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
Yoke assembly
Washer
Screw (7)
Lock (7)
Intermediate housing
Seal
Bearing
Seal
Thrust washer
Thrust washer (4)
Armature
Nut
Washer
Insulating washer
Cap washer
Washer
Screw (7)
Lock (7)
Head assembly
Bearing
Gasket
Bushing
Insulating washer
Frame and field assembly
Screw (3)
Washer (3)
Brush (8)
Brush plate (8)
Spring
1. Install armature (40) in frame
and field assembly (53) until armature (40)
commutator contacts brushes (56).
Brushes (56) must lie flat against sandpaper
on armature (40) commutator to obtain desired brush (56) seat contour.
2. Raise brushes (56), until brushes
are seated on armature (40) commutator.
4. Install armature (40) head assembly (48) on frame field assembly (53).
3. Cut a strip of No. 00 sandpaper
the width of the armature (40) commutator.
Install sandpaper on armature (38) commutator with sand side out by raising brushes
(56) and slipping sandpaper between armature (40) commutator and brushes (56).
5. Carefully rotate armature (40) in
a counterclockwise direction three to five
revolutions to properly seat all brushes
(56).
6. Remove head assembly (48). Lift
all brushes (56) and inspect seat contour
Change 8
8-17
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115 -457-34
to determine whether or not sanding operation is satisfactory. A satisfactorily seated
brush (56) should show evidence of contact
on at least 85 percent of its length and 100
percent of its thickness.
7. Lift brushes (56) and remove
sandpaper from armature (40) commutator.
WARNING
Compressed air used for cleaning and
drying purposes can create airborne
particles that may enter the eyes.
Pressure shall not exceed 30 psig.
Eye protection is required.
8. Remove armature (40) from
frame and field assembly (53). Clean armature (40), brushes (56) and frame and field
assembly (53). Blow out sanding dust using
compressed air.
9. Coat shaft and splines on armature (40) with grease MIL-G-23827. Install
armature (40) (steps 1. and 2. above).
e. When assembling intermediate and
pinion housing assemblies (2 and 34), torque
hex head screws (1) to 8 foot pounds. Make
sure locating marks are aligned.
WARNING
Sealant, Glytal is moderately toxic
to eyes, skin and respiratory tract.
Eye and skin protection required.
Good general ventilation is normally adequate.
f. After assembly, the insulation on
both terminal studs on frame and field assembly (53) should be coated with glytal
sealant. Keep sealant off of contact surfaces of terminal studs and nuts.
8-28. TESTING. (See figure 8-8).
a. The following equipment will be required to perform the starter tests:
1. Two 12 volt batteries - 4 batteries
will be required if stall torque is to be performed.
2. D.C. voltmeter (0 to 50 volt
scale).
8-18
Change 8
3. D.C. ammeter (0 to 500 amp
scale).
4. Carbon pile (0 to 600 amp
capacity).
5. Spring scale (0 to 50 lb scale).
6. Pony brake arm 12 inch long.
7. Hand held tachometer -010,000 RPM.
CAUTION
Never operate the
than 30 seconds at
Allow the motor to
2 minutes between
starter motor more
a time during test.
cool for at least
each crank cycle.
b. No load test.
1. Connect no load current test setup as shown in view A.
2. Adjust carbon pile to obtain a
voltage of 22 volts. Current drain should
be 90 amperes (maximum) at 7000 RPM.
3. Apply rubber tip of hand held
tachometer to end of shaft in drive housings
to read RPM.
4. If current is too high, check
bearing alignment end play. Two or three
sharp raps with a rawhide hammer while
motoring will often help align bearings and
free armature.
c. SOLENOID WINDING TEST.
1. Make solenoid winding test setup
as shown in view B.
2. Test current draw and make
ground and open test on winding. Series
winding values at 7 0°F should be 23.2 to
26.6 amperes at 12.9 volts. Shunt winding
values at 70° F should be 4.1 to 4.8 amperes at 12.9 volts. Adjust carbon pile to
obtain 12.9 volts.
P-8-627-34
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 8-8. Starting motor, test setup
Change 8
8-19
P-8-627-34
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
d. STALL TORQUE TEST.
1. Make stall torque test setup as
shown in view C.
2. The solenoid winding shall be
activated with a separate battery.
3. Stall torque test values should
be 4.9 volts, 400 amperes (maximum), and
22.0 foot pounds (minimum). Adjust variable
resistance to obtain 4.9 volts at 400 amperes,
4. If stall torque values are too
low, check armature, brush spring tension,
contact area, and switch contacts. If these
components are not at fault, replace entire
starting motor.
e. ARMATURE END PLAY ADJUSTMENT. Adjust end play to 0.005 to 0.030
inches by adding or removing thrust washers on commutator end of armature shaft.
f. PINION POSITION ADJUSTMENT
(See figure 8-9). This adjustment assures
correct relation beween solenoid and indexing drive assembly. If adjustment is
not correct, damage may result to drive
gear and/or flywheel ring gear.
WARNING
When connecting lead-acid batteries
connect positive terminal first.
1. Connect a 12-volt battery as
shown in view A.
2. Momentarily touch the jumper
lead between terminal stud of solenoid and
terminal stud in commutator and head.
This will shift solenoid and drive solenoid
and drive assembly into cranking position
until battery is disconnected,
3. Push drive assembly toward
commutator end of motor to eliminate any
Slack movement in linkage.
WARNING
When disconnecting batteries (leadacid) disconnect negative terminal
first.
8-20
Change 8
4. Measure distance between outside
edge of drive sleeve and thrust washer as
shown in view B. This distance should be
0.020 to 0.050 inches. If measurement is
not correct, remove plug and washer from
shift linkage cover and adjust nut as required to obtain proper measurement. Disconnect battery.
5, Make test setup as shown in view
C. Leave switch open.
6. Place suitable interference block
with 0.983 inch side against drive gear as
shown in view D.
CAUTION
Because of high amount of current
being passed through solenoid winding, these tests should be made as
brief as possible.
7. Close switch in battery circuit.
The 12-volt lamp should not light. Be sure
interference block is against drive gear
and not against drive sleeve. If lamp does
not light, proceed to step 8. If lamp lights,
solenoid is defective. Replace solenoid,
then repeat test.
8. If test lamp does not light, open
switch and connect a carbon pile and voltmeter into test circuit as shown in view E.
9. Place suitable interference block
with 1/2-inch side against drive gear,
Close switch and be sure interference block
is against drive gear and not against drive
sleeve.
10. Adjust carbon pile and observe
voltmeter. The test lamp must light before
the voltmeter reads 16 volts. If lamp does
not light, adjust nut view B until proper
setting is obtained.
11. Reinstall plug and washer in
shift linkage cover.
8-29.
INSTALLATION.
Refer to Operator and Organizational
Maintenance Manual and install starting
motor.
P-8-627-34
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 8-9. Starting motor pinion position, test setup
Change 8 8-21
P-8-627-34
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Section V. FAN MOUNTING GROUP
8-34. INSPECTION.
8-30. GENERAL.
The fan mounting group is mounted
at the front of the engine. It consists of a
fan, drive pulley, brackets, and mounting
hardware. The fan and pulley are driven
by the crankshaft pulley via the fan drive
belts. The fan forces cooling air through
the radiator.
8-31. REMOVAL.
a. Refer to Operator and Organizational
Maintenance Manual and remove alternator
belts, fan drive belts, fan guard and orfice
ring on radiator shroud.
CAUTION
Do not allow fan to hit radiator core
after it is removed from fan hub.
b. Refer to figure 8-10 and remove fan
and fan drive in the order of index numbers
assigned.
8-32. DISASSEMBLY .
Refer to figure 8-11 and disassemble
fan drive assembly in the order of index
numbers assigned.
8-33. CLEANING.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
Compressed air used for cleaning and
drying purposes can create airborne
particles that may enter the eyes.
Pressure shall not exceed 30 psig.
Eye protect ion is required.
CAUTION
Do not spin dry bearings.
a. Wash parts in an approved cleaning
solvent and dry thoroughly. Bearings
should be dried with compressed air.
b. Clean pulley cavity of old grease.
Flush with cleaning solvent and air dry.
8-22
Change 8
a. Inspect bearings for roughness of
rotation. Replace bearing if its rotation
is rough after lubrication.
b. Inspect bearings for scoring, pitting,
scratches, cracks and discoloration. Replace defective bearing.
c. Inspect spindle and bracket assembly
bearing surface for grooves, or galled conditions. Replace defective spindle and
bracket assembly.
d. Inspect fan for distorted blades,
worn pilot hole or elongated mounting holes.
Replace defective fan.
e. Inspect pulley for worn grooves,
nicks or cracks. Replace worn or cracked
pulley.
f. Inspect threaded holes for thread
damage.
g. Discard gasket and seal.
8-35.
REPAIR.
a. Minor nicks and burrs on fan and
pulley may be removed using a suitable
stone.
b. Repair minor thread damage using
a suitable thread chaser.
8-36. REASSEMBLY.
Refer to figure 8-11, and reassemble
fan drive assembly in the reverse order of
index numbers assigned. Pay particular
attention to the following:
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Figure 8-10. Fan and fan drive group, removal and installation
Legend to figure 8-10:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Bolt (5)
Lock washer (5)
Fan
Adjusting bolt
Lock washer
Bolts (4)
Lock washer (4)
Washer (4)
Fan drive assembly
Bolt (2)
Lock washer (2)
Bolt (2)
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Lock washer (2)
Bracket
Adjustment bar
Bolt (2)
Lock washer (2)
Mounting block
Support
Bolt (2)
Lock washer (2)
Spacer
Support
Change 8
8-23
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Figure 8-11. Fan drive assembly, exploded view
Legend to figure 8-11:
1.
2.
3.
4.
5.
6.
Bolt (2)
Lock washer (2)
Washer (2)
Fan mounting hub
Gasket
Screw (2)
7.
8.
9.
10 0
11.
12.
a. Install seal (16) with lip away from
bearing (13). Lubricate sealing lip (16)
lightly with engine oil.
WARNING
Grease, (MIL-G-23827) is moderately
toxic to skin, eyes and respiratory
t r a c t . Eye and skin protection required. Good general ventilation
is normally adequate.
b. Hand pack bearings (9 and 13) with
grease MIL-G-23827 before reassembly.
c . Completely fill cavity between bearings (9 and 13) with grease MIL-G-23827.
8-37. INSTALLATION.
8-24
Change 8
Lockplate
Plate
Bearing
Retaining ring
Spacer
Retaining ring
13.
14.
15.
16.
17.
Bearing
Plug
Pulley assembly
Seal
Spindle and
bracket assembly
Refer to figure 8-10 and install fan
drive group in reverse order of index
numbers assigned. Pay particular attention
to the following.
a. Before installing fan drive assembly
(9, figure 8-10), place fan belts and alternator belt on crankshaft pulley and fan
drive pulley.
b. Refer to Operator and Organizational
Maintenance Manual and tighten fan and
alternator drive belts. Install fan guard
and orfice ring on radiator shroud.
P-8-627-34
TM -07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Section VI. DAY TANK ASSEMBLY
8-38. GENERAL.
The day tank is mounted on the unit
lifting frame and is located on the left side
of the engine. It provides a gravity head of
fuel to the fuel injection pump. The day
tank is non-pressurized and is equipped
with a fuel level switch, a drain cock, a
vent, a fuel inlet port, a fuel outlet port,
and an excessive fuel return port. The fuel
level switch is one of the dual float type:
the upper float, senses fuel level and prevents the overflow of fuel in day tank: the
lower float senses fuel level and opens a
circuit breaker to stop the engine after the
fuel supply to the day tank has been shut off
for 4 minutes. The drain cock is provided
to completely drain the day tank, and the
vent prevents the system from becoming
air bound. The day tank has a usable fuel
capacity sufficient for a minimum of 5 minutes operation at rated load, after the fuel
supply to the day tank has been shut off.
8-39. REMOVAL AND DISASSEMBLY.
Refer to Operator and Organizational
Maintenance Manual. Remove and disassemble day tank assembly.
8-40.
CLEANING .
WARNING
1,1,1 Trichloroethane (Methyl Chloroform) is moderately toxic to skin,
eyes and respiratory tract. Eye and
skin protection required. Good general ventilation is normally adequate.
a. Clean fuel level switch with 1,1,1
Trichloroethane MIL-T-81533.
WARNING
Fuel Oil if flammable and moderately
toxic to skin, eyes and respiratory
t r a c t . Eye and skin protection required. Good general ventilation
is normally adequate.
b. Clean the day tank using clean fuel
oil. Be sure that any sediment in the
bottom of the tank is flushed out. After
cleaning, dry tank thoroughly.
8-41. INSPECTION.
a. Refer to Operator and Organizational
Maintenance Manual, and test fuel level
switch.
b. Block openings in day tank and apply
1 psi of air pressure to tank. Submerge
the tank in water, leaks will be indicative
by air bubbles.
c. Inspect all threaded holes for
damaged threads.
8-42. REPAIR.
a. Replace defective fuel level switch.
WARNING
Make sure inside of day tank is free
of fuel fumes and all tank ports are
open before welding.
Welding operations produce heat,
highly toxic fumes, injurious
radiation, metal slag and airborne particles. Welding goggles, with proper tinted lenses,
apron or jacket and welder’s
boots are required.
Change 8
8-25
P-8-627-34
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
b. Repair leaks in day tank by welding.
c. Recheck day tank for leaks after
welding (para 8-41 b.)
d. Repair minor thread damage, using
a suitable chaser.
8-43. REASSEMBLY AND INSTALLATION.
Refer to Operator and Organizational
Maintenance Manual. Reassemble and install day tank assembly.
Section VII. OVERSPEED SWITCH
8-44. GENERAL.
The overspeed switch is mounted on
the tachometer drive and operates at one
half engine speed. It is a three element
switch. Switch 1, disconnects starter and
initiates field flashing of generator. Switch
2, permits 24 VDC to energize precise
governor. Switch 3, initiates shutdown sequence of generator set in the event engine
speed increases to 2400-2450 RPM. Switch
3 must be manually reset when tripped, by
depressing the reset button.
8-45. REMOVAL.
Refer to Operator and Organizational
Maintenance Manual and remove overspeed
switch.
8-46.
DISASSEMBLY.
Refer to figure 8-12 and disassemble
overspeed switch in the order of index numbers assigned. Pay particular attention to
the following:
a. Remove lockwire (1) and remove
three screws (2). Mark three hole center
location on cap and cover assembly (6) with
scribe marks.
b. Separate cap and cover assembly (6)
from body assembly (11).
c. Remove cap and cover retaining
screws (12) and lift cover from cover assembly (6).
8-26
Change 8
d. Remove rotor assembly (9) by releasing retaining ring (8) which secures
rotor assembly to body assembly (11).
Retaining ring will come out with rotor
assembly.
8-47. CLEANING.
CAUTION
Do not immerse overspeed switch
in cleaning solvent.
a. Wipe outside of overspeed switch
with a clean cloth moistened with an approved cleaning solvent and dry thoroughly.
WARNING
Compressed air used for cleaning and
drying purposes can create airborne
particles that may enter the eyes.
Pressure shall not exceed 30 psig.
Eye protection is required.
b. Low pressure compressed air may
be used to remove any dust or dirt deposits
in switch assembly.
8-48.
INSPECTION .
a. Inspect cap and cover assembly, and
body assembly for cracks and loose hardware.
b. Inspect rotor assembly (9) bearing
for freedom of rotation. Replace rotor
assembly if bearing is frozen.
P-8-627-34
TM-07464A-35
c. Inspect switch assembly inside of
cap and cover assembly (6) for quality of
solder connections on switch terminals.
Check for corrosion on switch terminals.
d. Inspect for freedom of movement of
switch contact actuator plate. Depress
actuator plate with thumb on center of
actuator plate. There should be a total of
three separate clicks as each micro switch
T.O. 35C2-3-442-2
TM 5-6115-457-34
is actuated while the actuator plate is depressed to its lower limit. If third click
is not indicated, reset manual reset button.
Replace cover assembly (6) if switch/or
switches are defective.
e. Inspect inside of body assembly for
signs of moisture or corrosion.
Change 8
8-26A/(8-26B Blank)
P-8-627-34
TM-07464A-35
f. Inspect governor weights for freedom
of movement.
g. Inspect electrical wires inside of cap
and cover assembly (6) for insulation, continuity and proper connection. Replace
defective wires.
T O 35C2-3-442-2
TM 5-6115-457-34
Install screws (2) and washers (3), and align
assemblies with hole center location scribe
marks. Do not lockwire screws (2) at this
time,
8-51.
ADJUSTMENT.
a. MAJOR SPEED ADJUSTMENT.
h, Inspect electrical connector for damaged threads, bent, loose or missing pins;
and for shorts. Replace defective connector.
i.
Discard packing,
WARNING
Avoid breathing fumes generated by
unsoldering/soldering. Eye protection is required.
8-49. REPAIR.
a. If electrical connector (16) is defective, remove connector from cover by
removing screws (13), nuts (14) and washers
(15). Tag electrical leads and unsolder
wires from connector.
b. Install new electrical connector (16)
to cover and secure with screws (13), nuts
(14) and washers (15). Solder wires to
connector.
8-50.
NOTE
If speed switch has been disassembled, steps a. and b. both must be
performed. If switch has not been
disassembled and only a minor adjustment is required, perform step
b. only.
1. Remove minor speed adjustment
access screws on top of cap which provide
access to adjusting screws. Insert a 1/16
inch hex Allen wrench into adjusting screws.
NOTE
Do not allow screw to be disengaged
from lock nut assembly.
2. Turn switch 1 adjusting screw all
the way counterclockwise.
REASSEMBLY.
Refer to figure 8-12 and reassemble
overspeed switch in the reverse order of
index numbers assigned. Pay particular
attention to the following.
a. Position rotor assembly (9) into body
assembly (11) and secure with retaining
ring (8).
3. Turn switch 2 adjusting screw
approximately halfway between its minimum
and maximum adjustment range.
4. Turn switch 3 adjusting screw in
a clockwise direction until adjustment screw
is flush with top of lock nut.
b. Position cap onto cover assembly (6)
and secure with screws (12).
5. Rotate cap and cover assembly
(6) counterclockwise to maximum extended
position.
c. Align cap and cover assembly (6) to
body assembly so the three slots match up
with screw holes in body assembly (11).
6. Connect overspeed switch to test
setup as shown in figure 8-13.
Change 8
8-27
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Figure 8-12. Overspeed switch, exploded view
8-28
Change 8
P-9-TM-457-35
T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Legend to figure 8-12:
1.
2,
3.
4.
5.
6.
LockWire
Screw(3)
Washer(3)
Screw(2)
Nameplate
Cap and cover assembly
7.
8.
9.
10.
11.
Packing
Retaining ring
Rotor assembly
Spacer
Body assembly
12.
13.
14.
15.
16.
Cap and cover retaining screws (3)
Screw (4)
Nut (4)
Washer (4)
Connector
NOTE :
1. SPEED SWITCH OPERATES AT HALF OF ENGINE SPEED
2. ELEMENTS I AND 2 AUTOMATICALLY RESET
100 RPM BELOW TRIP SPEED
3. ELEMENT 3 MANUAL RESET
Figure 8-13. Overspend switch, test setup
Change 7 8-29
P-9-TM-457-35 T.O.35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
7. Set variable speed drive at approximately 200 RPM above actuation point
of switch 1. Speed of variable drive must
be measured with a tachometer of ±1 percent accuracy.
8. Rotate cap and cover assembly
(6) clockwise until switch 1 actuates. Scribe
this position on body assembly (11) and cap
and cover assembly (6).
9. Rotate cap and cover assembly
(6) clockwise an additional 1/16 of an inch
and lock the three screws.
1 0 . Proceed to set trip points of
two remaining switches, step b.
b. MINOR SPEED ADJUSTMENT.
CAUTION
Too many counterclockwise turns
will remove set screw from lock
nut assembly.
NOTE
All three switches may be individually adjusted. Under certain conditions the adjustment of one switch
may slightly effect the speed setting
of the other two. Compensating adjustments may be required. Switch
1 set screw will be turned clockwise
to increase speed to proper trip
8-30 Change 7
while switch 3 set screw will be
turned counterclockwise to decrease
trip point. Switch 3 set screw should
require adjustment either clockwise
or counterclockwise (increase or
decrease) depending upon where it
actuates.
1. Perform step a. , 1. above.
2. Turn adjusting screw clockwise
to increase trip point and counterclockwise
to decrease trip point. Set switches to
speeds indicated below by changing speed
setting of the test stand motor to a point
midway in the speed band range.
Switch 1- set at 290 to 310 RPM
Switch 2- set at 590-610 RPM for
60 hertz generator sets
and 825-850 RPM, for 400
hertz generator sets.
Switch 3- set at 1200 to 1225 RPM
3. Recheck all trip point settings.
4. After all bench adjustments have
been made, tighten cover hardware (2 and
3) and install lockwire.
8-52. INSTALLATION.
Refer to Operator and Organizational
Maintenance Manual and install overspeed
switch. Check to be sure reset button has
not tripped during installation.
P-8-627-34
TM-07464A-35
TO 35C2-3-442-2~
TM 5-6115-457-34
Section VIII. TACHOMETER DRIVE GROUP
8-53.
GENERAL.
The tachometer drive group is
mounted and driven off the fuel pump. The
tachometer drive senses engine speed and
actuates the overspeed switch when engine
speed is between 2400 to 2450 RPM. When
the overspeed switch is actuated, the switch
contacts close and signals the STOP-RUNRELAY to shut down the engine, this operation protects the engine from being damaged
due to overspeeding.
8-54.
REMOVAL.
a. Clean parts with an approved cleaning solvent. Scrub parts thoroughly using
a stiff bristle brush.
b. Dry parts with filtered low pressure
compressed air or a clean lint-free cloth.
8-57. INSPECTION.
a. Inspect bearings (8, 15 and 21) for
scoring, pitting, scratches and cracks.
Replace defective bearings.
b, Inspect housing for cracks. Replace
cracked housing.
a. Refer to Operator and Organizational
Maintenance Manual and remove overspeed
switch.
c . Inspect gear teeth for nicks, burrs,
cracks and broken teeth. Nicks and burrs
that extend below the hardened surface of
the gear teeth are cause for rejection of
the gear.
b. Refer to figure 8-14 and remove
tachometer drive group by removing bolts
(1), lockwashers (2) and clamps (3 and 4).
d. Inspect gear teeth for wear that may
have destroyed the original tooth shape.
If this condition is found, replace gear.
8-55. DISASSEMBLY.
e. Inspect gear shafts for nicks, burrs
and scratches.
Refer to figure 8-14 and disassemble
tachometer drive group in the order of index numbers assigned. Pay particular
attention to the following.
Bearings (8, 15 and 21) are press
fitted. If necessary, remove bearings
using suitable removal tools.
8-56. CLEANING..
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
Compressed air used for cleaning and
drying purposes can create airborne
particles that may enter the eyes.
Pressure shall not exceed 30 psig.
Eye protection is required.
f. Discard seal.
8-58. R E P A I R .
a. Remove minor nicks and burrs from
gear teeth and gear shafts using a smooth
file or hone.
b. If gears must be replaced, press
gears from shaft using a suitable arbor
p r e s s . Apply an approved adhesive to gear
diameter of shaft and press gear onto shaft.
Press fit must withstand 10 ft-lbs torque.
8-59,
REASSEMBLY.
Refer to figure 8-14, and reassemble
tachometer drive group in the reverse order
of index numbers assigned. Pay particular
attention to the following:
Change 8
8-31
P-8-627-34
TM-07464A-35
TO 35C2-3-442-2
TM 5-6115-457-34
Figure 8-14. Tachometer drive group, exploded view
Legend to figure 8-14:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
8-32
Bolt (2)
Lock washer (2)
Clamp
Clamp
Seal
Tachometer drive
Housing assembly
Bearing
Housing
Shim (14)
Shaft assembly
Change 8
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Gear
Shaft
Plug assembly
Bearing
Plug
Shaft assembly
Gear
Shaft
Housing assembly
Bearing
Housing
TO
35C2-3-442-2
TM 5-6115-457-34
P-8-627-34
TM-07464A-35
a. If bearings (8, 15 and 21) were removed, install new bearings. Bearings
are press fitted.
8-60.
INSTALLATION.
b. Pack housing assembly (22) cavity
with 7 cc’s of approved lubricant.
a. Refer to figure 8-14 and install
tachometer drive group, secure with bolts
(1), lockwashers (2) and clamps (3 and 4).
Torque bolts (1) from 6 to 10 foot pounds.
c . Use required number of shims to
produce 0. 001 to 0, 005 inch end play on
shaft (11).
b. Refer to Operator and Organizational
Maintenance Manual and install overspeed
switch.
Section IX. FUEL PUMP GROUP
8-61. GENERAL.
The fuel pump is mounted to the
accessory drive group, the pump is driven
by a gear on the accessory drive shaft.
The fuel pump consists of a gear driven
shaft, sleeve bearings, fuel propelling
gears, and seals. The pump causes fuel
to flow from the day tank into the fuel injection pump housing.
8-62. REMOVAL.
a. Refer to Operator and Organizational
Maintenance Manual and remove over speed
switch.
b. Refer to Operator and Organizational
Maintenance Manual and remove fuel hose
from fuel pump.
c. Remove tachometer drive group
(para 8-54).
d. Refer to figure 8-15 and remove fuel
pump by removing bolts (4), lock washers
(5) and gasket (7).
8-63.
DISASSEMBLY.
Refer to figure 8-15 and disassemble
fuel pump group in the order of index numbers assigned. Pay particular attention to
the following:
NOTE
Pump body (30) and cover (22) should
be carefully separated due to the
sealant that was used during assembly.
If necessary, remove gear (24)
from shaft (25), using a suitable puller and
step plate.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
●
Compressed air used for cleaning and
drying purposes can create airborne
particles that may enter the eyes.
Pressure shall not exceed 30 psig.
Eye protection is required.
8-64.
CLEANING .
Clean parts with an approved cleaning solvent and dry parts with low pressure
compressed air.
8-65.
INSPECTION .
a. Refer to table 1-1 and inspect fuel
pump group for dimensional tolerances.
Replace all parts that exceed maximum
allowable wear and clearance.
b. Inspect pump cover for nicks, scoring and cracks. Replace defective cover.
c. Inspect gear teeth for nicks, burrs,
cracks and broken teeth. Nicks and burrs
that extend below the hardened surface of
the gear teeth are cause for rejection of
the gear.
Change 8
8-33
P-8-627-34
TM-07464A-35
TO
35C2-3-442-2
TM 5-6115-457-34
Figure 8-15. Fuel pump group, exploded view
8-34
Change 8
P-8-627-34
TM-07464A-35
TO
35C2-3-442-2
TM 5-6115-457-34
Legend to figure 8-15:
1.
2.
3.
4.
5,
6.
7.
8.
9.
10.
11.
12.
13,
14.
15.
d. Inspect gear teeth for wear that may
have destroyed the original tooth shape.
If this condition is found, replace gear.
e. Inspect gear shafts for nicks, burrs
and scratches.
f. Inspect bearings for scoring, pitting,
scratches and cracks.
g. Inspect a defective bearing’s housing
for grooved, burred or galled conditions
that would indicate that the bearing has been
turning in its housing.
8-66.
REPAIR.
Remove minor nicks and burrs from
gear teeth and gear shafts using a smooth
file or hone.
8-67.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Plug
Tee
Nipple
Bolt (2)
Lock washer (2)
Fuel pump
Gasket
Plug
Nut
Gear
Key
Seal (2)
Ring
Gauge assembly
Seal (2)
REASSEMBLY .
Refer to figure 8-15 and reassemble
fuel pump group in the reverse order of
index numbers assigned. Pay particular
attention to the following:
a. Before installation, lightly lubricate
seals (12, 15 and 20) with clean engine oil.
Bearing
Gauge
Screw (6)
Cover assembly
Seal
Ferrule
Cover
Shaft assembly
Gear
Shaft
Gear
Body assembly
Shaft
Bearing
Body assembly
CAUTION
Do not allow permatex to enter pump
assembly.
b. Apply a thin coat of permatex between body assembly (30) and cover (22).
c. Rotate pump shaft by hand to ensure
that pump parts rotate freely. If binding
exists, tap corner of pump cover with a
hammer to relieve binding.
d. Torque nut (9) from 17 to 27 foot
pounds .
8-68.
INSTALLATION.
a. Refer to figure 8-15 and install fuel
pump, secure with bolts (4), lock washers
(5) and gasket (7).
b. Install tachometer drive group
(para 8-60).
c . Refer to Operator and Organizational
Maintenance Manual and install overspeed
switch.
d. Refer to Operator and Organizational
Maintenance Manual and connect fuel hose
to fuel pump.
Change 8
8-35
P-8-627-34
TM-07464A-35
TO
35C2-3-442-2
TM 5-6115-457-34
Section X. TURBOCHARGER GROUP
8-69.
GENERAL.
Specification P-D-680. Dry unit thoroughly
and remove opening coverings.
The turbocharger is mounted on the
exhaust manifold. The Turbocharger consists of a turbine wheel and a compressor
impeller mounted on a common rotating
shaft, a bearing housing, compressor
cover, and compressor back plate. The
turbocharger, which is driven by the engine
exhaust gases, draws in ambient air, compresses the air, and directs it into the
engine intake manifold. This process
supercharges the engine which results in
a greater power output.
8-70.
REMOVAL.
Refer to Operator and Organizational Maintenance Manual, and remove the
turbocharger group.
8-71.
Before removing wheel (48),
mark shaft and wheel assembly
(60). Rotating parts should be
aligned during reassembly.
b. Before disassembly of parts, measure
wheel (48) end clearance. End clearance
should be O. 006 to O. 011 inches. If
clearance is excessive, or if either the
shaft and wheel assembly (60) or wheel (48)
has rubbed against housing assembly (65)
or shroud (61), the bearings (58) and/or
thrust bearing (56) and collar (55) must
be replaced.
c. Punch mark housing assembly (41),
housing assembly (65) and housing (45) to
ensure correct positioning upon reassembly.
DISASSEMBLY.
Refer to figure 8-16 and disassemble
turbocharger in the order of index numbers
assigned. Pay particular attention to the
following:
WARNING
Solvent, Dry Cleaning P-W680, Type II
is flammable and moderately toxic to
skin, eyes and respiratory tract. Eye
and skin protection required. Good
general ventilation is normally adequate.
a. Cover all turbocharger openings and
clean all exterior surfaces using a cleaning
solvent that is in accordance with Federal
8-36
NOT E
Change 8
d. Fabricate a fixture, fixture adapter
supporting screw, wood dowel, and wrench
as shown in figure 2-1, These tools are to
be used for disassembly of rotating parts.
e. Bolt fixture adapter to fixture,
figure 8-17. Attach bearing housing to
fixture with shaft and wheel assembly
(60) down.
CAUTION
Proper installation of supporting
screw is important so as to allow an
unobstructed pressing action on shaft
and still prevent turbine wheel from
being damaged by striking against
fixture base.
P-8-627-34
TM-07464A-35
f. Thread supporting screw into base of
fixture to contain turbine wheel and shaft
when pressed from wheel (48), Leave a
space between end of screw and turbine
wheel. Approximately l/2-inch of shaft
and turbine wheel movement is required to
free them from wheel.
g. When removing wheel (48), remove
nut (47) and then position compressor end
of housing in a hot oil bath so only wheel is
immersed. Heat wheel to 350°F for not
longer than 10 minutes. Remove unit from
oil bath and press shaft and turbine wheel
(60) as a unit from wheel (48).
h. Use the wood dowel to remove thrust
plate assembly from center housing. Refer
to figure 8-180
8-72. CLEANING.
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
CAUTION
Rotating components must be
thoroughly cleaned in order to maintain critical balance of turbocharger.
Do not use a wire brush or wheel on
any parts.
a. Clean all metal parts using an approved cleaning solvent. Dry parts
thoroughly. Use a piece of wood to clean
carbon and deposits from turbine housing
(65, figure 8-16). Discard all seals and
packings.
b. The turbine wheel must be cleaned
thoroughly to remove all carbon deposits.
It may be necessary to soak wheel in solvent
for at least one hour to remove hardened
carbon deposits. Scrape off loosened particles with a stiff brush or a specially shaped
piece of wood, If turbine wheel is covered
with soot only, use cleaning solvent and a
stiff brush, rinse with clean water, and dry
TO
35C2-3-442-2
TM 5-6115-457-34
thoroughly.
c. Clean oil passages in housing assembly using a pipe cleaner. This cleaning
should be done only when the housing assembly has been completely disassembled.
8-73.
INSPECTION .
Refer to table 1-1, and using a suitable micrometer and feeler gauge, inspect
parts for dimensional tolerances. Replace
parts that do not meet dimensional tolerances.
a.
CAUTION
The following step is a critical area
of inspection. Any deformation or
damage to wheels will cause a serious out-of -balance condition whit h
will damage turbocharger.
b. Inspect compressor and turbine
wheels (48 and 60, figure 8-16) for cracks,
wear, chips, or any other defect. Check
carefully for any blade distortion. If defective, replace wheel. Do not attempt to
straighten blades.
c. Inspect bearings for cracks, distortion, or any other defect,
d. Check runout of shaft. This can be
done by one of two methods, Use standard
bearings and place shaft in vee blocks or
use a partially open vise.
e. Inspect shaft for cracks, roughness,
distortion, or any other defect, Check ring
grooves for wear, Replace defective shaft.
f. Inspect housing for cracks, breaks,
or any other defect. Replace defective
housing,
Change 8
8-37
P-8-627-34
TM-07464A-35
TO
35C2-3-442-2
TM 5-6115-457-34
Figure 8-16.
8-38
Change 8
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Legend to figure 8-16:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Plug
Bolt (4)
Lock washer (4)
Washer (4)
E lbow
Gasket
Seal (2)
Pipe
Seal (2)
P lug
Plug
Clamp
E lbow
Ring
Coupling
Ring
Bolt (2)
Nut (2)
Support
Bolt (2)
Lock washer (2)
Tube assembly
Fitting
Gasket
Strainer assembly
Bolt (2)
Lock washer (2)
Tube assembly
Gasket
Seal
Bolt (2)
Nut (4)
Washer (4)
g. Inspect all other parts for cracks,
distortion, breaks, excessive wear, or any
other defect.
h. Inspect all attaching hardware for
damaged threads, distortion, cracks, or
any other defect.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49•
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
Gasket
Seal
Seal
coupling
Turbocharger assembly
Nameplate
clamp
Housing assembly
Bolt (6)
Plate (3)
Plate (3)
Housing
Cartridge assembly
Nut
Wheel
Ring (2)
Spacer
Seal
Screw (3)
Plate (3)
Plate assembly
Collar
Bearing
Ring (3)
Bearing (2)
Ring
Shaft and wheel assembly
Shroud
Seal
Nameplate
Screw (2)
Housing assembly
8-74. REPAIR.
Repair damaged threaded holes for
the oil pressure line flange bolts and for the
drain line flange bolts in the housing assembly by retapping holes to clean out burrs
and other obstructions.
8-39
P-9-TM-457-35
TM-0746A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 8-18.
Figure 8-17. Pressing shaft and turbine
wheel from compressor wheel
Removing thrust Plate
3. Remove wheel (48) from oil bath,
and immediately install wheel on shaft,
install old nut (47) and tighten to 120 inch
pounds torque.
8-75. REASSEMBLY.
4. Allow wheel to cool to less than
150° F and remove nut (47).
Refer to figure 8-16, and reassemble turbocharger group in the reverse order
of index numbers assigned. Pay particular
attention to the following:
5. Using lubricating oil MIL-L2104, lightly lubricate the threads of
turbine shaft and a new nut (47).
a. Torque screw (52) from 30 to 40
inch pounds.
6. Install new nut (47) and tighten
to 20 inch pounds torque, then tighten an
additional 120 degrees.
b. Install collar (55) so oil hole aligns
with oil hole in housing (65).
c. Install wheel (48) on shaft and wheel
assembly (60) as follows:
1. Place the shaft and wheel assembly end of center housing (65) in turbine
fixture.
2. Place wheel (48) in an oil bath,
heat wheel to a maximum of 350° F for no
longer than 10 minutes.
8-40
7. Coat threads of bolts (2 places)
(42) with an approved anti-seize compound.
Install both and tighten from 160 to 180
inch pounds torque.
8-76.
INSTALLATION.
Refer to Operator and Organizational
Maintenance Manual, and install the turbocharger group.
P-8-627-34
TM-07464A-35
TO
35C2-3-442-2
TM 5-6115-457-34
Section XI. OIL COOLER GROUP
8-77.
GENERAL.
The oil cooler group is mounted to
the engine block. It consists of the oil
cooler assembly, a water bonnet, and associated tubing and connections. The oil
cooler assembly contains a tube bundle, two
bypass valves, and a housing. On cold
engine starts, the cool viscous oil does not
flow immediately through the oil cooler and
oil filter. The cool oil fore es bypass valves,
located on the oil filter and oil cooler, to
open and the oil flows unrestricted through
the engine and to the turbocharger. As the
temperature of the oil increases, the viscosity and pressure of the oil decreases
and the oil filter bypass valves close. Now,
only filtered oil is delivered to all of the
engine parts. As oil temperature continues
to increase, the oil cooler bypass valves
close, allowing the oil to flow through the
oil cooler prior to entering the oil filters.
If an oil filter becomes clogged, that oil
filter bypass valve opens and allows the oil
to flow directly from the oil cooler into the
engine. Water from the engine cooling system flows through the tube bundle section
of the oil cooler to reduce the heat of the
engine lubricating oil.
8-78. REMOVAL.
a. Refer to Operator and Organizational
Maintenance Manual and remove oil filter
group.
b. Remove three bolts, lockwashers
and washers, securing oil filler tube and
gasket to cylinder block.
c. Refer to figure 8-19, and remove oil
cooler group in the order of index numbers
assigned.
8-79. DISASSEMBLY .
Refer to figure 8-20 , and disassem-
ble oil cooler group in the order of index
numbers assigned.
8-800 CLEANING,
a. If tube bundle is corroded, scale
deposits can be removed by either of the
following methods:
CAUTION
Care must be taken to avoid damaging sides of tubes.
1. Clean tubes with a suitable 5/32
inch diameter rod long enough to penetrate
length of tubes.
WARNING
Wear protective clothing and use
extreme caution when mixing acid
solution, and when cleaning oil
cooler. Always add acid to water
when mixing; never add water to
acid. Avoid any contact of solution
with skin. Keep away from eyes.
2. Clean tubes with a solution of 15
percent hydrochloric acid and 85 percent
water. The oil cooler should be immersed
in or flushed with the solution until the scale
is softened. Wash cooler thoroughly with
water to remove scale and solution. Repeat
procedure as necessary to achieve proper
cleaning.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
b. Clean metal components with an approved cleaning solvent, and dry thoroughly.
Change 8
8-41
I
P-8-627-34
TM-07464A-35
TO 35C2-3-442-2
TM 5-6115-457-34
Figure 8-19. Oil cooler group, removal and installation
8-42
P-9-TM-457-35 T. 0. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Legend to figure 8-19:
1,
2.
3.
4.
5,
6,
7.
8.
9.
10.
11.
12.
13.
14.
15.
Bolt (2)
Lock washer (2)
Tube assembly
Gasket
Seal
Bolt
Lock washer
Bolt
lock washer
Lug
Clip
Tube assembly
Gasket
Seal
Bolt (2)
8-81. INSPECTION.
a. Inspect tube bundle and end bonnets
for cracks, breaks, corrosion that cannot
be removed, and any other defects. Replace
defective components.
16.
17.
18.
19.
20.
21•
22.
23.
24.
25.
26.
27.
28.
29.
30.
Lock washer (2)
Tube
Fitting
Fitting
Bolt
Lock washer
Bolt
Lock washer
Bolt
Lock washer
Bolt
Lock washer
Oil cooler group
Gasket
Gasket
b. Repair minor thread damage using
a suitable thread chaser.
8-83. REASSEMBLY.
Refer to figure 8-20 and reassemble
oil cooler group in the reverse order of
index numbers assigned.
b. Inspect components for dents, cracks,
distortion, and damaged threads.
8-84. INSTALLATION.
c. Discard gaskets and seals,
d. Using a suitable spring compressor,
apply a load of 8.92 Ibs. and compress
relief valve spring (10, figure 8-20) to a
length of 2.5 inches. Replace relief valve
spring (10) if free length after test is not
3.61 inches.
a. Refer to figure 8-19, and install oil
cooler group in the reverse order of index
numbers assigned.
b. Install gasket and oil filler tube to
cylinder block and secure with three washers, lock washers and bolts.
8-82. REPAIR.
a. Repair dents and distortion using
proper tools.
c. Refer to Operator and Organizational
Maintenance Manual and install oil filter
group.
8-43
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 8-20. Oil cooler group, exploded view
Legend to figure 8-20:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
8-44
Plug
Bolt (4)
Lock washer (4)
Bolt
Lock washer
Bonnet
Gasket
Plug (2)
Gasket (2)
Spring (2)
Plunger (2)
Bolt
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Lock washer
Washer
Bolt (4)
Lock washer (4)
Cooler assembly
Gasket
Bonnet
clamp (2)
Hose
Plug
Elbow
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Section XII. HYDRAULIC TANK (PRECISE SETS ONLY)
8-85. GENERAL.
The hydraulic tank is located on
the left side at the front of the engine. It
is mounted to the rear of the front gear
cover plate behind the water pump. The
hydraulic tank is utilized on precise
generator sets only. The function of the
hydraulic tank is to provide a positive
head of hydraulic fluid for the hydraulic
pump. The tank contains a liquid level
gauge at the top of the tank. A return line
inlet is located below the lowest level of
liquid allowed by the liquid level gauge.
An outlet connection is located near the
bottom of the tank. This location prevents
sediment from following into the hydraulic
system. A plugged outlet is located at the
bottom of the tank for draining sediment.
A drain plug at this outlet is of the magnetic me.
8-86. REMOVAL.
Figure 8-21. Hydraulic tank,
removal and installation
Refer to figure 8-21 and remove
hydraulic tank in the order of index numbers assigned. Pay particular attention
to the following:
Legend to figure 8-21:
a. Remove magnetic plug, and drain
hydraulic fluid from tank. If hydraulic
fluid is to be reused, drain fluid into a
clean metal container. Loosen or remove
liquid level gauge on top of tank in order to
speed draining.
b. Disconnect hose assemblies (1 and
2), and drain fluid into the metal container,
Cover container.
c. Install liquid level gauge, if removed.
d. Install magnetic plug.
1.
2.
3.
4.
5.
6.
8-87.
Hose assembly
Hose assembly
Threaded spacer (2)
Nut (2)
Lock washer (2)
Hydraulic tank assembly
DISASSEMBLY .
Refer to figure 8-22 and disassemble hydraulic tank in the order of index
numbers assigned.
Change 1
8-45
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 8-22. Hydraulic tank, exploded view
Legend to figure 8-22:
1.
2.
3.
4.
5.
6.
8-46
Elbow
Elbow
Chain hook
Chain assembly
Chain hook
Liquid level gauge
7.
8.
9.
10.
11.
Magnetic plug
Screw (4)
lock washer (4)
Mounting bracket
Hydraulic tank
P-8-627-34
TM-07464A-35
TO 35C2-3-442-2
TM 5-6115-457-34
2. Fill tank with water.
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
8-88. CLEANING.
WARNING
Welding operations produce heat,
highly toxic fumes, injurious
radiation, metal slag and airborne particles. Welding goggles, with proper tinted lenses,
apron or jacket and welder's
boots are required.
Clean components with unapproved
cleaning solvent, and dry thoroughly. Ensure that all particles trapped on head of
magnetic plug are removed.
8-89. INSPECTION.
a. Inspect tank for leakage by air testing as follows:
3. Repair tank by welding.
4. Repair tank with large holes by
welding metal patches to tank.
5. After welding, drain water from
1. Connect a suitable air supply to
tank, and plug all openings.
2. Submerge tank in water, and
apply air pressure of 1.5 PSI. Check for
air bubbles.
b. Inspect liquid level gauge by holding
gauge in hand and twisting handle in a
clockwise direction. The rubber seal ring
should swell slightly as handle is twisted.
If rubber seal ring does not swell, replace
liquid level gauge.
c. Inspect magnetic plug for its capability to pick up metal particles. If it has
lost its magnetic capability, replace magnetic plug.
d. Inspect threaded holes in tank for
dam aged threads.
8-90. REPAIR.
a. Repair leakage or holes in tank as
follows:
1. Steam clean tank.
tank.
6. Pressure test tanks for leakage
in accordance with paragraph 8-89, step a.
b. Repair damaged threaded holes by
retapping holes.
8-91. REASSEMBLY
Refer to figure 8-22 and reassemble
hydraulic tank in the reverse order of index
numbers assigned.
8-92.
INSTALLATION.
a. Refer to figure 8-21 and install
hydraulic tank in the reverse order of index numbers assigned.
b. Refer to Operator and Organizational
Maintenance Manual, and service hydraulic
tank.
Change 8
8-47
P-8-627-34
TM-07464A-35
TO
35C2-3-442-2
TM 5-6115-457-34
Section XIII. HYDRAULIC PUMP (PRECISE SETS ONLY)
8-93.
3.
4.
5.
6.
7.
8.
GENERAL.
The hydraulic pump is mounted to
the hydraulic pump drive group and is
driven through the camshaft gear. The
hydraulic pump is used on precise generator sets only. The hydraulic pump is a
positive displacement gear type pump with
a built in adjustable relief valve. The pump
is coupled to the pump drive group by means
of a tang type drive coupling. The pump
consists of a shaft, dual gears, sleeve
bearing and seal.
b. When removing pump assembly (8)
from pump drive, hold hand under adapter
flange on pump drive to catch coupling
shaft (6) when it drops out.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
8-94. REMOVAL.
Refer to figure 8-23 and remove
hydraulic pump in the order of index numbers assigned. Pay particular attention to
the following.
a. Disconnect hose assemblies (1 and 2)
from pump suction and discharge ports, and
plug hose assemblies to prevent fluid spillage.
Bolt (4)
Washer (4)
Gasket
Coupling shaft
Fitting (2)
Pump assembly
8-95.
CLEANING.
Wash pump assembly in an approved
solvent to remove grease, and hydraulic
fluid residue. Dry with a lint free cloth.
8-96. INSPECTION.
a. Check pump shaft for freedom of
rotation.
b. Inspect coupling shaft (6) for nicks
and burrs on tang end.
c. Inspect condition of threaded holes
in suction and discharge ports.
d. Discard gasket.
8-97.
REPAIR.
CAUTION
Figure 8-23. Hydraulic pump, exploded
view (precise sets only)
Legend to figure 8-23:
1. Hose assembly (suction)
2. Hose assembly (discharge)
8-48
Change 8
I
Do not use a grinding wheel on
coupling shaft tang.
a. Remove nicks and burrs on drive
tang of coupling shaft using a suitable
file.
P-8-627-34
TM-07464A-35
WARNING
Hydraulic Fluid is highly toxic to
skin, eyes and respiratory tract.
Eye and skin protection required.
Good general ventilation is normally adequate.
b, Damaged threads on suction and discharge ports may be retapped with a 1/2
inch N.P.T.F. tap. Flush pump with clean
hydraulic fluid to remove cuttings after r e tapping.
8-98. HYDRAULIC PUMP TEST AND
ADJUSTMENT (ON PRECISE
GENERATOR
SETS ONLY).
—
Test and adjust the hydraulic pump
as follows:
NOTE
Rotation of pump is clockwise as
viewed from drive end.
a. Connect hydraulic pump drive shaft
to suitable vary-drive capable of 0 to 2500
RPM.
b. Connect supply line of suitable hydraulic test stand to IN port of pump. Pump
should have fluid reservoir mounted higher
than pump inlet.
NOTE
Test stand should have an adjustable
restriction valve in return line after
flow meter.
c. Connect a suitable 0 to 500 PSI gauge
and throttling valve to OUT port of pump.
Connect out port of throttling valve to test
stand flow meter.
TO
35C2-3-442-29
TM 5-6115-457-34
should indicate 320 ±10 PSI. If not, remove relief valve cap located next to pump
IN port. Adjust relief valve to obtain 320
±10 PSI. Open throttling valve and permit
approximately one gallon to flow through
valve. Close valve and check gauge, reading should be 320 ±10 PSI. If not, readjust
relief valve. Install relief valve cap after
adjustment is made.
e. Open throttling valve. Slowly close
test stand restriction valve until a flow of
2 GPM is indicated on flow meter. Check
gauge, reading should be 320 ±10 PSI.
f. Remove pump from test equipment.
Replace pump that does not provide a minimum of 2 GPM at 320 ±10 PSI.
8-99.
INSTALLATION .
Refer to figure 8-23 and reassemble
hydraulic pump in reverse order of index
numbers assigned. Pay particular attention to the following.
a . Use one wrap of thread sealing tape
or thread sealing compound MIL-T-5544 when
installing elbows (7) . Apply a liberal
amount of grease MIL-G-10924 to the pump
s h a f t , coupling (6) and drive shaft.
Grease will prevent coupling from dropping when installing pump and reduce wear
during operation.
b. Position pump so that relief valve
is pointing down.
c. Rotate shaft with fingers to position tang drive to mate with coupling
shaft tang.
CAUTION
d. Open throttling valve and test stand
restriction valve. Start vary-drive and
adjust speed to 1500 to 2116 RPM. Slowly
close throttling valve and observe gauge
reading. With valve fully closed, gauge
Do not force pump onto drive flange.
d. Pump must seat squarely on drive
flange.
Change 8
8-49
■ P-8-627-34
TM-07464A-35
TO
35C2-3-442-2
TM 5-6115-457-34
Section XIV. HYDRAULIC PUMP DRIVE GROUP
8-100. GENERAL.
The hydraulic pump drive group is
mounted to the engine front plate and is gear
driven from the camshaft gear. It is utilized on precise generator sets only. The
hydraulic pump drive group consists of a
shaft, a gear, bearings, a seal and gaskets.
The hydraulic pump drive group drives the
hydraulic pump.
8-101. REMOVAL.
a. Refer to paragraph 8-94 and remove
hydraulic pump (8) (precise generator sets
only).
Ž
Compressed air used for cleaning and
drying purposes can create airborne
particles that may enter the eyes.
Pressure shall not exceed 30 psig.
Eye protect ion is required.
CAUTION
Do not spin dry bearings.
Clean all parts with an approved
cleaning solvent and air dry. Dry
bearings with low pressure compressed air.
8-104. INSPECTION.
b. Refer to figure 8-24 and remove the
hydraulic pump drive group by removing
screws (1 and 4), nuts (2 and 5), lockwashers (3 and 6) and gasket (7).
a. Check bearings for freedom of rotation. Replace a bearing if its rotation is
rough.
8-102. DISASSEMBLY.
b. Inspect bearings for pits, scratches,
cracks or chipped races.
Refer to figure 8-24 and disassemble
hydraulic pump drive group in the order of
index numbers assigned. Pay particular
attention to the following:
a. When removing adapter (14) note
position of drain hole to ensure correct
positioning during reassembly.
b. If necessary, remove gear (21) and
bearing (22) from shaft (23) using a suitable
arbor press.
c. Press bearing (20) out of adapter (24),
using a suitable arbor press.
8-103. CLEANING .
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
8-50
Change 8
c . Inspect drive gear teeth for nicks,
burrs, cracks and broken teeth. Nicks find
burrs that extend below the hardened surface
of the gear teeth arc cause for rejection of
the gear.
d. Inspect. drive gear teeth for wear
that may have destroyed the original tooth
shape. If this condition is found, replace
gear.
c. Inspect adapters for cracks. Replace
cracked adapter.
f. Inspect adapter mounting surface
and shaft for nicks and burrs.
g. Inspect threaded holes for threaded
damage.
P-9-TM-457-35
TM-07464A-35
h. Discard seal, gasket and lockring.
T.O. 35C2-3-442-2
TM 5-6115-457-34
2. Preheat gear (21) to a maximum
of 600°F
●
i. Check tang drive end of shaft. Slot
in shaft should be 0.253 to 0.257 inch wide.
Replace shaft if slot is not within limits.
3. Using a suitable arbor press,
press gear (21) onto shaft (23).
8-105, REPAIR.
b. Hand pack bearing (20) with an approved grease. Press bearing into adapter
(14) .
a. Remove minor nicks and burrs using
a suitable file or hone.
b. Repair minor thread damage using
a suitable thread chaser.
8-106. REASSEMBLY .
Refer to figure 8-24, and reassemble hydraulic pump drive group in the reverse order of index numbers assigned.
Pay particular attention to the following:
a. If removed, install gear (21) and
bearing (22) on shaft (23) as follows:
1. Hand pack bearing (22) with an
approved grease. Install bearing onto
shaft (23) .
c. Lubricate seal lip of seal (16) with
an approved lubricant before installing on
shaft (23) .
d. Locate oil drain hole in end adapter
(14). Drain hole must be pointed downward
when drive is mounted in gear cover.
8-107. INSTALLATION.
a. Refer to figure 8-24 and install the
hydraulic pump drive group, secure with
bolts (1 and 4), nuts (2 and 5), lock washers
(3 and 6) and gasket (7).
b. Refer to paragraph 8-99 and install
hydraulic pump (precise generator sets
only).
Change 1
8-51
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 8-24. Hydraulic pump drive group, exploded view
8-52
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Legend to figure 8-24:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Bolt (3)
Nut (3)
Lock washer (3)
Bolt
Nut
Lock washer
Gasket
Bolt (4)
Lock washer (4)
Cover
Gasket
Bolt (2)
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Lock washer (3)
Adapter
Gasket
Seal
Nut
Locknut
Ring
Bearing
Gear
Bearing
Shaft
Adapter
Section XV. GOVERNOR ACTUATOR UNIT (PRECISE SET ONLY)
8-108. GENERAL.
The governor actuator unit is located
on the right side of engine, mounted on top
of the utility governor. The actuating unit
is an electro-hydraulic servo motor that
receives intelligence from the electric control unit and converts this low level electrical information to proportional high level
hydraulic pressures that position the engine
throttle by the action of a piston and a floating lever pivot linkage system. The governor actuator unit is composed of control
valves, a piston, a linkage assembly and
core and armature assembly,
8-109. TEST AND REMOVAL.
a. Symptom and Isolation of malfunction.
A malfunction of the hydraulic throttle actuator is usually indicated by engine shutdown
or overspeed when the Start-Run-Stop
switch is transferred from the START to
the RUN position, frequency drift observed
on the frequency meters, sluggish response
to load changes, or no response in load
changes. To isolate the malfunction, proceed as follows:
1. Check for 4 to 6 VDC at test
points AB and CD of electric governor control unit (A and D are positive), with engine
operating. If voltage at either point is
approximately 15 volts, the malfunction is
a result of an open in an actuator valve
coil, or connecting circuit.
2. Check that the throttle linkage is
not badly worn or disconnected. A worn
linkage can cause sluggish response or
drifting frequency. A disconnected or
broken linkage can cause overspeed, shutdown, or no response. Also check linkage
for binding due to dirt or distortion.
3. Check condition of hydraulic
filter and the level of hydraulic oil. Either
a clogged or dirty filter or low oil level
can reduce the hydraulic pressure required
to operate the actuator.
4. Check pressure output of hydraulic actuator by removing plugs in ports Al
and A2 (figure 8-25) and inserting 0 to 400
PSI range gauges. The pressure at each
port should be 160 ±25 PSI and equal, with
engine operating under governor control.
8-53
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35
TM 5-6115-457-34
Operating under manual control, the
pressure at port Al should be 180±20
PSI and approximately 50 PSI higher than the
pressure at port A2.
5. Check the transducer in the
actuator for freedom of movement, Transducer must move freely for good response.
index numbers assigned. Pay particular
attention to the following.
1. Disconnect harness plug from
governor actuator unit before removing
from engine.
2. Plug hydraulic lines after removal.
6. If any of the above examinations
indicates that the actuator has failed, proceed with removal, disassembly and repair
instructions.
b. Removal. Refer to figure 8-25 and
remove governor actuator unit in order of
8-110. DISASSEMBLY.
Refer to figure 8-26 and disassemble
governor actuator unit in the order of index
numbers assigned. Pay particular attention
to the following.
Figure 8-25. Governor actuator unit, removal and installation (precise sets only)
8-54
TO
35C2-3-442-2
P-8-627-34
TM-07464A-35 TM 5-6115-457-34
Legend to figure 8-25:
1. Nut
2. Bolt
3. Clevis
4. Nut
5. Hose fitting
a. To remove transducer assembly (40),
setscrew (20) must be loosened.
WARNING
Avoid breathing fumes generated by
unsoldering/soldering. Eye protection is required.
b. To remove the core and armature
assembly(9), leads to receptacle J6
must be unsoldered. Unsolder these leads
only if armature and coil assembly are to
be replaced.
c. Remove needles (10) from armature
and coil assembly to prevent damage while
handling armature and coil assembly.
d. Top orifice (11) is removed by pulling
directly upward,
8-111. CLEANING.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
Compressed air used for cleaning and
drying purposes can create airborne
particles that may enter the eyes.
Pressure shall not exceed 30 psig.
Eye protection is required.
CAUTION
Do not immerse armature and coil
assembly in solvent.
a. Wash all governor actuator parts
except armature and coil assembly in an
approved cleaning solvent. Use low pressure compressed air to dry parts or a lint
free cloth.
6.
7.
8.
9.
Hose fitting
Precise actuator assy.
Bolt (4)
Lock washer (4)
b. Clean armature and coil assembly
with a cloth moistened with an approved
cleaning solvent and dry with a clean lint
free cloth.
c. Clean electrical connector sockets
and test jacks with low pressure, compressed air.
8-112. INSPECTION ,
a. Inspect piston (39) for scoring or
scuff marks. Inspect for nicks or burrs
or edge diameters in the center section of
the piston.
b. Inspect top orifice (11), spacer (13)
and bottom orifice (15) for nicks and burrs.
Inspect 3 cornered valve (14) for nicks and
burrs on vertical edges that could cause
binding. Inspect depth of needle hole in
top of valve. Hole should be at least 0,125
inch in depth. Inspect bottom of valve
(end opposite the needle hole) for indications
of grooving.
c. Using a suitable feeler gauge, check
the air gap on the armature and coil assembly (9) . Air gap should be 0.030 to 0.038
inch for each coil.
d. Inspect the condition of the filter
mesh in the filter assembly (27) for breaks
or oversize holes in the mesh screen. Inspect the solder joint securing the mesh
screen to inlet port body.
e. Inspect receptacles (18 and 23) for
broken pins and locating keys. Replace
defective receptacle.
f. Inspect all tapped holes in transducer
body for nicks or otherwise damaged threads.
g. Roll pin (33) when pressed into transducer body (41) must extend a minimum of
1 3/8 inches from the transducer body (41).
h. Discard all packings and gaskets.
Change 8
8-55
P-8-627-34
TM-07464A-35
TO
35C2-3-442-2
TM 5-6115-457-34
Figure 8-26. Governor actuator unit, exploded view (precise sets only)
8-56
Change 8
P-8-627-34
TM-07464A-35
TO
35C2-3-442-2
TM 5-6115-457-34
Legend to figure 8-26:
1. Screw (3)
2. Lock washer (3)
3. Cover
4. Gasket
5. Nut (2)
6. Setscrew (2)
7. Screw (2)
8. Lock washer (2)
9. Core and armature assembly
10. Needle (2)
11. Top orifice (2)
12. Preformed packing (4)
13. Spacer (2)
14. Valve (2)
15. Bottom orifice (2)
16. Screw (4)
17. Lock washer (4)
18. Receptacle
19. Gasket
20. Setscrew (2)
21. Screw (4)
8-113. REPAIR.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
a. Most repair work consists of polishing of parts. Use No. 320 to 500 fine grit
emery cloth for polishing all moving parts.
Clean after polishing with approved solvent
and dry thoroughly ,
b. Damaged threads can recleaned
up using the proper size pipe tap to remove burrs.
CAUTION
Under no condition use a file on this
valve surface, its length is critical.
c. The valves (14) may be polished to
remove nicks and burrs or slight groove
marks on the bottom of the valve. If after
polishing the lower face the overall length
of the valve is less than 0.240 inch, replace
the valves (14).
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
Lock washer (4)
Receptacle
Gasket
P lug (2)
Preformed packing (2)
Filter assembly
Preformed packing
Setscrew
Bolt
Lock washer
Link
Roll pin
Retaining ring (2)
Washer (2)
Preformed packing (2)
Collar (2)
Quad-ring (2)
Piston
Transducer assembly
Transducer body
Avoid breathing fumes generated by
unsoldering/soldering. Eye protection is required.
d. The filter assembly (27) may be repaired by soldering if screen mesh has
broken loose from the port body. Do not
attempt to solder up broken areas in the
screen mesh.
8-114. REASSEMBLY.
Refer to figure 8-26 and reassemble
governor actuator unit in the reverse order
of index numbers assigned. Pay particular
attention to the following:
a. Coat piston (39) with clean hydraulic
oil conforming to Military Specification
MIL-H-5606, prior to reassembly.
b. If receptacle (23) had to be removed
due to armature and coil assembly (9) replacement, reconnect coil leads to receptacle L1 and L2 coils as shown in figure
8-27 as they are located when transducer
Change 8
8-57
TO 35C2-3442-2
TM 5-6115-457-34
P-8-627-34
TM-07464A-35
Figure 8-27. Governor actuator unit, test and adjustment
body of actuator unit is positioned like that
shown in figure 8-27.
to transducer body (41). This dimension
is critical.
c. When inserting transducer assembly
(40, figure 8-26) in transducer body (41),
refer to figure 8-27 for location of transducer body and position of core in relation
d. After core is positioned in transducer
body, tighten set screw (29) in link (32) to
secure core control arm.
8-58
Change 8
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
8-115. TEST AND ADJUSTMENT.
a. Test equipment required.
1. Hydraulic pump (310 to 320 psi
at 2 GPM).
2. Power source (120V 60 Hz).
3. D.C. power source (0 to 1 AMP
24 V. D.C. ).
4. Switch, 2 pole, 3 position, 1 amp
2, If gauges G1 and G2 do not indicate the required pressures, adjustment of
valve screws (6, figure 8-26) on the armature and coil assembly (9) will have to be
made. Proceed as follows.
(a) Remove cover (3) and
place the governor actuator in a catch pan.
The catch pan should drain back to the
reservoir.
(b) Loosen lock nuts (5, figure
8-26) on each valve adjustment screw (6).
rating.
5.
Meter (2) (0 to 800 ma milliam-
eter).
6. Meter (1) (0 to 60 volts A.C.).r
7. Resistor (fixed -5000 ohms,
1 watt).
8. Gauge (3) (pressure 0 to 400 psi).
b. Actuator Valve and Piston Test.
Connect the governor actuator unit to test
equipment as illustrated in figure 8-27 and
proceed as follows:
1. With 24 vdc supply off, turn on
the hydraulic pump drive and adjust the
pressure to port P until G3 indicates 320
±10 psi. Adjust pressure by setting the
relief valve in the pump.
NOTE
The actuator output shaft shall be
in the fully extended position (throttle
open). Gauge G1 shall indicate 150
±10 psi. Gauge G2 shall indicate
200 ±10 psi.
(c) To adjust pressure at gauge
Gl, insert an allen wrench in screw (6) on
coil L1 adjustment screw (6) and rotate
clockwise (or in) to reduce pressure on
gauge G1. Rotating screw (6) counterclockwise will increase pressure on G1.
(d) Adjust pressure at gauge G1
by rotating screw (6) on coil L2 in the same
manner as pressure adjustment on coil L1
was preformed.
NOTE
Adjustment of one side (Ll) will in
some degree effect the opposite side
(L2); therefore, several adjustments
of both sides will be required to obtain the setting specified in step c.
(e) Tighten lock nuts (5).
(f) Turn power supply on and
position switch S1 to B and adjust 24 vdc
power source until MA1 and MA2 indicate
350 ±20 ma. The actuator output shaft
shall remain in the extended position.
Gauge G1 shall indicate 150 ±10 psi.
Gauge G2 shall indicate 200 ±10 psi.
Change 1
8-59
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
(g) Position switch S1 to A. Adjust 24 vdc power supply until MA2 indicates
700 ±40 ma. Piston shall fully retract.
Gauge G1 shall indicate 310 to 400 psi.
Gauge G2 shall indicate 0 to 20 psi.
(h) Position switch S1 to C. Adjust 24 vdc power supply until MA1 indicates
700 ±40 ma. Piston shall fully extend.
Gauge G1 shall indicate 0 to 40 psi. Gauge
G2 shall indicate 310 to 400 psi.
c. Actuator Output Shaft Position Transducer Test and Adjustment. Connect voltmeter V1 and power sources to receptacle
J4 on actuator as illustrated in figure 8-27
and proceed as follows:
NOTE
Hydraulic system components are not
used during this test.
CAUTION
The output shaft position transducer
is factory aligned and does not normally require readjustment.
1. Turn on the power supply.
2. Move the actuator output shaft
to fully extended position. Transducer
assembly (40) locked in place at dimensions
indicated in figure 8-27. V1 shall indicate
0.5 to 2.5 volts. This shall be minimum
voltage regardless of what other position
the output shaft is placed.
3. If voltage range on V1 is not with
the required 0.5 to 2.5 volts, loosen transducer core set screw (29, figure 8-26) on
link (32) and move the core relative to the
body until the minimum voltage of 0.5 to
8-60
2.5 is obtained on meter VI. Adjust to 1
volt as a starting point. Tighten the set
screw (29) in place.
d. Move the piston (39) gradually
towards the fully closed throttle position.
The transducer secondary voltage shall
increase in a linear manner to a maximum
of 48 to 55 volts. Loosen set screw (29) and
adjust to 50 volts as a starting point. Repeat core adjustment until the transducer
secondary voltage increases linearly from
the lowest possible value to a maximum
value over the entire 1.0 inch travel of the
piston (39). The ideal voltage range would
be from 0.5 volt minimum to 55 volts maximum. This range may not be possible to
obtain so the widest voltage spread will be
acceptable as long as the minimum and
maximum voltages are within the specified
limits.
e. Tighten transducer core set screw
(29) .
8-116. INSTALLATION.
Refer to figure 8-25 and install precise governor actuator in reverse order of
index numbers assigned. Pay particular
attention to the following.
a. Before connecting actuator clevis to
linkage, rotate fuel injection pump lever to
maximum throttle position and scribe an
indicating mark for referent e. Then rotate
fuel injection pump lever to minimum
throttle position and scribe an indicating
mark for reference.
NOTE
Fill FUEL POSITION on pump lever
is when top of lever is pushed towards
f rent of engine.
b. Install actuator on mounting plate and
secure with four mounting bolts.
P-8-627-34 TO 35C2-3-442-2
TM-07464A-35
TM 5-6115-457-34
c. Connect hydraulic and electrical
connections.
d. Align actuator clevis hole with hole
in linkage.
e. Loosen bolts securing pin bracket
and slide bracket forward. Pass pin through
clevis and pin bracket. Then tighten bolts
and secure clevis to pin with cotter pin.
f. Check that actuator output shaft can
move fuel inspection pump lever from full
throttle to closed throttle position according to the scribe marks.
g. If full operating range cannot be
reached, refer to linkage adjustment procedure in the Operator and Organizational
Maintenance Manual.
Change 8
8-61
P-8-627-34
TM-07464A-35
TO
35C2-3-442-2
TM 5-6115-457-34
Section XVI. WATER PUMP GROUP
8-117.
GENERAL
The water pump is mounted on the
front side of the timing gear cover. The
centrifugal-type pump is driven by the camshaft gear. The pump consists of an
impeller and drive gear mounted on a
common rotating shaft. Seals mounted on
the shaft prevent water from leaking into
the gear section and oil from leaking into
the impeller section. As the engine is
running, the drive gear in the water pump
turns the shaft and impeller. The impeller
creates a forceful flow of water through the
engine cooling system.
8-118.
REMOVAL
Refer to Operator and Organizational maintenance Manual, and remove
water pump.
8-119.
DISASSEMBLY
Refer to figure 8-28, and disassemble water pump in the order of index
numbers assigned. Pay particular attention
to the following:
a. Remove impeller (30) by removing
cotter pin (27), nut (28) and lock w a s h e r
(29). Install three 5/16-18 inch bolts in
tapped holes provided on the impeller.
Thread bolts evenly as they bottom out on
housing. As tension is increased,
impeller will slide from tapered shaft.
b. When pressing shaft (35) and bearing
(34) out of housing, place a nut on end of
shaft (35) to protect threads,
c . Press shaft (35)
of housing (42). Press
Do not remove bearing
front shaft (35) unless
8-62
Change 8
and bearing (34) out
from impeller end.
(34) and gear (23)
bearing (34), gear
(23) or shaft (35) is being replaced. Press
seal and ceramic ring assembly (33) out
of impeller end of housing.
8-120.
CLEANING
WARNING
Cleating Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protect ion required. Good general
ventilation is normally adequate.
a. Clean all metal parts with an approved cleaning solvent and dry thoroughly.
b. Clean calcium deposits from housing
using a stiff wire brush.
c . Remove all traces of old gasket
material from gear cover.
8-121.
INSPECTION
a. Check bearings for freedom of
rotation. Replace a bearing if its rotation
is rough.
b. Inspect bearings for pits, scratches,
cracks or chipped races. Replace
defective bearing.
c . Inspect shaft for nicks, burrs, pits
c r a c k s . Replace defective shaft.
d. Inspect threaded parts for thread
damage.
e. Inspect impeller for nicks, burrs,
erosion, or cracks, Replace erroded or
cracked impeller.
f. Inspect cover and housing for
c r a c k s . Replace defective parts.
I
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
g, Inspect gear teeth for nicks, burrs,
cracks and broken teeth. Nicks and burrs
that extend below the hardened surface of
the gear teeth are cause for rejection of
the gear.
h. Inspect gear teeth for wear that may
have destroyed the original tooth shape.
If this condition is found, replace gear.
i. Discard seals and gaskets.
b. Allow shaft assembly to cool. Install
water pump seal (36) in housing (42) using
an installation tool. Hand pack bearings
(22 and 34) with an approved grease. Install
shaft assembly into housing.
c. Place seal ring (33) and ceramic
ring (32) onto shaft and seat into housing
(38) and press seal and spring assembly
(31) until carbon washer contacts ceramic
ring.
8-122. REPAIR.
a. Remove minor nicks and burrs
using a suitable file or hone.
b. Repair minor thread damage using
a suitable thread chaser.
8-123, REASSEMBLY.
Refer to figure 8-28, and reassemble
water pump in the reverse order of index
numbers assigned. Pay particular
attention to the following:
a. If bearing (34) is being replaced,
gear (23) and bearing (22) must also be
removed from shaft (35) by preheating
shaft assembly in oil to a temperature of
300° F. Reassemble in reverse order before installing shaft (35) in housing (42).
Make sure bearing housing (26) is installed
on shaft after pressing bearing (34) on
shaft (35).
d. Slide impeller (30) onto shaft (35).
Install washer (29) and nut (28). Tighten
nut slowly forcing the impeller over the
tappered shaft surface until washer (29)
bottom out on shaft shoulder.
e. Torque impeller nut (28) from 25 to
35 foot pounds.
f. Check impeller tip clearance between
backside of impeller and housing. Clearance should be between 0.010 and 0.030
inch. If clearance is not within limits
disassemble and reassemble pump to
achieve proper clearance.
8-124. INSTALLATION.
Refer to Operator and Organizational Maintenance Manual, and install
water pump group.
8-63
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 8-28. Water pump group, exploded view
8-64
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Legend to figure 8-28:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
clamp (2)
Hose
Nipple
Bolt (2)
Lock washer (2)
Tube assembly
Gasket
Plug
Bolt
Washer
Bolt
Washer
Cover
Seal
Seal
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Nut (4)
Lock washer (4)
Cover
Gasket
Nut
Lock
Bearing
Gear
Nut (4)
Lock (4)
Cage
Cotter pin
Nut
Washer
30. Impeller
31. Seal and spring assembly
32. Ceramic
ring
33. Seal ring
34. Bearing
35. Shaft
36. Seal
37. Gasket
38. Housing assembly
39. Stud (4)
40. Stud (4)
41. Ferrule
42. Housing
Section XVII. CRANKSHAFT PULLEY, DAMPER AND TIMING GEAR COVER GROUP
8-125.
GENERAL
The crankshaft pulley is installed
on the front end of the engine crankshaft
and, by means of V-type drive belts, drives
the cooling fan pulley. The timing gear
cover is sealed to protect the timing gear
train, which consists of five gears located
at the front of the engine.
8-126.
f. Remove water pump group (para
8-118).
g. Refer to Operator and Organizational Maintenance Manual and remove
alternator.
h. Remove five bolts, washers and
lockwashers securing oil pan to timing
gear cover.
REMOVAL
a. Remove engine assembly (para 2-8).
b. Remove fan mounting group (para
8-31).
c. Remove hydraulic tank (precise sets
only) (para 8-86).
d. Remove hydraulic pump (precise
sets only) (para 8-94).
e. Remove hydraulic pump drive group
(para 8-101).
i. Removal of the crankshaft pulley,
damper and timing gear cover group is
accomplished during disassembly (para
8-127).
8-127.
DISASSEMBLY
Refer to figure 8-29, and disassemble crankshaft pulley, damper and timing gear cover group in the order of index
numbers assigned. Pay particular attention to the following:
8-65
P-9-TM-457-35
TM-0746A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 8-29. Crankshaft pulley, damper, and timing gear cover group,
exploded view
8-66
P-8-627-34
TM-07464A-35
Legend to figure 8-29:
1. Bolt (6)
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27,
Washer (6)
Damper
Bolt
Washer
Pulley
Bolt (2)
Lock washer (2)
Cap
Shim (12)
Shim (2)
Bolt (3)
Lock washer (3)
Bolt (5)
Lock washer (5)
Bolt
Nut
Lock washer
Trunnion assembly
Bushing
Trunnion support
Nut (4)
Lock washer (4)
Cover
Gasket
Stud
Bolt
a. Remove bolts (1) from face of
vibration damper (3) and separate damper
from pulley (3).
b. After removing bolt (4), use a suitable puller and remove crankshaft pulley
(6).
c. Separate top half of trunnion (9) and
retain shims (10 and 11) if present, for
reuse.
d. Since the accessory drive gear,
camshaft gear, crankshaft gear and oil
pump gears are covered under separate
sections that deal with these gears as part
of other assemblies, their removal, cleaning and inspection are covered in the
following sections.
Accessory drive gear, Section XX,
Par 8-150
Oil pump gears, Section XXIII, Par 8-172
Camshaft gear, Section XXVII, Par 8-204
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
TO
35C2-3-442-2
TM 5-6115-457-34
Lock
Washer
Bolt
Nut
Lock washer
Washer
Bolt
Lock washer (2)
Washer (2)
Nut
Bolt
Nut
Lock washer
Washer
Bolt (2)
Lock washer (2)
Washer (2)
Bolt
Lock washer
Washer
Bolt (2)
Lock washer (2)
Lock washer (2)
Seal
Cover
Gasket
Crankshaft gear, Section XXIX, Par 8-220
e. If it is necessary to remove one of
the timing gears, bar engine over manually
to bring all timing marks in line as shown
in figure 8-30, before removing a gear.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protect ion required. Good general
ventilation is normally adequate.
Compressed air used for cleaning and
drying purposes can create airborne
particles that may enter the eyes.
Pressure shall not exceed 30 psig.
Eye protection is required.
8-128. CLEANING
Clean all parts in approved solvent
and dry using compressed air or a lint free
Change 8
8-67
P-8-627-34
TM-07464A-35
TO 35C2-3-442-2
TM 5-6115-457-34
e. Discard seal and gasket.
cloth. Remove rust from pulley groove
using a stiff wire brush.
8-130. REPAIR.
8-129. INSPECTION
a. Remove minor nicks and burrs using
a suitable file or hone.
a. Inspect threaded parts for thread
damage,
b. Inspect crankshaft pulley for cracks
and worn grooves. Replace defective
pulley.
c . Inspect timing gear cover for cracks,
burred or nicked gasket surfaces. Replace
cracked timing gear cover.
d. Check trunnion and trunnion support
for flat spots and rough or grooved surfaces.
Figure 8-30.
8-68
Change 8
b. Repair minor thread damage using
a suitable thread chaser.
c. Remove rough edges on pulley
grooves with a small hand file.
8-131. REASSEMBLY
Refer to figure 8-29, and reassemble crankshaft pulley, damper and
Alignment of timing marks
T O 35C2-3-442-2
P-9-TM-457-35
TM-07464A-35 TM 5-6115-457-34
timing gear cover group in the reverse
order of index numbers assigned. Pay
particular attention to the following:
a. Apply a thin coat of approved sealant
to timing gear cover studs (26) before
installing cover (52).
b. When installing new gasket (53),
trim gasket flush with bottom face of
cylinder block and top front flange of oil
pan.
g. Torque bolt (4) from 210 to 250 foot
pounds, tap bolt head with a hammer, and
retighten to specified torque.
8-132.
INSTALLATION
a. Installation of the crankshaft pulley,
damper and timing gear cover group is
accomplished during reassembly (para
8-131).
b. Install oil pan to timing gear cover
and secure with five bolts, washers and
lock washers.
c. Torque all timing gear cover bolts
from 27 to 37 foot pounds.
d. Lubricate seal (51) lightly with
engine oil. Put MIL-S-22473 sealant on
the outer metal shell of the seal. Install seal into cover with flexible lip
toward the engine.
e. Fill slot in trunnion (9) with an approved grease. Install trunnion (9) and
trunnion support (21) using shims (10 and
11) previously removed.
c. Refer to Operator and Organizational Maintenance Manual and install
alternator.
f. Place a feeler gauge between trunnion (9) and bearing collar (19), add enough
shims to one side to maintain a clearance
of 0.002 inch to 0.003 inch tight.
h. Install fan mounting group (para
8-37).
d. Install water pump group (para 8-124).
e. Install hydraulic pump drive group
(para 8-107).
f. Install hydraulic pump (precise sets
only) (para 8-99).
g. Install hydraulic tank (precise sets
only) (para 8-92).
i. Install engine assembly (para 2-8).
Section XVIII. UTILITY GOVERNOR GROUP
8-133.
The ulility governor group is made
up of two major assemblies mounted on the
right side of the engine, the hydraulic
governor assembly and the governor drive
assembly. The governor consists of a
governor drive shaft, speed adjusting shaft,
low speed and high speed stop screws, r e lated linkages, and shutdown solenoid valve.
The speed adjusting shaft is used to set the
governor at the desired running speed. Low
speed and high speed stop screws are provided to limit the speed range of the governor. The utility governor is mechanicalhydraulic type which senses engine speed
by means of flyweights balancing against a
speeder spring. This governor is designed
to correct the fuel rate as a result of an
off-speed condition only. On units equipped
with the precise governor, the utility
governor is adjusted to maintain an engine
Change 9
8-69
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
speed above the desired speed. Therefore,
when the precise governor is controlling
the engine, the utility governor will move
to the position to deliver maximum fuel,
while the precise governor controls the fuel
rate so as to maintain the desired speed.
control arm from injector rack. Remove
housing, but do not force it.
8-134.
8-135.
REMOVAL
a. Refer to Operator and Organizational Maintenance Manual and remove
manual speed control.
b. Remove governor actuator unit
(precise sets only) (para 8-109).
c. UTILITY GOVERNOR, LINKAGE AND
OVERSPEED SHUTDOWN DEVICE. Refer to
figure 8-31 and remove utility governor,
linkage, oil lines and overspeed shutdown device in the order of index numbers assigned. Refer to figure 8-31A
when disassembly of overspeed shutdown
device is required.
NOTE
Prior to removal of the utility governor, make a note of the overall distance between the ball joint centers
(4, 5, and 6) so that this rod assembly can be reinstalled at the same
distance between ballpoint centers.
d. GOVERNOR DRIVE HOUSING. Refer
to figure 8-32 and remove governor drive
housing in the order of index numbers assigned. Pay particular attention to the
following:
1.
Remove governor drive coupling
(1) before removing housing bolt.
2. When bolts (2, 4, and6) are removed. governor housing (10) may be separated from rear plate assembly (12) by
pulling housing (10) to the rear approximately 1/2 inch. Allow housing (10) to drop
approximately 1/2 inch to disengage rack
8-70
Change 2
3. Remove nut (8) and remove rear
plate assembly (12) from rear of fuel
injection pump.
DISASSEMBLY
a. UTILITY GOVERNOR. Refer to
figure 8-33 and disassemble utility governor assembly in the order of index numbers
assigned. Pay particular attention to the
following:
1. Clamp the governor lightly in a
vise; vise jaws must grasp the base below
the base case joint on the sides under” the
terminal shaft.
2. Insert a 5/16 inch diameter rod
in the opening left after removing shaft
(13), and drive the other shaft (13) out.
3. Make a note of the distance the
high speed stop screw (19) protrudes from
the case (69) so that it can be set approximately the same when reassembling.
4. Use a 1/8 inch diameter punch or
rod to drive the pin (22) down from the top
of lever (28) into the case (69).
5.
Pull shaft (25) out of the case
(69).
6. Lift out the assembly consisting
of the lever (28), pilot valve plunger (49),
bearing assembly (50), and connecting
parts.
7.
Remove plug (29), and gasket
(30).
8. Remove springs (31 and 32).
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35
TM 5-6115-457-34
NOTE
If the valve (33) and sleeve assembly (34) cannot be removed easily
with a small pair of long-nosed
pliers (or tweezers) and a hook
scriber, leave them in the case (69)
until step 14,
9. Remove the valve (33), and
sleeve assembly (34).
14. Remove pump gears (58 and 59)
and gasket (61).
15. If the valve (33) and sleeve assembly (34) could not be removed in step 9,
insert a 3/16 inch diameter rod in the tapped
hole opposite the relief valve opening and
push the valve (33) out. Then insert a
suitable extracting tool in the relief valve
opening to pull out the sleeve assembly (34).
16. Clamp stud (66) in a vise.
10.
Take the governor out of the
vise and invert it, catching pin (39), piston
(40), and rollpin (22) (driven out of the
speed adjusting lever earlier),
Twist and pull case (69) to remove stud.
CAUTION
Be careful not to score the ground
Use snap ring pliers to take out
the snap ring (53) under the ballarms. Lift
out the ballhead assembly (57),
11.
1 2 . Remove snap ring (43) around
the bushing assembly (54) drive shaft spline,
and drive out bushing assembly (54) from
base (62).
1 3 . Remove screws (42) from the
base (62) and remove the base (62). If the
base (62) does not easily detach from the
case (69), clamp base (62) (governor nameplate side of the case up) lightly in a vise;
using a plastic or soft hammer, tap the
underside of case (69) to loosen it from
base (62).
CAUTION
Hold a hand under the base (62) and
case (69) joint to catch the pump
gears (58 and 59) which may drop
out as the base (62) and case (69)
are separated.
bottom surface of case (69).
17. If necessary, drive out bushings
(67 and 68) using a 3/8 diameter rod and a
suitable piloted driving block. In each instance drive the bushing (67 and 68) out of
the case (69) (rather than in towards the
center).
18. Clamp the fork (45) in a vise
with a pin hole up; use a thin screwdriver
or a small punch to drive the spring (46)
Off of the fork (45).
19. Twist the spring (46) to detach
it from the spring seat.
b. GOVERNOR DRIVE HOUSING. Refer
to figure 8-34 and disassemble governor
drive housing in the order of index numbers
assigned. Pay particular attention to the
following:
1. If maximum fuel stop assembly
(1, 2, 3, 4, and 5) is not to be repaired it
should not be disassembled,
8-71
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 8-31.
8-72
Change 2
Utility governor and linkage, exploded view
P-9-TM-457-35
TM-07464A-35
T.O. 35C-3-442-2
TM 5-6115-457-34
Legend to figure 8-31:
1. Nut (2)
2
Bolt (2)
3. Lock washer (2)
4 . Rod end (2)
5. Nut, lock (2)
6. Rod
7. Nut
8. B o l t
9. Bolt (2)
10. Lock washer
11. Washer
12.
Lever
13. Key
13A. Nut
13B. Washer
13C. Screw
Bolt (2)
14.
15.
Lock washer (2)
1A Overspeed shutdown device
16. Bracket
16A. Nut
16B.Screw,
cap
16C. Washer
16D. Bracket
17. Nut
18. Lock washer (2)
19. Washer (2)
20. B o l t
21•
Spring end (2)
22. Nut
23. Lock washer
24. Washer
25. Washer
26. B o l t
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47•
48.
49.
50.
51.
52.
53.
54•
55*
56.
57.
58.
59.
Spring
Screw set
Lever
Spring end (2)
Spring
Tube fitting (2)
Tube
Elbow (2)
Coupling
Bolt (2)
Lock washer (2)
Flange
Gasket
Elbow (2)
Tube
Tube Assembly
Inverted flare nut (2)
Tube
Elbow (2)
Solenoid valve
Union
Elbow 45”
Safety wire
Bolt (2)
Lock washer (2)
Flange
Gasket
Nut (4)
Lock washer (4)
Utility gov. assy
Gasket
Mounting plate
Gasket
Change 2
8-73
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 8-31A.
8-74
Change 2
Overspeed Shutdown Device
T.O. 35C2-3-442-2
P-9-TM-457-35
TM-07464A-35 TM 5-6115-457-34
Legend to figure 8-31A:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Solenoid
Rod end (3)
Link
Lever
Baseplate
Bushing
Spring
Rod
Bushing
Nut, flanged
Nut (4)
Nut (6)
Washer (4)
Screw, cap (4)
Nut
Spacer
Washer
Screw, cap
Washer
Screw, cap
Screw
Washer
Washer
Nut (2)
Change 2
8-74A
P-9-TM-457-35
T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 8-32. Governor drive housing, removal and installation
8-74B
Change 2
P-8-627-34
TM-07464A-35
TO
35C2-3-442-2
TM 5-6115-457-34
Legend to figure 8-32:
1.
2.
3.
4.
5.
6.
Coupling
Bolt(2)
Lock washer (2)
Bolt
Lock washer
Bolt
7.
8.
9.
10.
11.
12.
(b) Pilot valve (49) lands.
2. Seals (50) must be removed from
the outside of the housing. Do not attempt
to push towards center of housing.
(c) Bushing (55) O.D.
(d) Shaft (56) spline end,
8-136. CLEANING.
a. UTILITY
GOVERNOR.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
Compressed air used for cleaning and
drying purposes can create airborne
particles that may enter the eyes.
Pressure shall not exceed 30 psig.
Eye protection is required.
1. Clean all parts in unapproved
cleaning solvent and dry with a lint free
cloth.
CAUTION
Use extreme care when polishing
the pilot valve (49, figure 8-33)
control land. Leave corners sharp;
broken or rounded corners on this
land will ruin the valve.
2. Polish parts using No. 320 to
500 fine grit emery cloth.
b. GOVERNOR DRIVE HOUSING. Clean
all parts in an approved cleaning solvent
and dry with a lint free cloth.
8-137. INSPECTION.
a. UTILITY GOVERNOR
1. Refer to table l-1, and using a
suitable micrometer, check the following
parts for wear:
(a) Power piston (40, figure
8-33) O.D.
Lock washer
Nut
Lock washer
Governor drive housing
Gasket
Plate assembly
(e) Speed adjusting shaft (13)
O.D.
(f) Terminal shaft (25) O.D.
(g) Idler gear stud (66).
(h) Drive gear (59) O.D.
(i) Relief valve (33) O.D.
(j) Replace parts that have exceeded maximum-allowable wear limits.
2. Inspect ground bottom surface of
case (69) for grooves, scratches or wear.
3. Inspect the ground flat surface
of the base (62) for warpage, nicks, or
deep scratches.
4. Inspect the pump gears (58 and
59) as follows:
(a) Place the pump gears in the
gear pockets and check for free rotation,
(b) If the gears turn roughly,
inspect for nicks or wear of the gear teeth,
and for interference at internal corners of
the gear pockets in the base (62).
5. Check clearance between piston
(40) and case (69), piston should move
freely without binding or catching.
NOTE
Excessive clearance between piston
(40) and case (69), however, will result in excessive oil leakage within
the governor.
Change 8
8-75
P-8-627-34
TM-07464A-35
TO
35C2-3-442-2
TM 5-6115-457-34
Figure 8-33.
8-76
Utility governor assembly, exploded view
T.O. 35C2-3-442-2
P-9-TM-457-35
TM-07464A-35 TM 5-6115-457-34
Legend to figure 8-33:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
Screw (3)
Screw
Washer
Screw
Nut
Cover
Gasket
Screw
Lockwasher
Washer
Bracket
Cotter pin (2)
Shaft (2)
Seal (2)
Lever assembly
Bushing (2)
cup
Lever
Screw
Nut
Washer
Roll pin
Seal
Plug
Shaft
Spring wire
Lever
Lever
Plug
Gasket
Spring
Spring
Valve
Sleeve assembly
Washer
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
Sleeve
Plug
Washer
Pin
Power piston
Plug
Screw (3)
Snap ring
Spring assembly
Fork
Spring
Nut
Spring retainer
Pilot valve
Bearing assembly
Race
Balls
Snap ring
Bushing assembly
Bushing
Shaft
Ball head assembly
Gear
Gear
Pin (2)
Gasket
Base
Case assembly
Screw (2)
Nameplate
Stud
Bushing (2)
Bushing (2)
Case
8-77
T.O. 35C2-3-442-2
P-9-TM-457-35
TM-07464A-35 TM 5-6115-457-34
Figure 8-34. Governor drive housing, exploded view
8-78
P-9-TM-457-35
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Legend to figure 8-34:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Cap
Locknut
Lock washer
Washer
Threaded rod
Rack extension
Spring
Drive coupling (ref)
Bolt
Lockplate
Bolt
Lockplate
Plate assembly
Ball
Bushing
Plate
Gear
Gear assembly
Bushing
Gear
Bolt
Lockplate
Gear
Gasket
Cover plate assembly
Cover plate
6. Inspect rod ends (4, figure
8-31 and 6, figure 8-31A) for freedom of
movement of the ball within the housing
socket. Replace rod ends that bind.
7. Inspect governor return spring
(27, figure 8-31) for cracked coils and
the extremities (21) for worn/elongated
holes. Replace defective spring assembly.
8. Inspect overspeed shutdown
device for worn or defective parts and
linkage for freedom of movement. Replace
worn or defective parts.
9. Discard gaskets (7 and 61,
figure 8-33).
10. DC Solenoid - Refer to
Figure 8-31.
a . Check DC solenoid for
loose connection.
b. Check for foreign material causing poor electrical connection.
27.
28.
29.
30.
31.
32.
33,
34.
35.
36.
37.
38.
39.
40.
41,
42,
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
Bushing
Stud
Shaft
Snap ring (2)
Bolt
Lock washer
Shaft
Coupling
Spring
Bolt (2)
Lockplate (2)
Lever
Lever
Bolt (2)
Lockplate (2)
Plate
Pin
Handle
Housing assembly
Stud (4)
Dowel (2)
Pin
Housing subassembly
Seal (2)
Bushing (4)
Housing
c . Inspect DC solenoid valve
for worn or defective parts and valve for
freedom of movement. Replace worn or
defective part.
d . Check for proper voltage
24 VDC at solenoid terminals.
b . GOVERNOR DRIVE HOUSING.
1. Inspect bushings (15, 19,
and 27, figure 8-34) for scoring,
excessive wear, and other damage. Replace worn bushings.
2. Inspect drive gears (20 and
23) for excessively worn gear teeth.
3. Inspect shaft (29) for wear.
Check to see that all four oil holes are
open and clean.
4. Inspect shaft bushings (51)
for excessive wear and for grooving.
Replace defective bushings.
5. Discard gaskets (24) and
seals (50).
Change 6
8-79
P-9-TM-457-35
TM-07464A-35
8-138.
T.O. 35C2-3-442-2
TM 5-6115-457-34
REPAIR
a. UTILITY GOVERNOR.
1. Most of the repair work consists
of cleaning and polishing of parts. Use
No. 320 to 500 fine grit emery cloth for
polishing. All pistons should move freely
without binding or catching; excessive
clearance between mating parts, however,
will result in excessive leakage of pressure
oil within the governor.
2, Clean plugged oil holes in shaft
(29) using a small piece of wire. Do not
attempt to redrill holes.
8-139.
REASSEMBLY
a. UTILITY GOVERNOR, Refer to
figure 8-33 and reassemble utility governor
assembly in the reverse order of index
numbers assigned. Pay particular attention
to the following:
1. Drive dowel pins (60) out of base
2. Be extremely careful when
polishing pilot valve (49, figure 8-33)
control land. Leave the corners sharp;
broken or rounded corners on this land will
ruin the pilot valve.
3. If ground bottom surface of the
case (69) is grooved or worn from rotation
of the pump gears (58 and 59), or scratched
from mishandling, it may be surface ground.
Up to 1/32 inch may be removed. Lap the
surf ace smooth on a flat plate if a surface
grinder is not available.
CAUTION
Do not remove more stock than
necessary to clean up.
4. If the ground, flat surface of the
base (62) is warped, nicked, or deeply
scratched, it may be lapped smooth on a
flat plate. If the depth of the gear pockets
is reduced, the gears will bind; in this
event, the faces of the gears (58 and 59)
must be lapped to provide clearance,
b. GOVERNOR DRIVE HOUSING.
1. Repair gear (20 and 23, figure
8-34) teeth that have small nicks with a
fine hone.
8-80
(62).
2. If necessary to install new bushings (67 and 68), insert a suitable support
plate of exactly the correct width between
the inner walls of the case (69). Press
bushings (67 and 08) in with arbor press to
dimensions shown in figure 8-35. Press in
idler gear stud (66) to depth shown in
figure 8-35.
3. After installing bushings (67 and
68, figure 8-33), line size or line ream
with standard 3/8 inch diameter line
reamer.
4. Place pump gears (58 and 59) in
gear pockets of base (62).
CAUTION
Do not use adhesive on surface of
base (62).
5. Coat surface of base (62) with
engine oil (precise generator sets only).
6. Place gasket (61) in groove of
base (62).
7. Place case (69) on base (62), invert, and put the bushing assembly (54) in
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
(plunger installed with small diameter
towards outside of governor). Sleeve must
fit freely into case (69) bore.
14. Install high speed stop screw
(19) to the distance noted during disassembly paragraph 8-135, step a. 3.
Figure 8-35. Dimensions for installing
utility governor assembly bushings
b. GOVERNOR DRIVE HOUSING. Refer
to figure 8-34 and reassemble governor
drive housing in the reverse order of index
numbers assigned. Pay particular attention to the following:
through the bottom of the base (62) to permit rotating the pump gears (58 and 59).
1. Assemble items (30 through 51)
in housing (52).
8. Insert base screws (42) and
tighten while turning bushing assembly (54)
to insure free rotation of gears (58 and 59).
2. Press bushing (27) into plate
(26) with open end of bushing flush with
housing side of plate.
9. Insert dowel pins (60) and drive
them down approximately 1/16 inch below
base (62) surface. Remove bushing assembly (54).
3. Press shaft (29) into plate (26)
flush with fuel injection pump side of plate.
10. Place the ballhead assembly
(57) and bushing assembly (54) into its correct position in the case (69), and using
suitable snap ring pliers install the snap
ring (43).
11. Turn bushing assembly with
fingers. If it binds, loosen screws (42)
slightly and free up by striking at corners
of base (62). Tighten screws (42) and recheck.
12. Assemble seat (48) to pilot
valve (49), secure with nut (47), and wind
the spring (46) and fork (45 ) firmly into
the spring seat. Each end of spring (46)
must be securely attached to its mating
part.
13. Be sure relief valve plunger (33)
moves freely in sleeve assembly (34)
4. Assemble items (11 through 23)
to plate (26). Secure all lock plates. Gears
(20 and 23) are not timed.
8-140.
INSTALLATION
a. GOVERNOR DRIVE HOUSING. Refer
to figure 8-32 and install governor drive
housing in reverse order of index numbers
assigned. Pay particular attention to the
following:
1. Install plate assembly (12) to
rear of fuel injection pump. Plate assembly is located with two dowels secured in
pump housing. When installing plate assembly, drive gear (23, figure 8-34) will
slide over the extended camshaft on fuel
injector pump. Rotate gear (23) until
dowel pin on pump camshaft engages hole
in rear face of gear (23).
2. Install new gasket (11, figure
8-32) and install nut (8) and lockwasher (9).
8-81
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
3. Install rack extension (6, figure
8-34) and compression spring (7) through
plate assembly (13) until rack extension
contacts fuel inject on pump control rack.
Press in to collapse spring and rotate until
collar on rack extension (6) locks over the
fuel injection pump rack land. Slide entire
rack assembly back and forth to ensure
that parts are not binding, The double
notch at the housing end of the rack extension (6) should be in a vertical position.
4. Refer to figure 8-36 (view B).
Remove two screws from front of fuel injection pump. Insert finger and push
control rack back. Note that entire rack
and each extension move together. View A
of figure 8-36 illustrates how the rack
extension will engage the control lever.
This connection is extremely
critical and since it is made by feel
only, extreme care must be used.
5. Rotate shutdown lever handle (44,
figure 8-34) to downward position. Pull
control rack extension to the rear. With
complete drive housing in left hand and with
fingers of right hand on control shaft (33),
position drive housing onto face of rear
cover plate (25) approximately 3/4 inch
below top of rear plate. Slowly raise drive
housing while rotating control shaft (33)
back and forth until engagement is felt
between the lever and rack extension (figure 8-36, view A). Raise drive housing
completely, and secure with bolts (2, figure 8-32) and lock washers (3).
6. With finger inserted in opening
or front of injection pump (figure 8-36,
view B), and touching control rack, rotate
control shaft lever (33, figure 8-34) back
and forth. Control rack should follow in
8-82
Figure 8-36. Engagement of control rack
to control lever
both directions. If control rack only
moves forward but not backward, remove
drive housing, and attempt to re-engage
control lever with rack extension.
P-9-TM-457-35
TM-07464A-35
NOTE
Under no condition should the
engine be run unless the control
shaft can move the fuel injection
pump rack in both directions at
the point.
Under no condition should the control lever (39, figure 8-34) or the
rack extension be filed to make an
easier fit. If the parts do not
mate, it is only because the parts
are damaged and should therefore
be replaced, or the parts have
been assembled incorrectly,
7. If fuel rack stop assembly (1, 2,
3, 4, and 5) has been removed, assemble
to rear of housing but do not install cap (l).
Fuel stop will have to be set. This is
covered under governor drive housing
adjustment.
b. GOVERNOR DRIVE HOUSING
ADJUSTMENT. Maximum fuel stop setting
must be checked whenever governor drive
housing is removed. Proceed as follows:
1. Using an approved rack setting
gauge, refer to figure 8-36, view B, and
remove two screws, flange, and gasket
from flange at rear of accessory drive
housing.
2. Rotate knob of rack setting tool
counter clockwise until the number 3
appears under the micrometer dial.
Install tool in opening, using the same
screws that secure the flange. Do not use
gasket or lockwasher. Tighten screws
with fingers just enough to engage threads.
3. Rotate shaft (33, figure 8-34)
in a clockwise direction, pushing the pump
rack toward the front of the unit. When end
of rack contacts open end of rack setting
T.O. 35C2-3-442-2
TM 5-6115-457-34
tool, wiggle the tool slightly so that rack
slides inside of collar on the rack setting
tool .
4. Tighten two screws holding rack
setting tool until they are tight. Use a
wrench to tighten these two screws only
enough to firmly anchor the tool against the
flange face.
5. Turn micrometer dial clockwise
until the leading edge of the rotating dial
lines up with NO. 1. on the non-rotating
shaft and #0 on the rotating dial. Refer to
figure 8-37 (view A).
6. Rotate shaft (33, figure 8-34)
clockwise, pushing fuel injection pump
rack forward until it contacts rack setting
tool; and hold in this position with right
hand,
7. With the rack setting tool, set in
position as described in step 5. , slowly
rotate rack stop screw (5) clockwise with the
fingers or a small flat bladed screw driver
until contact is felt. While holding rack
stop screw, remove right hand from shaft
(33, figure 8-34) and tighten lock nut (2)
without moving rack stop screw (5).
8. To check adjustment, turn the
rack setting tool micrometer dial a few
turns counterclockwise. Rotate shaft (33)
back and forth a few times and end up
rotating shaft (33) clockwise and hold in
full fuel position. Rotate micrometer dial
on rack setting tool clockwise until it contacts fuel injection pump rack. Dial should
be reading +1 on the shaft and “0” on the
rotating dial. Refer to figure 8-37 (view A)
for allowable tolerances.
9. If reading is not within indicated
tolerances (figure 8-37, view A), repeat
procedure starting with step 5.
8-83
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 8-37. Installing fuel rack setting gauge
10. Check to see that locknut (2,
figure 8-34) is secure, apply cap (1), and
tighten. Secure with safety wire.
from edge of lever (18) when viewed in the
position shown.
NOTE
c. UTILITY GOVERNOR ADJUSTMENT - OFF UNIT. Set utility governor
droop setting prior to installation on the
engine. Refer to figure 8-38 and set droop
adjust bracket (11, figure 8-33) 0.187 inch
8-84
This setting is nominal. Additional
adjustment may have to be made.
Refer to paragraph 8-237 for final
adjustments during engine operation.
P-9-TM-457-35
T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 8-38. Utility governor droop setting
d. UTILITY GOVERNOR, LINKAGE AND OVERSPEED SHUTDOWN DEVICE. Refer to figures
8-31 and 8-31A and install utility governor, linkage, oil lines and overspeed
shutdown device in the reverse order of
index numbers assigned. Pay particular
attention to the following:
Insert governor drive coupling
(1, figure 8-32) into governor drive
housing and engage spline.
2. Install new gaskets (57 and 59,
figure 8-31) and mounting plate (58).
3. Install utility governor (56) on
the four mounting studs of the governor
drive housing. Governor drive coupling
(1, figure 8-32) will engage spline on
utility governor drive shaft. Do not force.
If coupling and spline do not engage, pull
Change 2
8-85
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
utility governor back just far enough to
rotate utility governor drive shaft with
the fingers, into a new position.
4. Install oil lines in such a
manner that undue stress is not applied
to the tube assemblies when positioning
the fittings.
5. Install governor linkage in
accordance with figure 8-31. Adjust rod
assembly (4, 5, and 6) in accordance
with Operator and Organizational Maintenance Manual. Whenever precise governor
linkage is to be installed, refer to
Operator and Organizational Maintenance
Manual.
6. Adjust overspeed shutdown
device linkage as follows:
(a) Disconnect governor rod
assembly (6, figure 8-31) from the governor control fuel rack lever (12).
(b) Adjust flanged nut (10,
figure 8-31A) against the spring limiter
bracket (16D, figure 8-31) to allow
approximately .03 inch free travel of
governor control fuel rack lever (12,
figure 8-31). This free travel measurement is made at the top of the lever.
(c) Tighten nut (11, figure
8-31A) against flanged nut (10).
(d) Adjust lower bushing
(6, figure 8-31A) to provide a measurement of 3.0 (+.125, -.062) inches
between the outside faces of bushings
(6 and 9, figure 8-31A).
Install governor actuator unit
(precise sets only) paragraph 8-116).
f . Refer to Operator and Organizational Maintenance Manual for the
following:
1. Install manual speed control.
2. Make final adjustment.
Section XIX. FUEL INJECTION GROUP
8-141. GENERAL.
8-142. REMOVAL.
The fuel injection group is mounted
to the rear of the accessory drive housing.
The fuel injection group consists of the fuel
injection pump housing, camshaft, fuel
injection pumps, fuel injection valves, and
associated tubing. Fuel, after passing
through the filters, flows into the injection
pump housing manifold which distributes
the fuel to the injection pumps. The injection pump for each cylinder measures and
delivers the fuel to its associated fuel
injection valve for insertion into the precombustion chamber. The amount of fuel
pumped per stroke is varied by turning the
pump plunger in the barrel. This turning
is accomplished by governor action through
the fuel regulator rack and gear arrangement. Injection pump plungers and lifters
are lifted by lobes on the fuel injection
camshaft.
a. Refer to Operator and Organizetional Maintenance Manual and remove
secondary fuel filter and relief valve
group, hydraulic oil filter (precise generator sets only), and overspeed switch,
8-86
Change 2
b. Remove utility governor group
(paragraph 8-134).
c. Removal of the fuel injection group
is accomplished during disassembly (paragraph 8-143).
CAUTION
Do not rotate engine crankshaft
after fuel injection pump has
been disconnected from accessory
drive.
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35
TM 5-6115-457-34
Figure 8-39. Fuel injection group, exploded view
(sheet 1 of 2)
8-87
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 8-39. Fuel injection group, exploded view
(sheet 2 of 2)
8-88
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T O 35C2-3-442-2
TM 5-6115-457-34
Legend to figure 8-39:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Bolt (5)
Nut (5)
Lock washer (5)
Clamp (10)
Fuel line assembly
Fuel line assembly
Fuel line assembly
Fuel line assembly
Fuel line assembly
Fuel line assembly
Seal assembly (6)
Seal (6)
Valve assembly (6)
Nut
Body
Nozzle assembly
Bolt
Lock washer
Bolt
Lock washer
Bolt
Lock washer
Bolt (2)
Lock washer (2)
Seal
Seal
Seal
Seal
Plug
Plug
Bracket
Bolt
Lockwasher
Nut
Lock washer
Bolt (4)
Lock washer (4)
Bolt (2)
Lock washer (2)
Fuel regulator rack
Felt washer (6)
Bushing (6)
Seal (6)
Bonnet (6)
Retainer ring (6)
Spring (6)
Check valve (6)
Plunger and barrel
assembly (6)
49. Screw
50. Gear
51. Barrel
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
8-143. DISASSEMBLY.
Refer to figure 8-39 and disassemble
fuel injection group in the order of index
numbers assigned. Pay particular attention
to the following:
NOTE
Tag all lines from each cylinder
for ease of assembly.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
Plunger
Spacer (6)
Spring (6)
Washer (6)
Lifter assembly (6)
Camshaft assembly
Dowel
Sleeve
Camshaft
Housing assembly
Bearing
Bearing
Pin (3)
Bearing
Plug
Bearing
Bearing
Ball (6)
Dowel (6)
Ball (6)
Dowel (6)
Plug
Plug
Dowel (2)
Housing
a clean, lint free cloth. Keep
parts for each injection pump
separate since each pump has
matched parts that are not
interchangeable.
b. Using a suitable extracting tool,
remove fuel pumps items (41 through 55,
figure 8-39).
a. Prior to disassembly of the valve
assemblies (13) and the fuel injection pumps,
perform tests outlined in paragraph 8-149,
step a.
c. Fuel regulator rack (40) must be
removed before removing lifters (56).
CAUTION
d. Using a suitable driver, remove
bearings (67 and 68).
All service work should be done at
a cleaning facility. Hands should
be clean and disassembly done on
e. Using a suitable removal tool,
remove camshaft bearing (63).
Change 8
8-89
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f. When removing fuel regulator rack
bearings (62 and 65, figure 8-39), first
make two scribe marks on housing above
groove on bearing (figure 8-40). This
procedure allows for the alignment of
groove on bearing with drilled lubrication
passage during reassembly.
g. Wire together each spacer (55, figure 8-39) and fuel pump lifter (56). Tag
each pair and identify the pump bore from
which they were removed.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protect ion required. Good general
ventilation is normally adequate.
8-144. CLEANING.
Clean metal components with an
approved cleaning solvent to remove fuel
oil, dirt, and accumulated deposits, and
dry thoroughly.
8-145. INSPECTION.
a. Refer to table 1-1, and using a
suitable micrometer and feeler gauge,
check for excessive wear as follows:
1. Rack bearing bore.
2. Fuel rack diameter.
3. Fuel rack to bearing clearance.
4. Camshaft bearing bore.
5. Camshaft bearing journal
diameter.
6. Camshaft to bearing clearance.
7. Pump plunger length. Inspect
plungers (52, figure 8-39) for excessive
wear on end which makes contact with
lifting washers (55 ). Length of new plunger
is 2.5931 to 2.5937 inches. The minimum
allowable length that a worn plunger may
continue to be used is 2.5881 inches.
NOTE
Whenever a plunger is replaced, it
is necessary to replace the entire
pump assembly.
8. If allowable limits are not met
on above parts, replace part.
b. Inspect pump housing (76) for cracks,
breaks, and clogged oil passages.
c. Inspect the drive tang on camshaft
(60) and drive sleeve (59) for signs of
wear.
d. Inspect camshaft (60) for damaged
lobes.
e. Inspect plunger and barrel assembly
(48), lifter assembly (56), and washer (55)
for excessive wear or damage.
Figure 8-40. Removing fuel regulator
rack bearings
8-90
Change 8
f. Inspect fuel rack (40) for nicks and
burrs and for chipped or cracked gear
teeth. If gear segments are cracked or
chipped, replace fuel rack.
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T O 35C2-3-442-2
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g. Inspect threaded holes for damaged
threads.
h. Discard seals.
8-146. REPAIR.
a. Repair minor nicks and burrs on
fuel rack (40, figure 8-39) using a suitable
file or hone.
WARNING
Fuel Oil if flammable and moderately
toxic to skin, eyes and respiratory
t r a c t . Eye and skin protection required. Good general ventilation
is normally adequate.
b. Ream out clogged passages in housing (76) with a thin flexible wire. After
cleaning passages, flush with fuel oil.
c. Repair minor thread damage using
a suitable thread chaser.
8-147. REASSEMBLY.
Refer to figure 8-39 and reassemble fuel injection group in the reverse order
of index numbers assigned. Pay particular
attention to the following:
a. All assembly should be done with
clean hands and on a clean, lint-free cloth.
b. Using a suitable installing tool,
install camshaft bearing (63) so that hole in
bearing aligns with oil passage in housing
(76) and is flush with housing face.
c. Install fuel regulator rack bearings
(62 and 65) so that groove in bearings
aligns with scribe marks on housing (76).
Bearing (65) must be installed 0.195 ±
0.005 inch deep from the housing face.
Figure 8-41. Installing regulator fuel rack
pump, align the notches in the bonnet (44,
figure 8-39), and barrel (51) with the
alignment mark 180 degrees from the pump
gear segment center tooth {figure 8-42).
Position pump so that the notches align
with the two locating dowel pins (70 and 72,
figure 8-39) in the housing bore. Align the
pump gear segment center tooth with fuel
regulator rack center notch (figure 8-43).
Install pump. Keep a downward force on
the pump, and install bushing (42, figure 8-39) until flush with the top of the
housing. If the bushing cannot be installed,
this far by hand, remove bushing, realign
component parts, and install again.
CAUTION
When tightening bushing (42), a
lesser torque value will allow pump
to leak; a greater torque value can
damage housing.
d. Use a suitable fuel rack setting
gauge when installing fuel regulator rack,
figure 8-41. Position fuel regulator rack
so that gauge indicates 0.00 inch.
e. Use the same extractor that was
used to remove each pump to install each
fuel injection pump. Sighting down the
Figure 8-42. Fuel injection pump alignment
Change 8
8-91
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that the gear segment is properly positioned with the rack.
CAUTION
An injection pump improperly installed in the “fuel on” side position of its gear segment can cause
an engine to overspeed with
resulting serious damage to the
engine and driven equipment.
Figure 8-43. Correct position of gear
segment and rack
h. Torque nozzle retaining nut (14,
figure 8-39) from 100 to 110 foot-pounds.
i. Torque fuel line nuts from 25 to
35 foot-pounds.
f. Tighten each pump bushing (42, figure 8-39) to a torque value of 140 to
160 foot -pounds.
CAUTION
A misaligned fuel injection pump
can cause an engine to overspeed
with resultant damage to engine,
turbocharger, and compressor.
g. Measure the rack travel to make
sure that the plunger gear segment is
properly meshed with the fuel rack. The
gear segment and rack are so constructed
that the maximum travel of the rack in
either direction can be obtained only when
the fourth tooth of the gear segment is
meshed with the fourth notch on the fuel
rack (figure 8-43). If the gear segment is
misplaced in either direction, the rack
travel will be reduced in both directions.
It is, therefore, necessary to measure the
rack travel in only one direction to make
certain that the gear segment is properly
meshed with the fuel rack. This is measured by using the rack setting gauge (figure 8-41). The rack is moved to its
extreme fuel on position. A minimum
reading of +0.312 on the gauge indicates
8-92
Change 8
8-148. INSTALLATION.
a. Installation of the fuel injection
group is accomplished during reassembly
(paragraph 8-147).
b. Install utility governor group (paragraph 8-140).
c. Refer to Operator and Organizational Maintenance Manual and install
overspeed switch, hydraulic oil filter (precise generator sets only), and secondary
fuel filter and relief valve group.
8-149. TESTING.
a. TEST FUEL INJECTION VALVES
FOR SPRAY CHARACTERISTICS, VALVE
OPENING PRESSURE AND LEAKING
RATE. Using a suitable diesel injector
pump test stand and diesel injector tool
test set, perform the following:
1. Before testing the valve assembly (13, figure 8-39), inspect screen filter.
If the screen is broken or clogged, discard
the valve assembly (13). If the screen appears normal, test the valve assembly (13).
P-9-TM-457-35
TM-07464A-35
2. Apply 1875 PSI to the valve
assembly (13, figure 8-39), a satisfactory
valve should emit a complete atomized
spray with a sharp cut-off of fuel and no air
dribble. If the valve assembly (13) emits a
solid stream of fuel with little or no
atomization, replace the nozzle assembly (16).
3. Valve assembly (13) unseating
pressure should be between 400 to 800 PSI.
If valve assembly fails to reach a minimum
of 400 PSI, replace valve assembly (13).
Reduce gauge pressure to 300 PSI. Observe
the gauge and note whether leakage causes
an additional drop in pressure. If the pressure falls more than 100 PSI in 30 seconds,
replace the nozzle assembly (16).
T. O. 35C2-3-442-2
TM 5-6115-457-34
b. FUEL INJECTION PUMP TIMING
DIMENSION CHECK AND ADJUSTMENT ON ENGINE (See figure 8-44).
1. Remove two bolts and lockwashers and timing pointer cover from flywheel
housing.
2. Remove fuel injection pump for
Cylinder No. 1 as outlined in paragraph 8-143.
3. Rotate crankshaft counterclockwise (as viewed from flywheel end) at least
60 degrees. Continue rotating crankshaft
counterclockwise until TC1-6 CYL mark
on flywheel is aligned with timing pointer
as shown in figure 8-45 and both the inlet
Figure 8-44. Fuel injection timing on the engine
8-93
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
9. Install fuel injection pump for
Cylinder No. 1 as outlined in paragraph 8-148.
10. Install timing pointer cover and
two bolts and lockwashers on flywheel
housing.
NOTE
Figure 8-45. Aligning timing pointer
on flywheel
and exhaust valves of Cylinder No. 1
are closed.
4. Install a suitable gauge in pump
bore. Measure timing dimension using a
depth micrometer. Timing dimension
should be 4.2159 to 4.2199 inches. If
timing dimension is correct, proceed to
step 9. If timing dimension is not correct,
proceed to step 5., and make an adjustment.
5. Remove small cover (24, figure 8-29) from front of timing gear cover
(50) and loosen accessory drive gear retaining nut (figure 8-44) (do not remove nut).
6. Using a suitable gear pulling tool,
separate gear from accessory drive shaft
(figure 8-44). Remove pulling tools.
Timing the fuel injection pump on
engine will take into consideration
a slipped accessory drive shaft
coupling or worn timing gears.
c. FUEL INJECTION PUMP TIMING
DIMENSION CHECK AND ADJUSTMENT (OFF ENGINE (See figure 8-46).
NOTE
Timing the fuel injection pump
off engine will adjust for wear on
the fuel injection pump only.
1. Install a suitable pointer assembly on fuel injection pump housing.
2. Install a suitable timing plate on
drive end of fuel injection camshaft (60,
figure 8-39).
3. Remove fuel injection pump for
cylinder being checked (paragraph 8-143).
Install a suitable gauge in pump bore.
7. Turn accessory drive shaft
extension counterclockwise and adjust
timing dimension. Timing dimension
should be 4.2159 to 4.2199 inches. If
timing dimension is within specified depth
range, proceed to step 8. If timing dimension is not within specified depth range,
replace worn spacer (55, figure 8-39) with
an approved spacer of additional thickness.
4. Refer to table 8-1 and select the
timing plate degree setting for lifter being
checked. Rotate timing plate counterclockwise until proper degree setting aligns with
pointer assembly (figure 8-46). Tighten
screw to lock in position.
8. Install accessory drive gear.
Tighten retaining nut from 90 to
110 foot-pounds. Recheck timing dimension. Replace cover.
5. Measure timing dimension using
a depth micrometer. Timing dimension
should be 4.2670 to 4.2680 inches. If
timing dimension is correct, proceed to
8-94
Change 1
P-9-TM-457-35
TM-07464A-35
Table 8-1. Timing Plate Degree Settings
T.O. 35C2-3-442-2
TM 5-6115-457-34
step 7. If timing dimension is not correct,
proceed to step 6.
6. If timing dimension is not correct, replace spacer (53, figure 8-3 9).
Select a spacer thickness which will correct the timing dimension. Spacers (53) are
available in varying thicknesses from 0.170
to 0.198 inch. Re-check timing dimension.
7. Install fuel injection pump as
outlined in paragraph 8-148.
8. If timing dimension is to be
checked for each cylinder, repeat step b.
following firing order of engine.
Figure 8-46. Fuel injection timing - off the engine
Change 1
8-95
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Section XX. ACCESSORY DRIVE GROUP
fuel filter and relief valve, speedswitch,
and hydraulic filter (precise sets only).
8-150. GENERAL.
The accessory drive group is
mounted to the timing gear housing plate.
The accessory drive group consists of
housing assembly, gear assembly, drive
shaft, bearing, sleeve, idler gear and
shaft. The accessory drive shaft drives
the utility governor, fuel injection pump,
fuel supply pump, and speedswitch. The
accessory drive gear is driven indirectly
by the crankshaft gear through an idler
gear which reduces the accessory drive to
one half engine speed.
8-151. REMOVAL.
NOTE
Removal of the accessory drive
group does not require removal
of the timing gear cover unless
the drive gear on the accessory
drive shaft or the idler gear has
to be replaced. If removal of the
accessory drive group less accessory drive gear and idler gear is
required, perform step a. If
removal of the accessory drive
gear and idler gear is required,
perform step b.
4. Remove fuel pump (paragraph 8-62).
b. If drive housing, drive shaft, drive
gear, and idler gear are to be removed,
proceed as follows:
1. Remove engine assembly
(paragraph 2-8).
2. Refer to Operator and Organizational Maintenance Manual and remove
alternator.
3. Remove fan group (paragraph 8-3 1).
4. Remove water pump group
(paragraph 8-118).
5. Remove hydraulic tank (precise
sets only) (paragraph 8-86).
6. Remove hydraulic pump (precise
sets only) (paragraph 8-94).
7. Remove hydraulic pump drive
group (paragraph 8-101).
a. If only the removal of the accessory
drive group less the drive gear and idler
gear is required, proceed as follows:
8. Remove crankshaft pulley,
damper, and timing gear cover group (paragraph 8-126).
1. Remove utility governor group
(paragraph 8- 134).
2, Remove fuel injection pump group
(paragraph 8-142).
9. Refer to Operator and Organizational Maintenance Manual and remove
secondary fuel filter and relief valve,
speedswitch and hydraulic filter (precise
sets only).
3. Refer to Operator and Organizational Maintenance Manual and remove
10. Remove fuel pump group
(paragraph 8-62).
8-96
Change 1
P-8-627-34
TM-07464A-35
11. Remove utility governor group
(paragraph 8-134).
12. Remove fuel injection group
(paragraph 8-142).
c. Removal of the accessory drive
group is accomplished during disassembly.
8-152. DISASSEMBLY.
Refer to figure 8-47 and disassemble accessory drive group in the order of
index numbers assigned. Pay particular
attention to the following:
a. If only the accessory drive housing
and drive shaft is to be removed and not the
accessory drive gear and idler gear, proceed as follows:
1. Refer to figure 8-29 and remove
cover (24) and gasket (25) by removing
nuts (22) and lockwasher (23).
CAUTION
Do not allow parts to drop inside
of transmission.
2. Remove nut (1, figure 8-47) and
washer (2) securing gear (3) to shaft (9).
Using a suitable puller, loosen drive gear
(3, figure 8-47) from shaft (9). Remove
bolts (5) and locks (6).
CAUTION
Do not allow puller to hook bearing
on outer race.
3. Remove bearing (8) using a
suitable puller.
4. Accessory drive shaft (9) may
be removed from housing, using a suitable
drift pin on hex head end of shaft inside
gear cover. Shaft (9) and bearing (8) can
be removed through rear of housing.
T O 35C2-3-442-2
TM 5-6115-457-34
NOTE
Idler gear assembly can not be removed for repair without removing
front gear cover. If repair or
replacement is required, refer to
paragraph 8-126 and remove
timing gear cover.
5. Before removing idler gear (26,
figure 8-47), bar engine over manually to
bring timing gear marks in line as shown
in figure 8-30.
8-153. CLEANING.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
Compressed air used for cleaning and
drying purposes can create airborne
particles that may enter the eyes.
Pressure shall not exceed 30 psig.
Eye protection is required.
a. Wash all parts in approved solvent
and dry with low pressure compressed air
or a lint-free cloth. Do net spin dry
bearing.
8-154. INSPECTION.
a. Refer to table l-l and inspect parts
for dimensional tolerances.
b. Check bearing (8, figure 8-47) for
freedom of rotation. Replace a bearing if
its rotation is rough.
c. Inspect bearing (8) for pits,
scratches, cracks, or chipped race.
d. Inspect bearing (25) and shaft (30)
for grooves and discoloration.
e. Inspect housing for cracks. Replace
cracked housing.
f. Inspect gear teeth for nicks, burrs,
cracks, and broken teeth. Nicks and burrs
that extend below the hardened surface of
the gear teeth are cause for rejection of
the gear.
Change 8
8-97
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T O 35C2-3-442-2
TM 5-6115-457-34
Figure 8-47. Accessory drive group, exploded view
8-98
Change 8
P-9-TM-457-35
T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Legend to figure 8-47:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Nut
Washer
Gear
Sleeve
Bolt (4)
Lock (2)
Retainer
Bearing
Shaft
Gasket
Plug (2)
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Bolt (2)
Lock washer (2)
Cover
Gasket
Housing assembly
Dowel (3)
Dowel
Housing
Gasket
Bolt
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
Lock
Plate
Gear assembly
Bearing
Gear
Nut
Bolt (2)
Lock
Shaft
Stud
g. Inspect gear teeth for wear that may
have destroyed the original tooth shape.
If this condition is found, replace gear.
a. Install idler gear washer (23) with
concave side toward idler gear.
h. Inspect threaded parts for thread
damage.
b. Remove timing pointer cover from
flywheel housing.
i. Measure O. D. of rear bearing surface at tang end of shaft. Measure I.D. of
bearing surface at fuel pump end of housing.
Maximum allowable clearance between
shaft bearing surface and housing should
not exceed 0.006 inch.
Inspect tang at fuel pump end of shaft
for nicks, burrs, and damage. Replace
damaged shaft.
j.
c. Rotate crankshaft counterclockwise
(as viewed from flywheel end) at least
60 degrees. Continue rotating crankshaft
counterclockwise until TC1-6-CYL mark on
flywheel is aligned with timing pointer as
shown in figure 8-45 and both the inlet and
exhaust valves of Cylinder No. 1 are
closed.
k. Discard gaskets.
8-155. REPAIR.
a. Remove minor nicks and burrs,
using a suitable file or hone.
b. Repair minor thread damage using
a suitable thread chaser.
8-156. REASSEMBLY.
Refer to figure 8-47 and reassemble accessory drive group in the reverse
order of index numbers assigned. Pay
particular attention to the following:
d. Install timing plate on rear face of
accessory drive housing as shown in figure 8-48. If timing plate can be installed,
timing is correct; proceed to step g. If
timing plate cannot be installed, proceed to
step f. and adjust timing.
e. Turn accessory drive shaft, using
extension nut, as shown in figure 8-48
until timing plate fits properly on accessory
drive housing. When plate fits flush
against housing (19, figure 8-47), drive
shaft is properly timed.
8-99
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T.O. 35C2-3-442-2
TM 5-6115-457-34
b. If only the accessory drive housing
and drive shaft were removed, proceed as
follow s :
1. Install fuel injection group
(paragraph 8-148).
2. Install utility governor group
(paragraph 8-140).
3. Install fuel pump group (paragraph 8-68).
4. Refer to Operator and Organizational Maintenance Manual and install
secondary fuel filter tank, speed switch,
and hydraulic filter (precise sets only).
c. If drive housing, drive shaft, drive
gear, and idler gear were removed, proceed as follows:
1. Install fuel injection group
(paragraph 8-148).
Figure 8-48. Accessory drive shaft timing
f. Remove timing plate. Install accessory drive gear as shown in figure 8-30.
Install conical washer with O.D. in contact
with gear, Align timing marks as shown
in figure 8-30. Tighten retaining nut (1,
figure 8-47) from 90 to 110 foot-pounds.
g. Refer to figure 8-29 and install
cover (24) and gasket (25) and secure with
nuts (22) and lockwashers (23).
8-157. INSTALLATION.
a. Installation of accessory drive group
is accomplished during reassembly
(paragraph 8-156).
8-100
2. Install utility governor group
{paragraph 8-140).
3. Install fuel pump group
(paragraph 8-68).
4. Refer to Operator and Organizational Maintenance Manual and install
secondary fuel filter and relief valve,
speedswitch and hydraulic filter (precise
sets only).
5. Install crankshaft pulley, damper, and timing gear cover group (paragraph 8-132).
6. Install hydraulic pump drive
group (paragraph 8-107).
7. Install hydraulic pump (precise
sets only) (paragraph 8-99).
P-8-627-34
TM-07464A-35
8. Install hydraulic tank (precise
sets only) (paragraph 8-92).
T O 35C2-3-442-2
TM 5-6115-457-34
11. Refer to Operator and Organizational Maintenance Manual and install
alternator.
9. Install water pump group
(paragraph 8-124).
10. Install fan group (paragraph 8-37).
Scction XXI.
12. Install engine assembly
(paragraph 2-8).
EXHAUST MANIFOLD GROUP
8-158. GENERAL.
The exhaust manifold group is
mounted to the cylinder head. The exhaust
manifold group consists of a heat shield,
manifold assembly, and gaskets. The
exhaust gases from the cylinders enter the
exhaust manifold and are then directed to
the turbocharger.
8-159. REMOVAL AND DISASSEMBLY.
Refer to figure 8-49 and remove
and disassemble exhaust manifold group
in the order of index numbers assigned.
Pay particular attention to the following:
Refer to Operator and Organizational Maintenance Manual and remove
turbocharger.
8-160. CLEANING.
a. Remove any traces of old exhaust
manifold gaskets,
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protect ion required. Good general
ventilation is normally adequate.
b. Use an approved cleaning solvent
and a stiff brush and remove all excess
rust and carbon deposits from manifold
and manifold hardware. Dry thoroughly.
Place hardware in a container of light
weight oil and allow to soak until needed
for reassembly.
c. Clean turbocharger mounting studs
with a stiff brush to remove rust.
8-161. INSPECTION.
a. Inspect manifold for casting cracks
around mounting flange bolt holes. Replace
defective casting.
b. Inspect threaded parts for thread
damage.
c. Inspect manifold mating surfaces
for nicks and burrs.
d. Replace all gaskets.
e. Replace all locks and lockwashers.
8-162. REPAIR.
a. Remove minor nicks and burrs from
manifold mating surfaces, using a suitable
file or hone.
b. Repair minor thread damage using
a suitable thread chaser.
8-163. REASSEMBLY AND
INSTALLATION.
Refer to figure 8-49 and reassemble and install exhaust manifold group in
Change 8
8-101
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Figure 8-49. Exhaust manifold group, exploded view
Legend to figure 8-49:
1.
2.
3.
4.
5.
6.
7.
Bolt (2)
Lock washer (3)
Shield
Nut (2)
Nut (8)
Lock (5)
Washer
8-102
Change 8
8. Nut
9. Lock
10. Washer
11. Manifold
12. Nut
13. Lock
14.
15.
16.
17.
18.
19.
Washer
Plug
Manifold assembly
Stud (2)
Manifold
Gasket (3)
P-8-627-34
TM-07464A-35
the reverse order of index numbers
assigned. Pay particular attention to the
following:
a. Coat stud threads with an approved
antiseize compound.
T O 35C2-3-442-2
TM 5-6115-457-34
b. Torque manifold bolts from 29 to
35 foot-pounds.
c. Refer to Operator and Organizational Maintenance Manual and install
turbocharger.
Section XXII. OIL PAN GROUP AND RELATED PARTS
8-164. GENERAL.
8-166. DISASSEMBLY.
The oil pan group is bolted to the
bottom of the crankcase. The oil pan group
consists of scavenge pump suction tube,
fluid level indicator and drain plug. The
oil sump contains an oil heater tube with
external water connections. The oil pan is
the reservoir which supplies the oil pump
with lubricating oil.
Refer to figure 8-50 and disassemble oil pan group in the order of index
numbers assigned.
8-165. REMOVAL.
NOTE
Fuel tank must be moved to the
rear approximately two feet if the
oil pump is not to be removed.
a.
Drain oil from oil pan.
b, Remove fuel fired heater if unit is
so equipped.
c.
Disconnect oil pan drain line at valve
d. Disconnect water connections at the
rear of oil pan if unit is equipped with a
heater kit.
8-167. CLEANING.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
a. Clean components with an approved
cleaning solvent, and dry thoroughly.
b. Flush interior of oil pan with an
approved cleaning solvent, and dry
thoroughly. Use a stiff brush to remove
encrusted oil sediment in bottom of pan.
c. Flush tube (2, figure 8-50) with an
approved cleaning solvent, and dry
thoroughly.
e, Refer to figure 8-50, and remove
oil pan group as follows:
d. Flush tube (19) with an approved
cleaning solvent to remove encrusted
calcium deposits, and dry thoroughly.
1. Remove bolts (6, 9, and 12),
lockwashers (7, 10, and 13), and washers
(8, 11, and 14). Remove pan (20) and
gasket (15).
8-168. INSPECTION.
2. Remove bolts (21 and 23), lockwashers (22 and 24), and plates (25 and 26).
3. Remove bolts (27), lochwashers
(28), plate assembly (34), and gasket (29).
a. Inspect gasket seal surface at top of
oil pan for burrs, nicks, or other damage.
b. Inspect scavenge tube (33, figure 8-50) to ensure that tube is open
throughout its length.
Change 8
8-103
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Figure 8-50. Oil pan group and related parts, exploded view
8-104
Change 8
T O 35C2-3-442-2
TM 5-6115-457-34
P-8-627-34
TM-07464A-35
Legend to figure 8-50:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Gauge assembly.
Tube
Fitting (3)
Plug
Plug
Bolt (20)
Lock washer (20)
Washer (20)
Bolt (3)
Lock washer (3)
Washer (3)
Bolt (5)
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Lock washer (5)
Washer (5)
Gasket
Bolt (2)
Lock (2)
Clip (2)
Tube
Pan
Bolt (6)
Lock washer (6)
Bolt (8)
c. Inspect tube (19) for damage.
Replace damaged tube.
d. Inspect fittings (3) for damage.
Replace damaged fittings.
e. Inspect components for dents, cracks,
distortion, and damaged threads.
f. Discard gaskets (15 and 29) and seal
(32).
8-169. REPAIR.
a. Remove minor nicks and burrs using
a suitable file or hone.
b. Repair dents and distortion using
proper tools.
c. Repair minor thread damage using
a suitable thread chaser.
8-170. REASSEMBLY.
Refer to figure 8-50 and reassemble oil pan group in the reverse order of
index numbers assigned.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
Lock washer (8)
Plate
Plate
Bolt (4)
Lock washer (4)
Gasket
Bolt
Lock
Seal
Tube assembly
Plate assembly
8-171. INSTALLATION.
a. Refer to figure 8-50 and install oil
pan group as follows:
1. Install new gasket (29), plate
assembly (34), lock washers (28), and bolts
(27).
2. Install plates (25 and 26), lock
washers (22 and 24), and bolts (21 and
23).
3. Install new gasket (15) and pan
(20). Install washers (8, 11, and 14),
lock washers (7, 10, and 13), and bolts
(6, 9, and 12).
b. Connect water lines at the rear of
oil pan.
c. Connect oil pan drain line.
d. Remount fuel fired heater if so
equipped.
Change 8
8-105
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Section XXIII. OIL PUMP GROUP
8-172. GENERAL.
The oil pump is mounted on the
bottom face of the cylinder block at the front
of the engine. The pump is a two-section,
positive displacement, gear-type pump.
One section scavenges oil from the rear of
the engine and dumps it into the oil pan
sump. The other section supplies lubrication, under pressure, to the basic engine
through passages in the cylinder block, and
to external components through oil lines.
The pump is driven by the crankshaft
through the oil pump idler gear.
8-173. REMOVAL.
a. Remove fuel fired heater and mounting brackets on right side if so equipped.
from shaft (41).
c. Using a suitable arbor press,
remove bearings (22) from body (24) and
bearings (36 and 44) from body (45).
d. Using a suitable arbor press,
remove shift (11) from body (45).
e. Do not remove ball (42) from body
(45). If ball (42) is damaged, replace
body (45).
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
b. Drain oil from oil pan.
8-175. CLEANING.
c. Disconnect oil pan drain line at valve.
CLean components with an approved
cleaning solvent, and dry thoroughly.
d. Disconnect water connections at the
rear of oil pan.
e. Refer to figure 8-50 and remove
bolts (6, 9, and 12), lock washers (7, 10,
and 13), and washers (8, 11, and 14).
Remove oil pan (20) and gasket (15). Discard gasket.
f. Refer to figure 8-51 and remove oil
pump in the order of index numbers assigned.
8-174. DISASSEMBLY.
Refer to figure 8-52 and disassemble oil pump group in the order of index
numbers assigned. Pay particular attention
to the following:
a. Using a suitable puller, remove
gears (30, Figure 8-52) from shaft assemblies (33 and 31).
b. Using a suitable puller, remove
gear (28) from shaft (33) and gear (37)
8-106
Change 8
8-176. INSPECTION.
a. Inspect gear teeth for nicks, burrs,
cracks, and broken teeth. Nicks and burrs
that extend below the hardened surface of
the gear teeth are cause for rejection of
gear.
b. Inspect gear teeth for wear that may
have destroyed the original tooth shape.
If this condition is found, replace gear.
c. Refer to table 1-1 and, using a
suitable micrometer and feeler gauge,
check for excessive wear as follows:
1. Drive gear shaft (33) diameter.
2. Gear to cover clearance.
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
figure 8-51:
Figure 8-51. Oil pump group, removal and installation
3. Idler gear shaft (34, figure 8-52)
diameter.
4. Drive idler gear shaft (41)
diameter.
5. Relief valve pressure spring (13)
outside diameter.
to 43.0 pounds, replace spring. Replace
spring if free length is not 3.57 inches
after test. . Do not attempt to stretch
spring.
e. Inspect components for dents, cracks,
distortion, and damaged threads.
f. Discard gaskets.
6. If allowable limits are not met,
replace part.
d. Using a suitable spring compressor,
apply a load of 36.6 to 43.0 pounds and
compress spring (13) to a length of 3.25
inches. If spring does not compress to a
length of 3.25 inches under a load of 36.6
8-177. REPAIR.
a. Repair minor nicks and burrs using
a suitable file or hone.
b. Repair dents and distortion using
proper tools.
Change 7
8-107
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 8-52. Oil pump group, exploded view
8-108
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Legend to figure 8-52:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Bolt (2)
Lock
Bell assembly
Gasket
Bolt (2)
Lock
Elbow
Gasket
Pump assembly
Bolt (2)
Lock (2)
Cover
Spring
Plunger
Bolt (2)
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Lock
Bolt
Lock
Bolt (2)
Lock
Body assembly
Bearing (2)
Dowel (2)
Body
Cotter pin
Nut
Washer
Gear
Key
Gear (2)
c. Repair minor thread damage using a
suitable thread chaser.
8-178. REASSEMBLY.
Refer to figure 8-52 and reassemble oil pump group in the reverse order of
index numbers assigned. Pay particular
attention to the following:
a. Using a suitable arbor press, install
bearing (36) flush with face opposite timing
mark.
b. Using a suitable arbor press, install
bearings (44, figure 8-52). The edges of
bearings (44) must be recessed O. 20 inch
beneath face of body (45) toward gear (28).
c. The edges of the bearings (22) must
be recessed 0.060 inch beneath face of
body (24) toward gears (30).
d. Using a suitable puller, install gear
(28) on shaft assembly (33). Tighten gear
retaining nut (26) to 60 foot-pounds torque,
plus amount to align cotter pin (25).
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
Key
Spacer
Shaft assembly
Shaft assembly
Gear assembly
Bearing
Gear
Body assembly
Shaft assembly
Dowel
Shaft
Ball
Dowel
Bearing (2)
Body
e. Make sure that all shafts turn freely
with no binding or drag on gears after
reassembly. If gears bind, loosen bolts
(15, 17, and 19) slightly, and relocate the
pump bodies by tapping them lightly until
shafts turn freely. Retighten bolts (15,
17, and 19).
8-179. INSTALLATION.
a. Refer to figure 8-51 and install
oil pump group.
b. Refer to figure 8-50 and install new
gasket (15) and oil pan (20). Install washers (8, 11, and 14), lockwashers (7, 10,
and 13), and bolts (6, 9, and 12).
c. Connect water lines at the rear of
oil pan.
d. Connect oil pan drain line.
e. Install fuel fired heater and mounting brackets if so equipped.
f. Refer to engine run-in (paragraph 8-237) for testing of oil pump.
Change 8
8-109
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Section XXIV. VALVE COVER AND VALVE MECHANISM GROUP
8-180. G E N E R A L .
The valve cover and valve mechanis m group is mounted on top of the cylinder
head. The valve cover is equipped with a
breather assembly, Which is provided for
crankcase ventilation. The valve mechanism group consists of intake and exhaust
rocker arm assemblies, push rods, and
lifters. Two arm assemblies are provided
for each cylinder, one operating the intake
valve and the other operating the exhaust
valve. The arm assemblies are operated
by the camshaft through lifters (and push
rods.
Removal of valve cover and valve
mechanism group is accomplished during
disassembly (paragraph 8-182).
8-182. DISASSEMBLY.
Refer to figure 8-53 and disassemble the valve cover and valve mechanism
group in the order of index numbers
assigned. Pay particular attention to the
following:
8-110
Change 8
NOTE
All lifters (20), except those in the
number one cylinder can be removed without removing the cylinder head.
b. Use a suitable piece of wire approximately 15 inches long, bent into a 1/2 inch
hook at one end, to remove lifters (20). If
lifters in the number one cylinder must be
removed, refer to paragraph 8-189 and
remove cylinder head.
8-183. CLEANING.
8-181. REMOVAL.
Legend to figure 8-53:
1. Clamp (2)
2. Hose
3. Bolt
4. Washer
5. Breather assembly
6. Seal
7. Bolt (4)
8. Lock washer (4)
9. Cover
10. Gasket
11. Bolt (15)
12. Lock washer (15)
13. Cover assembly
a. Using a suitable driver, remove
bearings (26 and 31) from arm assembly
bores (25 and 30).
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
a. Soak breather assembly in an
approved cleaning solvent to remove oil
fume deposits, and dry thoroughly.
b. Clean components with an approved
cleaning’ solvent, and dry thoroughly.
Gasket
Bolt (6)
Washer (6)
Nut (12)
Screw (12)
Push rod (12)
Lifter (12)
Retaining ring (2)
Washer
Spring (2)
Washer (2)
Arm assembly (6)
Bearing
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Bracket assembly (6)
Dowel
Front bracket
Intake arm assembly (6)
Bearing
Washer (11)
Spring (5)
Bracket (4)
Shaft assembly
Dowel
Rear bracket
Plug (2)
Shaft
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Figure 8-53. Valve cover and valve mechanism group,
exploded view
Change 8
8-111
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
8-184. INSPECTION.
a. Refer to table 1-1 and, using a
suitable micrometer, check for excessive
wear as follows:
1. Rocker arm bearing (26 and 31,
figure 8-53) bore.
2. Shaft (39) diameter.
3. Clearance between bearings and
shaft.
4. If allowable limits are not met,
replace part.
b. Inspect ball end of adjusting screw
(18) and valve contact surface of rocker
arm assembly (25) for nicks, discoloration,
and uneven wear.
c. Inspect rocker arm assembly (30)
and shaft (35) to ensure that oil passages
are open.
d. Check clearance between lifter (20)
and bore in block. Maximum allowable
clearance is 0.012 inch. If clearance is
exceeded, replace lifter.
e. Inspect push rod (19) for straightness. Rotate push rod on its ball center.
Maximum allowable runout is 0.020 inch
T.I.R. If limit is exceeded, replace push
rod. Do not attempt to straighten push
rod.
f. Inspect spring for cracks or distortion. If defective, replace spring.
g. Inspect rocker arm contact surfaces
for excessive wear. If defective, replace
rocker arm.
h. Inspect components for cracks,
breaks, and other damage.
i.
8-112
Discard seal and gaskets.
Change 8
8-185. REPAIR.
CAUTION
Do not remove any more material
than is required to remove discoloration and small nicks.
NOTE
The contact surfaces on adjustment
screw (18) and lifter end of push
rod (19) may be noted to have a flat
surface on the ball end. This flat
surface is allowed by the manufacturer during production and is
not to be considered a worn part.
The adjusting screw ball end is
allowed a 0.19 inch diameter flat,
and the lifter end of the push rod
is allowed a 0.125 inch diameter
flat .
a. Clean up contact surfaces on adjusting screw (18, figure 8-53) and rocker arm
assembly (25), using a hone.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
b, Clean out oil passages in rocker
assembly and shaft using a thin wire.
Flush with an approved cleaning solvent.
8-186. REASSEMBLY.
Refer to figure 8-53 and reassemble the valve cover and valve mechanism
group in the reverse order of index numbers assigned. Pay particular attention to
the following:
CAUTION
When installing bearing (26 and 31)
into arm assembly bores (25 and 30),
ensure that hole in bearing aligns
with hole in bore arm.
P-8-627-34
TM-07464A-35
a. Using a suitable driver, install
bearings (26 and 31, figure 8-53) into arm
bores (25 and 30).
8-187. INSTALLATION.
Installation of valve cover
and valve mechanism group is
T O 35C2-3-442-2
TM 5-6115-457-34
accomplished during reassembly (paragraph 8-186).
Refer to Operator and Organizational Maintenance Manual and adjust
valve lash.
Section XXV. CYLINDER HEAD GROUP
8-188. GENERAL.
The cylinder head group is mounted
to the cylinder block. The cylinder head
group consists of chamber assemblies,
valve springs, valve guides, and lifting
eyes. Cored passages in the cylinder head
directs the flow of coolant around the valve
ports and precombustion chambers. Oil
passages allow lubricant to be distributed
to the valve mechanism.
8-189. REMOVAL.
a. Refer to Operator and Organizational Maintenance Manual and remove the
following:
b. Remove exhaust manifold group
(paragraph 8-159).
c. Disconnect fuel injection pump lines
and injectors (paragraph 8-142) and install
plugs or caps to prevent dirt entering fuel
injection pump.
d. Remove fan mounting group
(paragraph 8-31).
e. Remove valve cover and valve mechanism group (paragraph 8-181).
1. Lifting frame.
f. Refer to figure 8-54 and remove
cylinder head by removing bolts (6 and 8)
and lockwashers (7 and 9). Attach a
suitable lifting device to lifting eyes (3)
and remove cylinder head.
2. Air cleaner assembly.
8-190. DISASSEMBLY.
3. Drain cooling system, loosen
hose clamp, and remove top radiator hose
and water pump by-pass hose.
Refer to figure 8-54 and disassemble cylinder head group in the order of index
numbers assigned. Pay particular attention to the following:
4. Ether start atomizer.
5. Water temperature sensing bulb.
6. High water temperature shutdown
sensing bulb.
7. Lube oil filter assembly.
8. Remove turbocharger group.
a. Using a suitable wrench, remove
precombustion chamber assemblies (21)
from cylinder head (38).
b. Using a suitable spring compressor,
remove springs (28) from exhaust and
intake valves (30 and 32).
Change 8
8-113
T O 35C2-3-442-2
P-8-627-34
TM-07464A-35 TM 5-6115-457-34
c. Tag each intake and exhaust valve
and the cylinder number it was taken from.
d. Using suitable bushing driver,
remove bushings (29, figure 8-54) from
cylinder head (38).
NOTE
Do not remove inserts (31 and 33)
unless replacement is required.
e. Using a suitable extracting tool,
remove inserts (31 and 33) from cylinder
head (38).
8-191. CLEANING.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protect ion required. Good general
ventilation is normally adequate.
CAUTION
Do not use a wire brush or a grinding wheel when cleaning components.
a. Place valves, valve bushings, and
retainers in an approved cleaning solvent
and allow to soak for at least one hour.
Using a stiff brush, remove all carbon
lacquer, and residue from parts, and dry
thoroughly.
b. Remove scale from cylinder head
using an approved cleaning solvent and a
stiff brush, and dry thoroughly.
c. Clean metal components with an
approved cleaning solvent, and dry
thoroughly.
8-192. INSPECTION.
a. Inspect cylinder heads for cracks,
damaged threads, distortion, or any
other defect.
b. Inspect precombustion chambers for
damaged threads, distortion, or cracks.
Check tightness of plug (20) on the side of
precombustion chamber.
c. Inspect valve springs for damaged
coils, cracks, and distortion. Check spring
8-114
Change 8
force. Compress each spring to a length
of 1.766 inches. Force required for compression should be 54.8 to 60.6 pounds.
Refer to table 1-1 for spring free length
and valve spring O.D. If limits are not
met, replace springs.
d. Inspect valve guides (29, figure
for cracks, distortion, and excessive
Check inside diameter of valve guides
using suitable pilot gauges. Refer to
table 1-1 for acceptable diameter and
mum allowable wear limits. If limits
exceeded, replace valve guides.
8-54)
wear.
(29),
maxiare
e. Inspect valve seat inserts for excessive
wear, pitting, cracking or improper seat
angle. The proper angle for seat and valve
is 30 degrees. Refer to table 1-1, and
using a suitable micrometer, check diameters
of inlet valve seat inserts and exhaust valve
seat inserts. If allowable limits are
exceeded, replace insert.
f. Inspect valves (30 and 32) for cracks,
pitting, distortion, or excessive wear, Use
a suitable micrometer and check valve stem
diameter. Refer to table 1-1 for maximum
allowable wear limits. If limits are not
met, replace valve.
g. Coat each valve face with a thin film
of Prussian blue, then rotate each valve in
associated valve seat. Remove valves and
examine contact pattern on each valve and
valve seat, A line of contact near top and
around entire circumference of valve seat
indicates line contact with valve. This
amount of line contact would indicate that
the valves and valve seats are acceptable.
If, however, line contact is not noted to
extend completely around the seat, or gaps
in line contact appear around the seat, it
would indicate that the valves have to be
reground.
h. Inspect valve seats (31 and 33). If
valve seat does not conform to the
P-9-TM-457-35
T.O. 35C2-3-442-2
TM-07464A-35
TM 5-6115-457-34
manufacturer’s minimum and maximum
dimension, it can not be reground and must
be replaced. Refer to figure 8-55.
seat inserts (31 and 33) must be replaced.
Use a suitable valve seat extractor to
replace valve seat inserts.
i. Inspect valves (30 and 32) using a
suitable micrometer, and check valve head
diameter, valve face angle, closed valve
projection, valve head diameter, and valve
lip thickness. Refer to figure 8-55. If
limits are exceeded, replace valve.
d. To install new valve seat inserts
that have been worn beyond acceptable
grinding tolerances, observe the following:
(This does not include valve seat inserts
that are loose.)
j. Inspect rotocoil assembly (27) for
freedom of rotation. Place rotocoil assembly in suitable test fixture with a 1 inch hole.
Insert the rotocoil in the hole and load the
top of the rotocoil to 58 pounds. The deflected height of the rotocoil under this load
should be 0.295 ± 0. 010 inch when measured from the fixture surface to the top of
the rotocoil. If this deflection required is
not met, replace rotocoil assembly.
k. Discard all gaskets.
8-193. REPAIR.
a. When results of inspections in step g. ,
paragraph 8-192 indicate that valves were
not properly seated, grind the valve seat
or seats using an approved valve seat
grinder, and grind the valve or valves,
using a suitable valve face grinding
machine.
b. After valve seats and/or valve faces
have been ground until they are smooth and
concentric with valve guides, clean all
parts with an approved cleaning solvent,
and dry thoroughly.
c. If exhaust and intake valve faces
(30 and 32, figure 8-54) and valve seat
inserts (31 and 33) have been ground for
proper seating, the dimensional specifications outlined in figure 8-55 must be met.
If dimensions are unacceptable, exhaust
and intake valves (30 and 32) and valve
1. Clean cylinder head with an
approved cleaning solvent, and dry
thoroughly.
2. Refer to table 1-1 to ensure that
head counterbores meet allowable limits
before installing inserts.
3. Immerse the cylinder head in
water heated to 180°F to 200°F for at least
30 minutes.
4. Rest the cylinder head upside
down on a bench, and lay a new insert in
counterbore, valve seat up. This must
be done quickly while the cylinder head is
hot and the insert is cold (room
temperature).
5. Using an approved valve seat
insert installation tool, drive insert down
tight into counterbore.
6. Grind the new valve seat insert
to the minimum allowable limit of the valve
seat insert tolerances shown in table 1-1.
e. To replace a loose valve seat insert,
the insert counterbore must be enlarged to
accept the next standard oversize insert.
After enlarging counterbore, refer to
preceding step d. for insert installation
procedure.
8-194. REASSEMBLY.
Refer to figure 8-54 and reassemble cylinder head group in the reverse
Change 1
8-115
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TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 8-54. Cylinder head group, exploded view
8-116
Change 1
P-9-TM-457-35
TM-07464A-35
Legend to figure 8-54:
1. Bolt (2)
2. Washer (2)
3. Lifting eye (2)
4. Nut
5. Plate
6. Bolt (18)
7. Washer (18)
8. Bolt (7)
9. Washer (7)
10. Plug
11. Bolt (4)
12. Lock washer (4)
13. Housing assembly
14. Seal
15.
16.
17.
18.
18A.
18B.
18C.
18D.
19.
20.
21.
22.
23.
24.
Temperature regulator
Washer
Gasket
Plug (4)
Screw (4)
Lock washer (4)
Cover
Gasket
Head assembly
Plug (6)
Chamber assembly (6)
Seal (6)
Gasket (6)
Gasket (6)
order of index numbers assigned, Pay
particular attention to the following:
. Lubricate exhaust and intake valve
(30 and 32), stems and valve guides (29)
prior to installation. Exhaust and intake
valve (30 and 32) heads are marked on top
for identification; e.g. , EX for exhaust
and IN for inlet,
b. If removed, install inserts (31 and
33) into cylinder head (38) using a suitable
installing tool.
c. Make preliminary valve clearance
adjustment. Adjust clearance for each
exhaust valve to 0.028 inch and each inlet
valve to 0.015 inch. Refer to Operator
and Organizational Maintenance Manual for
final valve adjustment.
d. Using a suitable valve guide driver,
install valve guides (29) into cylinder head
(39). Valve guide projection above cylinder must not exceed 0.875 inch.
e. Using a suitable spring compressor,
install springs (28) with painted end up.
Tap rotocoil assembly (27) lightly as spring
compressor is being removed to help seat
locks (26) properly.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
37A.
38.
39.
T.O. 35C2-3-442-2
TM 5-6115-457-34
Gasket (6)
Lock (24)
Rotocoil assembly (12)
Spring (12)
Valve guide (12)
Valve (6)
Insert (6)
Valve (6)
Insert (6)
Plug (7)
Plug (6)
Director (18)
Stud (12)
Bushing (12)
Head
Gasket
f. Align opening in director (36) with
“V” mark stamped on head.
g. Install new gaskets (25, 24, 23,
18D and 14.
h. Coat seal (22) and mating surface in
bore with liquid soap. Using a suitable
wrench, install chamber assemblies (21)
into cylinder head (38).
i. Torque plug (20) from 96 to
144 inch-pounds.
j. Torque chamber assemblies (21)
from 140 to 160 foot-pounds.
NOTE
Gasket (39) is to be clean and dry
prior to installation.
k. Position a new cylinder head gasket
(39) on the cylinder block. Rock head
gentle until it seats flat on head gasket.
1. Install cylinder head (38) and torque
cylinder head bolts (6 and 8) as shown in
figure 8-56.
Change 1
8-117
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TM-07464A-35 TM 5-6115-457-34
Figure 8-55. Valve and valve seat specifications
8-118
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Figure 8-56. Tightening sequence for cylinder head
8-195. INSTALLATION.
a. Attach a suitable lifting device to
lifting eyes (3, figure 8-54) on cylinder
head. Install cylinder head and secure with
bolts (6 and 8) and lock washers (7 and 8).
Refer to figure 8-56 for torquing sequence.
b. Install valve cover and valve mechanism group (paragraph 8-187).
c. Install fan mounting group (paragraph 8-37).
d. Install fuel injection pump lines and
injectors (paragraph 8-148).
e. Install exhaust manifold group
(paragraph 8-163).
f. Refer to Operator and Organizational Maintenance Manual and install the
foil owing:
1. Turbocharger group.
2.
Lube oil filter assembly.
3. High water temperature shutdown sensing bulb.
4. Water temperature sensing bulb.
5. Ether start atomizer.
6. Connect water pump by-pass
hose and top radiator hose.
7. Air cleaner assembly.
8.
Lifting frame.
9. Service cooling system.
Change 8
8-119
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Section XXVI.
FLYWHEEL AND FLYWHEEL HOUSING GROUP
8-196. GENERAL.
The flywheel and flywheel housing
group is mounted on the rear of the cylinder
block, The flywheel and flywheel housing
group consists of a cast housing flywheel,
ring gear, and engine support brackets.
The ring gear is shrink-fitted to the rim of
the flywheel. The purpose of the flywheel
is to provide a mass at the end of the crankshaft to smooth out power impulses and
reduce variation in rotative speed; and to
provide a mounting surface for the generrater coupling disc. The ring gear provides
a place for starting motor engagement when
cranking the engine. The flywheel housing
also provides a machined surface to mount
the generator adapter flange. Special
brackets are bolted to the housing pads to
provide support for the engine when the
generator is removed for repair. The
flywheel housing also provides a counterbore for locating the rear main oil
seal.
8-197. REMOVAL.
a. Remove engine assembly (paragraph 2-8).
b. Refer to Operator and Organizational
Maintenance Manual and remove air cleaner
assembly, starter motor, and turbocharger.
c. Removal of flywheel and flywheel
housing group is accomplished during disassembly (paragraph 8-198).
8-198. DISASSEMBLY.
Refer to figure 8-57 and disassemble
flywheel and flywheel housing in the order of
index numbers assigned. Pay particular attention to the following:
a. Scribe a mark on flywheel and crankshaft to show a relative position between
these two parts.
8-120
Change 8
WARNING
Attach lifting device prior to removal of bolts (8) to prevent flywheel from falling off the crankshaft end.
b. To lift flywheel assembly (10),
thread eyebolt into tapped hole provided on
flywheel face.
c. Attach lifting device, minimum capacity
250 lb (113.4 kg), and remove bolts (8), lockring (9), and flywheel (10).
d. Using a suitable mallet, stroke front
face of flywheel housing (21) alternately on
each side of engine to loosen and work flywheel housing (21) off dowel pins.
NOTE
Do not remove ring gear (11) from
flywheel assembly (10) unless
damage to ring gear (11) or housing ( 12) is evident.
e. Discard crankshaft seal (22).
8-199. CLEANING.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
Compressed air used for cleaning and
drying purposes can create airborne
particles that may enter the eyes.
Pressure shall not exceed 30 psig.
Eye protection is required.
a. Clean parts with an approved cleaning solvent and dry thoroughly.
b. Remove rust from ring gear, using a
stiff brush. Wash ring gear with solvent
and dry thoroughly.
T. O. 35C2-3-442-2
P-9-TM-457-35
TM-07464A-35
TM 5-6115-457-34
c. Flush out turbo drain port in housing
with solvent and dry with low pressure
compressed air.
8-200. INSPECTION.
a. Inspect flywheel housing for cracks.
Replace cracked flywheel housing.
b. Check machined gasket surface at
ring of flywheel housing for nicks and burrs.
c. Inspect threaded holes for damaged
threads.
d. Inspect ring gear teeth for nicks,
burrs, cracks, and broken teeth. Nicks
and burrs that extend below the hardened
surface of the gear teeth are cause for
rejection of the gear. Replace ring gear if
cracked or if teeth are broken.
e. Inspect ring gear for wear that may
have destroyed the original tooth shape.
If this condition is found, replace gear.
f. Inspect coupling disc counter bore
on flywheel for burred edges or an indication that coupling disc on generator does
not seat properly.
g. Discard seal and gaskets.
8-201. REPAIR.
a. Remove minor nicks and burrs from
flywheel housing and ring gear teeth,
using a suitable file or hone.
b. Repair minor thread damage using
a suitable thread chaser.
c. Replace a defective ring gear as
follows:
1. Cut or press off defective ring
gear.
CAUTION
Under no circumstances should the
ring gear (11, figure 8-57) be
heated over 600°F as excessive
heating may destroy the original
heat treatment. Do not heat
ring gear in one area.
2. Heat new ring gear to a maximum
of 600°F. Use a torch and apply heat
evenly around diameter of ring gear.
3. Install ring gear with chamfered
portion of ring gear teeth facing toward
starter pinion or to backside of flywheel.
Gear must be flush with flywheel shoulder.
CAUTION
Be careful to remove only the
burred material on the edge of the
coupling disc counterbore.
d. Remove sharp edges and burrs from
coupling disc counterbore in flywheel using
a suitable file,
8-202. REASSEMBLY.
Refer to figure 8-57 and reassemble flywheel and flywheel housing group in
the reverse order of index numbers
assigned. Pay particular attention to the
following:
a. Bottom edges of housing gasket
(22) that contacts oil pan plate must be cut
square and flush with oil pan plate before
flywheel housing is secured to crankcase.
b. Install two
cylinder block to
flywheel housing
located on dowel
suitable pilot studs in
act as guide pins while
is hoisted into position and
pins.
c. Install crankshaft seal (13) as
follows :
8-121
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 8-57. Flywheel and flywheel housing group,
exploded view
8-122
P-8-627-34
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TM 5-6115-457-34
Legend to figure 8-57:
1.
2.
3.
4.
5.
6.
7.
8.
Bolt (4)
Lock washer (4)
Plate
Bolt (2)
Lock washer (2)
Cover
Pointer
Bolt (9)
9.
10.
11.
12.
13.
14.
15.
Lockring
Flywheel assembly
Ring gear
Flywheel
Seal
Bolt (2)
Lock washer (2)
1. Fabricate pilot and sleeve as
shown in figure 2-1 (view F and G).
Lubricate sealing lip of seal
(13, figure 8-57) lightly with crankcase
oil. Put MIL-S-22473 sealant on the
outer metal shell of the seal. Bolt
pilot to the crankshaft flange and position seal on pilot with lip facing cylinder block as shown in figure 8-58
(view B).
3. Place sleeve on stud and install
3/4 inch washer 3/4-10 inch NC nut.
4. Tighten nut to press seal (13,
figure 8-57) into flywheel housing (21).
Remove installation tools.
16.
17.
18.
19.
20.
21.
22.
Bolt (9)
Lock washer (9)
Bolt (2)
Lock washer (2)
Plug
Flywheel housing
Gasket
g. Refer to figure 8-50 and install
lockwashers (22) and bolts (21) to secure
bottom of flywheel housing.
h. Check flywheel and flywheel housing
for parallelism and concentricity, using
suitable dial indicators as follows:
1. Remove fuel injectors, this will
relieve engine compression when rotating
crankshaft.
d. Torque flywheel housing bolts to
100 foot-pounds.
2. When making checks, position
dial indicators straight and square as
shown in figure 8-59 and 8-60 and make
sure indicators have adequate travel in each
direction.
e. Before locating flywheel assembly
(10, figure 8-57) on crankshaft, make sure
that alignment scribe lines are lined up.
3. Using a suitable board, apply
pressure to front end of crankshaft to make
sure end play is in one direction only.
f. Torque flywheel bolts to 150 footpounds. If lock rings tabs do not match
with flats on bolt heads, tighten bolts
slightly to match.
CAUTION
Do not loosen bolts to line up lock
ring tabs with bolt head flats.
4. Perform concentricity check as
shown in figure 8-59. Adjust dial indicator
to read zero at twelve o’clock position.
Apply continuous pressure to front end of
crankshaft and using tool, rotate crankshaft
one full revolution, taking readings at
45 degree intervals (8 readings each on
Change 8
8-123
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Figure 8-58. Installing crankshaft seal
8-124
Change 8
P-8-627-34
TM-07464A-35
Figure 8-59.
Figure 8-60.
T O 35C2-3-442-2
TM 5-6115-457-34
Flywheel housing bore concentricity check
Flywheel housing face parallelism check
Change 8
8-125
P-8-627-34
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flywheel housing (21, figure 8-57) bore).
Stop and remove tool before recording each
reading to ensure accuracy. The maximum
total indicator reading must not exceed
0.012 inch.
5. If the flywheel housing (21) bore
run-out is excessive, remove flywheel (12)
and loosen flywheel housing attaching bolts
(14, 16, and 18) slightly and tap the flywheel
housing (21) with a soft hammer in the
required direction until the run-out is within
limits. Re-tighten the attaching bolts (14,
16, and 18), install flywheel (12) and recheck the run-out.
6. Perform parallelism check as
shown in figure 8-60. Adjust dial indicator
to read zero at twelve o’clock position.
Apply continuous pressure to front end of
crankshaft and using tool, rotate crankshaft
one full revolution, taking readings at
45 degree intervals (8 readings each on flywheel face). Stop and remove tool before
recording each reading to ensure accuracy.
The maximum total indicator reading must
not exceed 0.006 inch.
7. If the flywheel housing (21 , figure 8-57) face run-out is excessive, remove
flywheel housing (21), and check for dirt or
foreign material (such as old gasket material) between flywheel housing (21) and
cylinder block. Install flywheel housing
(21) and recheck the run-out. When run-out
is correct, bend up lock ring tabs (9, Figure
8-57).
8-203. INSTALLATION.
a. Installation of the flywheel and flywheel housing is accomplished during
reassembly (paragraph 8-202).
b. Refer to Operator and Organizational
Maintenance Manual and install air cleaner
assembly, starter motor, and turbocharger.
c. Install engine assembly (paragraph 2-8).
Section XXVII. CAMSHAFT GROUP
8-204. GENERAL.
The camshaft group is located on
the upper left side of the cylinder block and
is driven by the crankshaft gear. The camshaft group consists of a camshaft gear,
a thrust washer secured to the cylinder
block, and four sleeve type bearings. The
cams are forged integrally with the shaft.
As the camshaft rotates, the cams move
the valve lifters and push rods which activate inlet and exhaust valves.
b. Remove valve cover and valve mechanism group (paragraph 8-181).
c. Remove fan mounting group (paragraph 8-3 1).
d. Remove water pump group (paragraph 8-118).
e. Refer to Operator and Organizational
Maintenance Manual and remove alternator.
8-205. REMOVAL.
f. Remove hydraulic tank (precise
generator sets only) (paragraph 8-86).
a. Remove engine assembly
(paragraph 2-8).
g. Remove hydraulic pump (paragraph 8-94).
8-126
Change 8
P-8-627-34
TM-07464A-35
h. Remove hydraulic pump drive group
(paragraph 8-101).
i. Remove crankshaft pulley, damper,
and timing gear cover group (paragraph 8-126).
j . Removal of the camshaft group is
accomplished during disassembly (paragraph 8-206).
8-206. DISASSEMBLY.
Refer to figure 8-61 and disassemble camshaft group in the order of index
numbers assigned. Pay particular atten tion to the following:
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
Figure 8-61.
T
O
35C2-3-442-2
TM 5-6115-457-34
CAUTION
Use extreme care when removing
camshaft from engine block so
that camshaft bearings will not be
damaged by cam lobes passing
through bearings. Do not rotate
crankshaft with camshaft gear
removed.
8-207. CLEANING.
Clean components with an approved
cleaning solvent and dry thoroughly.
8-208. INSPECTION.
a. Refer to table 1-1 and, using a
suitable micrometer and feeler gauge,
check for excessive wear as follows:
1. Camshaft bearing journal
diameter.
2. Camshaft end clearance.
3. If allowable limits are not met,
replace part.
Camshaft group, exploded view
Legend to figure 8-61:
1. Bolt (4)
2. Lock
3. Gear
4. Bolt (2)
5. Lock
6. Washer
7. Camshaft
Change 8
8-127
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b. Measure bearing clearance between
bearings and camshaft journals as follows:
NOTE
Camshaft bearing clearance can be
determined only when camshaft
bearings are pressed into the cylinder block.
1. If camshaft journal dimension
measured in step a. indicates that journal
wear is within 0.002 inch of each other,
clearances between camshaft journals and
camshaft bearings can be calculated.
2. Using a suitable inside micrometer, measure the I.D. of the front camshaft bearing in the cylinder block. Subtract the measured diameter of the front
camshaft journal from the I. D. of the front
camshaft bearing in the cylinder block.
The result is the running clearance. Maximum allowable clearance is 0.008 inch.
3. If camshaft journal wear was
found to be more than 0.002 inch difference
between any two journals, the individual
camshaft bearings in the cylinder block will
have to be checked using the following
procedure.
4. Rotate cylinder block so that
bottom of block is facing up.
5. Using a suitable micrometer,
measure I.D. of each camshaft bearing.
Measure diameter of camshaft journal that
corresponds to bearing just measured.
Subtract measured diameter of camshaft
journal from measured I.D. of bearing.
The result is the running clearance. Maximum allowable clearance is 0.008 inch. If
within limit, proceed to step 9. If limit is
exc ceded, replace al 1 five camshaft bearings. Proceed to step 6.
6. Using a suitable puller, remove
all five camshaft bearings.
7. Using a suitable tool, install new
camshaft bearings. Front bearing must be
recessed 0.06 inch from front face of camshaft bore. Oil hole in bearing must align
with oil hole in cylinder block, and joint in
bearing must face cylinder block centerline.
Intermediate bearings must be flush with
front face of bearing bore. Rear bearing
must be recessed 0.06 inch from rear face
of bore.
8. Recheck running clearance.
Refer to step 5.
(a) Refer to Operator and Organizational Maintenance Manual and remove air
cleaner assembly and turbocharger group.
9. Rotate cylinder block so that top
of block is facing up.
(b) Remove flywheel and flywheel
housing (paragraph 8-197).
10. Install oil pump group (paragraph 8-179).
(c) Refer to figure 8-50 and
remove bolts (6, 9, and 12), lock washers
(7, 10, and 13), and washers (8, 11, and
14). Remove oil pan (20) and gasket (15).
Discard gasket.
11. Refer to figure 8-50 and install
new gasket (15) and oil pan (20). Install
washers (8, 11, and 14), lockwashers (7,
10, and 13), and bolts (6, 9, and 12).
(d) Remove oil pump group
(paragraph 8-173).
12. Install flywheel and flywheel
housing (paragraph 8-203).
8-128
Change 8
P-8-627-34
TM-07464A-35
13. Refer to Operator and Organizational Maintenance Manual and install turbocharger group and air cleaner assembly.
c . Inspect camshaft gear for nicked or
cracked gear teeth. If cracked, replace
gear.
d. Inspect camshaft for cracks and
distortion. If defective, replace camshaft.
T
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35C2-3-442-2
TM 5-6115-457-34
face cylinder block centerline. Intermediate bearings must be flush with front
face of bearing bore. Rear bearing must
be recessed 0.06 inch from rear face of
bore.
8-211. INSTALLATION.
a. Installation of the camshaft group is
accompli shed during reassembly (paragraph 8-210).
8-209. REPAIR.
Repair minor nicks and burrs on
camshaft gear using a suitable file or hone.
8-210.
REASSEMBLY.
c. Install hydraulic pump (paragraph 8-99).
Refer to figure 8-61 and reassemble camshaft group in the reverse order of
index numbers assigned. Pay particular
attention to the following:
a. Apply a graphite grease to camshaft
lobes prior to installing camshaft (7).
b. Align letter C on camshaft gear (3)
with letter C on crankshaft gear. Refer
to figure 8-30.
c . Measure gear end clearance. End
clearance should be 0.025 inch.
d. Camshaft front bearing
recessed 0.06 inch from front
Oil hole in bearing must align
in cylinder block, and joint in
b. Install crankshaft pulley, damper,
and timing gear cover pump (paragraph 8-132).
must be
face of bore.
with oil hole
bearing must
d. Install hydraulic tank (precise generator sets only) (paragraph 8-92).
e. Refer to Operator and Organizational
Maintenance Manual and install alternator.
f. Install water pump group (paragraph 8-124).
g. Install fan mounting group (paragraph 8-37).
h. Install valve cover and valve mechanism group (paragraph 8-187).
i. Install engine assembly (paragraph 2-8).
Section XXVIII. CONNECTING RODS AND PISTONS GROUP
8-212. GENERAL.
The connecting rods and pistons
group is located in the cylinder block. The
connecting rods and pistons group consists
of piston assemblies, connecting rod
assemblies, bearings, pins, and retainers.
The piston assemblies are attached to the
crankshaft by connecting rods.
Change 8
8-129
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8-213. REMOVAL.
a. Refer to Operator and Organizati onal Maintenance Manual and remove the
following:
1. Air cleaner assembly.
2. Drain cooling system. Loosen
hose clamps and remove top radiator hose
and water bypass hose.
3. Drain crankcase oil.
4. Remove ether start atomizer.
5. Remove sensing bulbs from
thermostat housing.
6. Remove oil filter assembly.
b. Remove lifting frame assembly
(paragraph 3-8).
c . Remove fan mounting group (paragraph 8-31).
d. Refer to Operation and Organizational Maintenance Manual and remove
turbocharger.
e. Remove exhaust manifold group
(paragraph 8-159).
f. Disconnect fuel lines from fuel
injection pump (paragraph 8-142).
g. Remove valve cover and valve mechanism group (paragraph 8-181).
h. Remove cylinder head group (paragraph 8-189).
i. Remove oil pan group (paragraph 8-165).
8-130
Change 8
Remove oil pump group (paragraph 8-173).
k. Removal of the connecting rods and
pistons is accomplished during disassembly (paragraph 8-214).
8-214. DISASSEMBLY .
j.
Refer to figure 8-62 and disassemble connecting rods and pistons group in
the order of index numbers assigned. Pay
particular attention to the following:
a. Prior to removing piston, note the
condition at the top of cylinder liner. If a
carbon ridge is present, it must be removed
using a suitable ridge reamer.
b. Rotate crankshaft until the connecting
rod and piston to be removed is at top dead
center. Carefully remove each connecting
rod and piston by pushing it out through top
of cylinder.
c. Using a suitable retaining ring
remover, remove two retaining rings (5).
Using a suitable drift, drive out piston
pin (6).
d. Using suitable tools, drive out
bushing (8) from connecting rod (7).
e. Tag each bearing halve (3), connecting rod assembly (9), and piston assem bly
(14) indicating which cylinder they were
removed from.
f. Use a suitable piston ring expander
to remove piston rings (10, 11, and 12)
from the pistons (13).
8-215. CLEANING.
WARNING
Cleaning Solvents are f lammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
a. Clean parts with an approved cleaning solvent and dry thoroughly.
P-9-TM-457-35
TM-07464A-35
CAUTION
Do not use broken piston rings or
carbon scrapers on ring lands
since this practice can result in
cutting sides of grooves. Be sure
bottom of each ring groove is
clean and oil return holes in oil
ring groove are open.
b. If pistons have carbon on them, soak
pistons in cold water overnight and then let
them dry (preferably in sunlight). Most of
the carbon can then be removed with a
hardwood stick.
8-216. INSPECTION.
a. Refer to table 1-1 and inspect parts
for dimensional tolerances. Replace defective parts.
b. Inspect piston for burned condition,
cracks, distortion, galling, or any other
defects. Replace defective piston.
c. Inspect piston pins and rod bearings
for scoring, galling, distortion, or cracks.
Replace defective bearings.
d. Inspect connecting rod for cracks,
breaks, or distortion. Replace defective
connecting rod.
NOTE
Bent rods should be discarded. D O
not attempt to align rods by bending.
Abrasive materials may roll around
between bearings (8) and crankshaft
journals causing scratches in the
bearing without actually becoming
embedded in the aluminum. Such
scratches are not necessarily harmful and do not indicate that bearings
(8, figure 8-62) should be replaced.
T. O. 35 C2-3-442-2
TM 5-6115-457-34
e, To measure clearance and gap for
each piston ring (10, 11, and 12), insert a
piston (13) in cylinder bore in the inverted
position. Insert each piston ring, one at a
time, about two inches down in the cylinder
bore and bring the bottom edge of the piston
(13) up against the ring to square the ring
in the cylinder bore. Check gap with a
feeler gauge. If gap clearance for any ring
is not as specified in table 1-1, the ring
must be filed or honed to specification, or
replaced.
8-217. REPAIR.
a. When installing a new bearing (8)
into the connecting rod, the joint on the
diameter of the bearing must be at right
angles (90 ± 10 degrees, either left or right)
of the vertical centerline of the connecting
rod. After pressing new bearing in place
machine accurately to dimensions in table
1-1.
b. Connecting rod bearings (3) should
always be replaced as a set (two halves
make a set). If inspection of one bearing
shell indicates minimum thickness, then
replace all six connecting rod bearing
shells.
8-218. REASSEMBLY.
Refer to figure 8-62 and reassemble connecting rods and pistons group in
the reverse order of index numbers
assigned. Pay particular attention to the
following:
a. Reassemble rod (7) on piston (13) so
that the etched cylinder number on rod (7)
is on the same side as the "V" mark in the
piston (13).
b. Use a suitable piston ring expander
to install piston rings (10, 11, and 12) on
8-131
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 8-62.
8-132
Connecting rods and pistons group,
exploded view
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Legend to figure 8-62:
1.
2.
3.
4.
5.
Nut (2)
Bearing cap (6)
Bearing (6)
Bolt (2)
Retaining ring (2)
6.
7.
8.
9.
10.
Pin
Rod
Bearing
Connecting rod assembly (6)
Ring
pistons (13). On each ring, the word “UP”
is stamped. Start with ring (12) and
install ring with the word “UP” pointing
toward the top of the piston. Stagger ring
gaps on piston so they are not in line with
each other.
c . Lubricate bearings (3 and 8), piston
rings (10, 11, and 12), and the liner walls
with clean engine oil.
d. Compress piston rings (10, 11, and
12) with a suitable ring compressor tool
and install piston (13) so that the “V” mark
on top of the piston lines up to the “V”
mark on top of the block.
e. When assembling lower bearing cap
(2) to connecting rod (7), make sure that
protruding tab on back of each bearing half
(3) lines up with corresponding recess in
connecting rod (7) and bearing cap (2).
f. Guide lower end of each connecting
rod (7) over crankshaft journal so as not to
damage crankshaft bearing surface.
11.
12.
13.
14.
Ring
Ring
Piston
Piston assembly (6)
3. Remove caps (2) and bearings
one at a time and measure thickness of
plastic strips. The measurement represents the bearing clearance. If the maximum clearance exceeds 0.010 inch, replace connecting rod bearings. It would be
advisable to replace all rod bearings (3) at
this time.
NOTE
Excessive bearing clearance can
also be an indication of crankshaft
surface being out-of-round.
g. Install caps (2) and bearings (3) and
torque bolts (4) as follows:
1. Lubricate threads of bolts with
crankcase oil, and tighten from 27 to
33 foot-pounds torque.
2. Mark bolts and caps. Tighten an
additional 85 to 95 degrees from mark.
8-219.
INSTALLATION.
g. Check connecting rod bearing clearance as follows:
a. Installation of the connecting rods
and pistons group is accomplished during
reassembly (paragraph 8-218),
1. Place an approved piece of
soft plastic measuring strip between
crankshaft journal and lower bearing half,
on all six connecting rod assemblies.
b. Install oil pump group (paragraph
8-179).
2. Install lower bearing caps (2,
figure 8-62) and tighten bolts, (4) and nuts
(1) from 27 to 33 foot-pounds torque.
c. Install oil pan group (paragraph
8-171).
d. Install cylinder head group (paragraph 8-195).
8-133
P-9-TM-457-34
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
e. Refer to Operator and Organizational Maintenance Manual and install
turbocharger.
f. Install fan mounting group (paragraph 8-37).
g. Install exhaust manifold (paragraph 8-163).
h. Refer to Operator and Organizational Maintenance Manual and install the
following:
Section XXIX
1. Install oil filter assembly.
2. Install sensing bulbs to thermostat housing.
3. Install ether start atomizer.
4. Install air cleaner assembly.
5. Connect top radiator hose and
water by-pass hose. Tighten clamps.
6. Install lifting frame (paragraph 3-8).
7. Service cooling system.
8. Fill engine crankcase.
CRANKSHAFT GROUP AND MAIN BEARINGS
8-220. GENERAL.
8-221. REMOVAL.
The crankshaft group and main
bearings are located in the cylinder block.
The crankshaft group and main bearings
consist of a crankshaft assembly, main
bearings, plates, gear, and plugs. The
end thrust of the crankshaft is taken up by
flanges on the lower half of the rear main
bearing, An oil seal pressed into the
timing gear housing cover prevents oil
leakage at the front of the engine. An oil
seal, pressed into the flywheel housing,
bears against the crankshaft flange and
prevents leakage at the rear of the engine.
Counterweights are forged integrally with
the crankshaft and are drilled to obtain
shaft balance. The crankshaft timing gear
is pressed on the front of the crankshaft.
The main bearings and caps support the
crankshaft in the cylinder block. Tabs
which are punched outward on each bearing
half fit into recesses in the cylinder block
and bearing cap, securing the bearing and
preventing it from rotating.
a. Remove engine assembly (paragraph 2-8).
8-134
b. Remove fan mounting group (paragraph 8-3 1).
c. Remove water pump group (paragraph 8-118).
d. Remove hydraulic tank (precise sets
only) (paragraph 8-86).
e. Remove hydraulic pump (precise
sets only) (paragraph 8-94).
f. Remove hydraulic pump drive group
(paragraph 8-101).
g. Refer to Operator and Organizational Maintenance Manual and Remove
alternator.
P-9-TM-457-35
TM-07464A-35
h. Remove crankshaft pulley, damper,
and timing gear cover group (paragraph 8-126).
i. Remove oil pan group and related
parts (paragraph 8-165).
j. Remove oil pump group (paragraph 8-173).
k. Refer to Operator and Organizational Maintenance Manual and remove air
cleaner assembly and turbocharger.
1. Remove flywheel and flywheel housing
group (paragraph 8-197).
m. Removal of the crankshaft group and
main bearings is accomplished during disassembly (paragraph 8-222).
8-222. DISASSEMBLY.
Refer to figure 8-63 and disassemble crankshaft group and main bearings in
the order of index numbers assigned. Pay
particular attention to the following:
NOTE
If only main bearing removal is
required, perform steps a.
through e.
a. Turn engine upside down and support
in a suitable fixture.
b. Remove bolts (1), washers (2), main
bearing caps (3), and lower bearing
halves (4).
c . Tag each bearing cap as to which
main bearing it was removed from.
T.0. 35C2-3-442-2
TM 5-6115-457-34
NOTE
Cylinder block is upside down.
The bearing half under the crankshaft is still referred to as the
upper bearing half.
d. Place a suitable tool in oil hole in
crankshaft, and rotate crankshaft to roll
out upper bearing half (4). Bearing half
must be rolled out tab end first.
e . Place bearing half with its mating
bearing half and bearing cap.
NOTE
If crankshaft removal is required,
perform steps f. through i.
f. Refer to paragraph 8-214, and
remove connecting rod bearing and bearing
caps. Tag each cap as to which connecting
rod it was removed from.
NOTE
Do not remove crankshaft gear (8,
figure 8-63) and sleeves (7 and 10)
unless excessive wear or damage
is noted.
g. Lift crankshaft from block using
suitable web sling around connecting rod
journals on crankshaft at cylinder No. 1
and 6 or 2 and 4. Place crankshaft on
suitable bench support.
h. Attach each connecting rod bearing
cap and insert to the connecting rod from
which they were removed.
i. Heat sleeves (7 and 10) and gear (8) to
600°F maximum and remove from crankshaft (11) .
CAUTION
With crankshaft removed from
block, do not attempt to rotate
camshaft gear.
Change 1
8-135
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Figure 8-63. Crankshaft group and main bearings,
exploded view
8-136
Change 1
P-8-627-34
TM-07464A-35
Legend to figure 8-63:
1.
2.
3.
4.
5.
Bolt (14)
Washer (14)
Cap (7)
Bearing (half) (14)
Thrust washer (2)
8-223. CLEANING.
WARNING
Cleaning Solvents are f lammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
a. Clean bearing caps and bearing
halves in an approved cleaning solvent, and
dry thoroughly.
b. Clean crankshaft in an approved
cleaning solvent, and dry thoroughly
Lubricate and wrap the bearing journals
after cleaning.
c . Clean oil passages in the crankshaft
with a small soft brush.
8-224. INSPECTION.
6.
7.
8.
9.
10.
11.
T
O
35C2-3-442-2
TM 5-6115-457-34
Crankshaft assembly
Sleeve
Gear
Key
Sleeve
Crankshaft
3. Rotate crankshaft one complete
revolution. Remove main bearing cap (3,
figure 8-63) and measure the thickness of
the plastic strip. This measurement is the
main bearing clearance. The maximum
allowable clearance is 0.010 inch. If
allowable limit is exceeded, replace main
bearing. Repeat inspection for each main
bearing.
f. Refer to table 1-1 and, using an outside micrometer, check journal diameters
for excessive wear. If maximum allowable
wear limits have been exceeded, replace
crankshaft.
g. Inspect crankshaft for scoring or
galling on crankpin and main journals.
a. Inspect bearing surfaces for scoring,
flaring, chipping, and cracks.
b. Inspect main bearing caps for high
spots and burrs.
c. Inspect for damaged threads.
h. Inspect crankshaft gear (7) for
broken or chipped teeth. If defective,
replace gear.
d. Refer to table 1-1 and check bearing
clearances. If limits are exceeded, replace
bearing.
i . Inspect keyway in crankshaft and
test woodruff key for a snug fit. Perform
this inspection only if crankshaft gear
(7) had been removed for repair or
replacement.
e. Refer to table 1-1 and check bearing
to crankshaft clearance as follows:
1. Place a small strip of approved
plastic between lower bearing half (4, figure 8-63) and crankshaft. Light grease will
hold the plastic strip in position.
2. Install main bearing cap (3) and
torque bolts from 165 to 185 foot-pounds.
j . Inspect thrust washer contact area
at rear of crankshaft, on either side of
rear main crankshaft bearing journal for
excessive wear or roughness.
k. Inspect machined surface, at rear
of crankshaft that comes into contact with
rear oil seal, for a grooved condition.
Change 8
8-137
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
1. Inspect thrust washers (5, figure 8-63) for excessive wear, distortion,
and discoloration. Minimum allowable
thickness of washer is 0.175 inch. If
limit is not met, replace thrust washer.
8-225. REPAIR.
a. Remove minor nicks and burrs from
bearing caps using a smooth file.
b. Dress thrust washer contact area at
rear of crankshaft on either side of rear
main crankshaft bearing journal with a
hone to remove slight imperfections.
c . Polish machined surface, at rear of
crankshaft that comes into contact with
rear oil seal, to remove slight ridges less
than 0.0002 inch in variation, using a
crocus cloth wet with fuel oil. Rotate
crankshaft and polish the complete circumference of the surface.
8-226. REASSEMBLY.
Refer to figure 8-63 and reassemble crankshaft group and main bearings in
the reverse order of index numbers
assigned. Pay particular attention to the
following:
If crankshaft gear (8) and sleeves
(7 and 10) had been removed, install as
follows:
1. Heat sleeves (7 and 10) and gear
(8) to 600°F maximum and install on crankshaft.
NOTE
Position gear with timing mark
toward front, Ensure key (9) is
positioned properly in keyway of
crankshaft (11).
2. Install key (9) in keyway of
crankshaft (11).
3. Heat gear to 600°F maximum
and install on crankshaft with timing mark
toward the front.
b. Clean main bearing surfaces in
cylinder block.
8-138
Change 8
NOTE
If results of inspection in paragraph
8-224 indicated excessively worn
bearings, replace bearings at this
time. Ensure that bearing tab is
aligned with the recess in cylinder
block. The upper bearing half has
an oil groove machined on the inside
of bearing with two oil holes. This
bearing half can be installed only as
an upper main bearing. It is recommended that all bearings (4, figure
8-63) halves be replaced even if
only one bearing must be replaced.
When new bearings are installed,
proper clearance must be checked
as outlined in para. e, steps 1, 2,
and 3, above.
c. Lubricate inside surface of bearings
with clean engine oil.
d. Install upper main bearing halves (4)
in cylinder block.
e.
sling,
shaft
mark
been
Lift crankshaft using a suitable web
and install crankshaft with crankgear timing mark aligned with timing
on camshaft gear if camshaft has not
removed. Refer to figure 8-30.
f. install thrust washers (5, figure 8-63)
on each side of rear main bearing in cylinder block with the words “BLOCK SIDE”,
that are stamped on each thrust plate, next
to the cylinder block half of the upper main
bearing.
g. Install lower bearing halves (4) and
bearing caps (3) with lower bearing half tab
mating with tab on upper bearing half.
The bearing caps are numbered to ensure
installation on the same journal from
which they were removed. Torque bolts
as foil ows :
1. Lubricate thread of bolts (1) with
crankcase oil, and tighten from 27 to
33 foot-pounds torque.
P-9-TM-457-35
TM-07464A-35
2. Mark bolts (1, figure 8-63) and
caps (3).. Tighten an additional 85 to
95 degrees from mark.
h. Measure crankshaft end clearance
by pushing crankshaft to one end of cylinder
block, and using a feeler gauge, measure
the clearance between the machined face of
the crankshaft flange and the flange of the
lower half of rear main bearing. Clearance
should be 0.0025 to 0.0145 inch.
i. Refer to paragraph 8-218, and
install connecting rod lower bearing and
end caps.
d. Install oil pump group (paragraph 8-179).
e. Install oil pan group (paragraph 8-171).
f. Install crankshaft pulley, damper,
and timing gear cover group (paragraph 8-132).
g. Refer to Operator and Organizational Maintenance Manual and install
alternator.
h. Install hydraulic pump drive group
(paragraph 8-107).
i. Install hydraulic pump (precise sets
only) (paragraph 8-99).
8-227. INSTALLATION.
a. Installation of the crankshaft group
and main bearings is accomplished during
reassembly (paragraph 8-226).
b. Install flywheel and flywheel housing
group (paragraph 8-203).
c . Refer to Operator and Organizational Maintenance Manual and install
turbocharger group and air cleaner,
Section XXX,
T.O. 35C2-3-442-2
TM 5-6115-457-34
j. Install hydraulic tank (precise sets
only) (paragraph 8-92).
k. Install water pump group (paragraph 8-124).
1. Install fan mounting group (paragraph 8-37).
m. Install engine assembly (paragraph 2-8).
CYLINDER BLOCK AND COVERS GROUP
8-228, GENERAL,
The cylinder block and covers
group consists of replaceable cylinder
liners, plugs, covers, pins, and end plates.
The cylinder block assembly consists of a
cast cylinder block, which forms the main
structural part of the engine. The cylinder
block has passages that carry coolant to
and around the cylinder liners and other
passages that carry lubricating oil to all
moving parts. Seals on the liners prevent
leakage of coolant into the engine lubricating system. The flywheel housing attaches
to the rear of the cylinder block and the
timing gear cover and water pump to the
front end of the block. The oil pan and
plate attach to the bottom of the cylinder
block. A compression gasket forms a
8-139
P-9-TM-457-35
TM-07464A-35
T.O. 35 C2-3-442-2
TM 5-6115-457-34
tight seal between the cylinder block
assembly and the cylinder head assembly.
h. Remove hydraulic pump (precise sets
only) (paragraph 8-94).
8-229. REMOVAL.
i.
Remove hydraulic pump drive group
(paragraph 8-101).
a. Remove engine assembly (paragraph 2-8).
b. Refer to Operator and Organizational Maintenance Manual and remove the
following:
1.
k. Remove crankshaft pulley, damper,
and timing gear cover group (paragraph 8-126).
Engine wiring harness.
2. Air cleaner assembly,
3. Ether atomizer.
4.
j.
Remove governor actuator unit
(paragraph 8-109).
1. Remove utility governor group
(paragraph 8-134).
m. Remove fuel injection group (paragraph 8-142).
Lube oil filter group.
5. Manual throttle control.
6. Day tank assembly.
n. Remove accessory drive group
(paragraph 8-151).
o. Remove exhaust manifold group
(paragraph 8-159).
7. Turbocharger group.
8. Starter motor assembly.
9. Alternator assembly.
p. Remove oil pan group and related
parts (paragraph 8-165).
q. Remove oil pump group (paragraph 8-173).
10. Water pump group.
r.
c . Remove fan mounting group (paragraph 8-31).
d. Remove tachometer drive group
(paragraph 8-54).
e. Remove fuel pump group (paragraph 8-62).
f. Remove oil cooler group (paragraph 8-78).
g. Remove hydraulic tank (precise sets
only) (paragraph 8-86).
8-140
Remove valve cover and mechanism
group (paragraph 8-181).
s. Remove cylinder head group (paragraph 8-189).
t. Remove flywheel and flywheel housing group (paragraph 8-197).
u. Remove camshaft group (paragraph 8-205).
v. Remove connecting rods and pistons
group (paragraph 8-213).
w. Remove crankshaft group and main
bearings (paragraph 8-221).
P-8-627-34
TM-07464A-35
8-230.
5. Cylinder liner flange thickness.
DISASSEMBLY.
Refer to figure 8-64 and disassemble cylinder block and covers group in the
order of index numbers assigned. Pay
particular attention to the following:
a. Use a suitable puller to remove
cylinder liners ( 12) from cylinder block (51).
Mark liners in accordance with cylinders
they were removed from.
b. Use a suitable puller and remove
camshaft bearings (40 and 45).
8-231. CLEANING.
T
0
35C2-3-442-2
TM 5-6115-457-34
6. Install lower main bearing caps,
and tighten bolts from 27 to 33 foot-pounds
torque. Measure main bearing bore
diameter.
7. If allowable limits are exceeded,
replace part.
b. Inspect cylinder liners for cracks,
scoring, distortion, excessive wear, and
other defects.
WARNING
Cleaning Solvents are f lammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
Compressed air used for cleaning and
drying purposes can create airborne
particles that may enter the eyes.
Pressure shall not exceed 30 psig.
Eye protection is required.
a. Clean parts with an approved cleaning solvent, and dry thoroughly.
b. Clean all oil passages with a brush
or rod, and use compressed air on passages.
c . Remove rust and scale from outside
surface of cylinder liners using a stiff
brush.
d. . Remove rust and scale from water
jacket in cylinder Mock.
8-232. INSPECTION.
a. Refer to table 1-1 and, using a
suitable micrometer and feeler gauge,
check for excessive wear as follows:
1. Liner counterbore depth.
2.
Camshaft bearing bore.
3. Camshaft bearing to block
clearance.
4. Cylinder line bore.
c . Inspect covers for cracks, breaks,
distortion, and other defects.
d. Inspect cylinder bore for an out of
round c ondition.
e. Inspect top of cylinder block for
grooving or roughness.
f. Inspect camshaft bearings for
grooves or score marks on O. D. of bearings. If noted, this would indicate that
bearings have rotated in the block.
g. Inspect for damaged threads.
h. Discard all gaskets and seals.
8-233. REPAIR.
Repair tapped holes that are nicked
or burred by retapping with a suitable tap.
8-234.
REASSEMBLY.
Refer to figure 8-64 and reassemble cylinder block and covers group in the
reverse order of index numbers assigned.
Pay particular attention to the following:
a. Install new seals (13) on cylinder
liner (12).
Change 8
8-141
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Figure 8-64. Cylinder block and covers group, exploded view
(sheet 1 of 2)
8-142
Change 8
P-8-627-34
TM-07464A-35
Figure 8-64.
T O 35C2-3-442-2
TM 5-6115-457-34
Cylinder block and covers group, exploded view
(sheet 2 of 2)
b. Coat seals (13, figure 8-64) and
mating bore with liquid soap before installing cylinder liner (12).
NOTE
Cylinder liner shall be installed in
same cylinder bore from which it
was removed.
c. Position cylinder liner (12, figure 8-64) in bore chamber. Place a
suitable plate on top of cylinder liner (12).
Use a block of hard wood over the plate and
drive cylinder liner (12) into place.
d. Secure cylinder liner (12) in its bore
using a suitable crossbar and two 5/8 inch
NC bolts with flat washers as shown in
Change 8
8-143
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Legend to figure 8 - 6 4 :
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Bolt (3)
Lock
Bolt (3)
Lock
Front plate
Gasket
Plug
Bolt (2)
Lock washer (2)
Flange
Gasket
Liner (6)
Seal (12)
Orifice (6)
Plug
Dowel (2)
Plug
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
Plug (5)
Bolt (8)
Lock washer (8)
Cover
Gasket
Plug
Washer
Plug
Cap assembly
Bolt (3)
Lock washer (3)
Washer (3)
Pipe
Gasket
Cylinder block assembly
Bolt (12)
Washer (12)
figure 8-65. Tighten bolts evenly to
50 foot-pounds torque.
e. Using a suitable depth micrometer,
measure cylinder liner (12) projection
by measuring down from liner surface
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
Cap (6)
Bolt (2)
Washer (2)
Cap
Plug (2)
Bearing
Dowel (2)
Stud
Dowel (2)
Dowel (2)
Bearing
Plug (2)
Dowel
Dowel
Ball
Plug
Block
to the face of the cylinder block (12, figure 8-64). Liner projection must be
0.002 to 0.005 of an inch.
f. Cylinder block (51) may be pressure
tested as follows:
1. Seal off water inlet and outlet
holes air tight, using plates and suitable
rubber gaskets held in place by bolts.
2. Immerse cylinder block (51) i n
tank of water. Attach a suitable fitting at
one of the water inlet or outlet openings.
Apply 60 psi air pressure to water pocket
and observe water in tank for bubbles
indicating cracks or leaks.
WARNING
Compressed air used for cleaning and
drying purposes can create airborne
particles that may enter the eyes.
Pressure shall not exceed 30 psig.
Eye protection is required.
out passages with dry, compressed air.
Figure 8-65.
figure 8-54)
8-144
Change
8
g. Install camshaft bearings using a
suitable tool. Care must be taken to align
oil holes in bearings with oil holes in
cylinder block. The front camshaft
P-9-TM-457-35
TM-07464A-35
T. O. 35C2-3-442-2
TM 5-6115-457-34
bearing (40, figure 8-64) has two oil holes
and are positioned in a vertical position.
The remaining camshaft bearings (45) have
only one hole and must be positioned with
hole in a downward position.
c . Install connecting rods and pistons
group (paragraph 8-219).
h. Camshaft front bearing (40) must be
recessed 0.06 of an inch from front face of
camshaft bore, oil hole in bearing (40)
must align with oil hole in cylinder block
(51), and joint in bearing (40) must face
cylinder block (51) centerline. Intermediate
bearings (45) must be flush with front face
of bearing bore. Rear bearing (45) must
be recessed 0.06 of an inch from rear face
of bore.
e. Install flywheel and flywheel housing
group (paragraph 8-203).
i. The maximum allowable clearance
between camshaft journal and bearing that
is pressed into cylinder block is 0.008 inch.
This clearance can be measured by using a
suitable inside micrometer and check the
I. D. of each camshaft bearing after it has
been pressed into the block. Use a suitable’
outside micrometer and check the corresponding O. D. of each camshaft journal.
Subtract the O. D. dimension of the camshaft journal from the I.D. of the camshaft
bearing in the block. The result will be
the running clearance between the camshaft and the camshaft bearing. If the
clearance exceeds O. 008 inch, replace
camshaft bearing.
j . Install cylinder block covers using
new gaskets.
8-235. INSTALLATION.
d. Install camshaft group (paragraph 8-211).
f. Install cylinder head (paragraph 8-195).
g. Install valve cover and valve mechani sm group (paragraph 8-187).
h. Install oil pump group (paragraph 8-179).
i. Install oil pan group and related
parts (paragraph 8-171).
j. Install exhaust manifold group
(paragraph 8-163).
k. Install accessory drive group (paragraph 8-157).
1. Install fuel injection group (paragraph 8-148).
m. Install utility governor group
(paragraph 8-140).
n. Install crankshaft pulley, damper,
and timing gear cover group (paragraph 8-132).
o. Install governor actuator unit
(paragraph 8-116).
a. Installation of cylinder block and
covers group is accomplished during
reassembly (paragraph 8-234).
p. Install hydraulic pump drive group
(paragraph 8-107).
b. Install crankshaft group and main
bearings (paragraph 8-227).
q. Install hydraulic pump (precise sets
only) (paragraph 8-99).
8-145
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r. Install hydraulic tank (precise sets
only) (paragraph 8-92).
s. Install oil cooler group (paragraph 8-84).
t. Install fuel pump group (paragraph 8-68).
u. Install tachometer drive group
(paragraph 8-60).
v. Install fan mounting group (paragraph 8-37).
w. Refer to Operator and Organizational Maintenance Manual and install the
following:
Section XXXI.
1.
Water pump group.
2.
Alternator assembly.
3.
Starter motor assembly.
4.
Turbocharger group.
5.
Day tank assembly.
6.
Manual throttle control.
7.
Lube oil filter group.
8.
Ether atomizer.
9.
Air cleaner assembly.
10.
Engine wiring harness.
ENGINE TEST AFTER OVERHAUL
a. PRE-RUN-IN CHECKS.
8-236. GENERAL.
Following a complete overhaul or
any major repair, involving the installation
of piston rings, pistons, cylinder liners,
or bearings, the engine should be run-in
prior to release for service.
NOTE
Rotate engine in a clockwise direction only, when viewing engine
from front.
NOTE
Make sure all necessary adjustments have been performed and
engine is fully serviced before
starting test.
8-237. ENGINE ASSEMBLY RUN-IN AND
ADJUSTMENTS.
Connect engine assembly to a suitable engine dynamometer equipped with a
cooling system and means of monitoring
engine oil pressure, coolant temperature,
and engine RPM.
8-146
1. Manually rotate engine by applying a 1-1/8 socket with extension handle to
crankshaft nut inside of damper.
2. Hold manual fuel shutdown lever
in the closed rack or off position (figure 8-66).
CAUTION
Do not crank starter motor for a
period of more than 15 seconds.
P-9-TM-457-35
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T.O. 35C2-3-442-2
TM 5-6115-457-34
is tripped, the solenoid plunger should
release (move out of the solenoid) and
This movement of the
remain released.
solenoid plunger should rotate the
manual fuel rack lever clockwise to
almost full off position.
c . UTILITY GOVERNOR SPEED SETTING
Adjust utility governor
ADJUSTMENT.
low and high speed stops as follows:
1. Loosen nut (5, figure 8-33)
and turn low speed stop screw (4)
counterclockwise until it is free of
speeder spring (46).
CAUTION
Figure 8-66. Location of manual fuel
shutdown lever
3. Turn engine over using starter
until oil pressure builds up to 50 ± 10
PSIG.
Oil pressure should build up
within 15 seconds.
4. Release manual fuel shutdown
Inspect all fluid systems for
lever.
signs of leakage.
b. OPERATIONAL TEST OF OVERSPEED
SHUTDOWN DEVICE.
1. Dead crank engine and deternine if solenoid plunger (2, Figure
If the sole8-31A) pulls in (bottoms).
noid plunger does not bottom or does not
have enough power to overcome the spring
tension, increase the measurement
between the bushings (6 and 9, Figure
3-31A) by adjusting bottom bushing.
2. Each time the engine is
started, the solenoid plunger should
pull in (bottom) and remain pulled in.
This movement of the solenoid plunger
should rotate the manual fuel rack lever
counterclockwise to almost full on
position.
3. Each time the engine is
stopped or the governor overspeed switch
Do not crank engine for more
than 15 seconds at a time.
Permit starter to cool a minimum of three minutes between
crankings.
2. Crank engine over with
starter and turn low speed stop screw
(4) clockwise until governor output
shaft (13, figure 8-33) rotates, opening
fuel rack. Continue turning low speed
stop screw until engine starts.
3. Permit engine to run a minimum of five minutes for warmup and
adjust low speed stop screw (4) to
obtain 800 RPM idle speed.
Clockwise
rotation will increase speed. Hold screw
in position and tighten nut (5). Recheck
RPM setting.
4. Rotate speed adjusting shaft
(25) to maximum speed position and monitor engine RPM. Do not exceed 2300 RPM.
5. Engine high speed stop
setting should be 2250 RPM. To adjust
high speed stop, loosen nut (20) and
rotate high speed stop screw (19) to
obtain 2250 RPM when speed adjusting
shaft (25) is in maximum speed position.
Clockwise rotation will increase engine
RPM setting. Tighten lock nut and recheck RPM setting.
6.
If engine surges during
Change 2
8-147
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warmup, remove governor cover (6) while
engine is running and move droop bracket
(11) and pin (22) towards maximum position (away from governor ball head
assembly (57).
7. When the engine is warmed up,
adjust the droop bracket (11) and pin
(22) as much towards minimun (toward ball
head assembly (57) as possible while
maintaining steady speed. Manually move
the engine fuel linkage to cause a
If the
temporary engine speed increase.
engine returns to the original steady
speed, the adjustment is satisfactory.
If the engine speed does not settle out,
increase droop slightly (approximately
1/16 of an inch movement of bracket (11)
Continue to increase
and test again.
the droop until the operation is satisfactory.
NOTE
Three-quarter speeds are 1125
RPM for 50 hertz operation,
1350 RPM for 60 hertz operation,
and 1500 RPM for 400 hertz
operation.
2. Operate engine at 3/4 rated
speed and at 50 KW for fifteen minutes.
NOTE
Rated speeds are 1500 RPM for
50 hertz operation, 1800 RPM for
60 hertz operation, and 2000 RPM
for 400 hertz operation.
3. Operate engine at rated speed
and at 100 KW for 30 minutes.
NOTE
d . RUN- IN. During run-in, monitor
oil pressure and coolant temperature and
check for unusual noise and vibrations.
Discontinue run-in if oil pressure drops
below 20 psi, if coolant temperature
exceeds 217°F, or if unusual noise and
vibrations occur.
1. Start engine and operate at
idle speed (approximately 800 RPM), no
load for 10 minutes.
8-148
Change 2
Required tightness for cylinder
head bolts after test to be 150
foot-pounds minimum.
4 . Shut down engine and tighten
a l l b o l t s a n d n u t s . Tighten cylinder
head bolts, refer to figure 8-56.
5.
Inspect engine for leakage.
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CHAPTER 9
BASE ASSEMBLY, STOWAGE TOOL BOX, AND FUEL TANK REPAIR
INSTRUCTIONS
Section I.
9-1.
BASE ASSEMBLY
GENERAL.
4. Remove batteries and rollout
The base is a welded structure that
supports the generator set and the fuel tank.
It consists of tubular cross members, forklift openings, and ground stud The engine
and generator are mounted to the base, the
engine front support and generator mounting provide a three point support system
for the engine and generator. A battery
and rollout tray assembly is mounted in
the front end of the base and a stowage tool
box in the rear end. Each end of the base
is equipped with a tubular cross member
which permits connection of a towing
device for skidding the generator set, for
short distance moving. Openings are provided in the base to permit the generator
set to be lifted by a forklift, The base is
equipped with a split-stud terminal to permit electrical grounding of the set.
9-2.
tray,
b. Remove housing as specified in
paragraph 3-2.
c . Remove generator as specified in
paragraph 2-7.
ci. Remove engine as specified in
paragraph 2-8.
9-3.
DISASSEMBLY .
Refer to figure 9-1 and disassemble
base assembly in the order of index n u m bers assigned. Pay particular attention
to the following:
REMOVAL
Remove the following assemblies
from the base assembly:
a. Refer to Operator and Organizational
M aintenance Manual and perform the
following:
1.
Drain coolant from the radiator.
2 . Drain fuel from the day and
fuel tank.
3. Drain lubricating oil from engine
crankcase.
WARNING
When disconnecting bat teries (leadacid) disconnect negative terminal
first.
a. Tag hoses (1, 2, 3, and 4) with
location prior to removal
b. Disassemble stowage tool box (19)
as specified in paragraph 9-11.
c. Remove fuel tank (53) through stowage tool box opening. Disassemble fuel
tank (53) as specified in paragraph 9-19.
9-4.
C LEANING.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
a. Clean parts with an approved cleaning solvent and dry thoroughly. If neces- sary, remove hand deposits using a bristle
brush.
Change 8
9-1
P-8-627-34
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T O 35C2-3-442-2
TM 5-6115-457-34
Figure 9-1.
9-2 Change 8
Base assembly, exploded view
P-8-627-34 T O 35C2-3-442-2
T M - 0 7 4 6 4 A - 3 5 T M 5-6115-457-34
Legend to figure 9-1:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Hose
Hose
Hose
Hose
Elbow (5)
Tee (2)
Cross
Nut
Nipple
Washer
Screw (4)
Lock washer
Washer (4)
Upper filler
Upper filler
Screw (4)
Nut (8)
Washer (4)
Stowage tool
Screw (2)
Lock washer
(4)
panel
panel
box
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
Washer (1)
Filler panel
Screw (2)
Washer (2)
Bracket
Screw (4)
Nut (4)
Rear tank stop (2)
Screw (6)
Nut (6)
Washer (12)
Bracket (2)
Screw (2)
Nut (2)
Washer
Heater exhaust plate
Elbow (2)
Elbow
Cross
Nipple
(2)
b. Clean sealant from pipe threads
using a wire brush.
9-5.
e. Inspect support brackets for
distortion.
9-6.
REPAIR.
INSPECTION.
WARNING
a. Inspect parts for cracks, breaks,
and defective welds.
Welding operations produce heat,
highly toxic fumes, injurious
radiation, metal slag and airborne particles. Welding goggles, with proper tinted lenses,
apron or jacket and welder 's
boots are required.
CAUTION
If hose blockage is due to deterioration of internal portion of hose,
hose shall be replaced.
b. Check hose for blockage, chafing,
and condition of end fittings.
c. Inspect bevel washer for deterioration, cracks, and permanent set in washer
contact surface.
d. Inspect threads for damage.
Plug
Elbow
Screw (2)
Nut (2)
Washer (2)
Ground rod plate
Nut (4)
Washer (4)
Bevel washer (8)
Tee bolt (4)
Strap (2)
Fuel tank assembly
Nut
Ground stud
Lock washer (3)
57. Auxiliary fuel hose
58. Screw
59. Nut
60. Auxiliary fuel hose mount
61. Base
* Applicable to serial numbers
1 through 130
42.
43.
44.
45.
46.
47.
48.
49,
50.
51.
52.
53.
54.
55.
*56.
a. Weld cracks, breaks, and defective
welds.
b. Repair damaged threads by chasing
using a suitable die or tap.
c. Straighten distorted support brackets.
d. Remove damaged paint with a suitable
s c r a p e r . Blend in edges, prime, and paint
damaged areas.
9-7.
REASSEMBLY.
Change 8
9-3
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TM 5-6115-457-34
Refer to figure 9-1 and reassemble
base assembly in the reverse order of
index numbers assigned. Pay particular
attention to the following:
a. Reassemble fuel tank as specified in
paragraph 9-23.
b. Reassemble stowage tool box as
specified in paragraph 9-15.
c. Apply thread sealing compound conforming to Military Specification MIL-S45180, type III, to pipe threads prior to
installation.
d. Install fuel tank (53) in base (61)
through stowage tool box opening, making
sure that fuel tank needle valve is toward
opening. Push tank against front stops,
hold tank in position, and install rear tank
stops so that stops hold tank in position.
e. Install bevel washers (50) with thick
ends on top.
f. Install and align stowage tool box (19)
so that it is flush with base (61).
9-8.
INSTALLATION.
Install the following assemblies on
the base assembly.
a. Install engine as specified in paragraph 2-8.
b. Install generator as specified in
paragraph 2-7.
c. Install housing as specified in paragraph 3-6.
WARNING
When connecting lead-acid batteries
connect positive terminal first.
d. Refer to Operator and Organizational
Maintenance Manual and perform the
following:
1. Install batteries and rollout tray.
2. Service engine crankcase, fuel
tank, and radiator.
Section II. STOWAGE TOOL BOX
9-9.
GENERAL.
The stowage tool box is utilized for
storage of tools and miscellaneous equipment required for generator set operation.
The box consists of a hinged cover, seal,
and box. The cover covers the box opening
and the seal prevents moisture and dirt
entering the box.
Refer to figure 9-2 and disassemble
the stowage tool box in the order of index
numbers assigned.
9-12
CLEANING.
a. Clean seal with a clean lint-free
cloth.
9-10. REMOVAL.
Refer to figure 9-1 and remove stowage tool box from base by removing screws
(16), nuts (17), and washers (18).
9-11. DISASSEMBLY
9-4
Change 8
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
vent ilat ion is normally adequate.
b. Clean metal parts in an approved
cleaning solvent and dry thoroughly.
P-8-627-34 T O 35C2-3-442-2
TM 5-6115-457-34
TM-07464A-35
WARNING
Welding operations produce heat,
highly toxic fumes, injurious
radiation, metal slag and airborne particles. Welding goggles, with proper tinted lenses,
apron or jacket and welder’s
boots are required.
b. Weld cracks.
c. Remove damaged paint with a
suitable scraper. Blend in edges, prime,
and paint damaged areas.
9-15.
Figure 9-2. Stowage tool box,
exploded view
Legend to figure 9-2:
1. Seal
2. Nut (5)
3. Washer (10)
9-13.
4. Screw (5)
5. Cover
6. Stowage box
INSPECTION.
a. Inspect sheet metal parts for cracks,
dents, distortion, and worn hinges.
b. Inspect seal for cuts, cracks, and
deterioration.
c.
9-14.
REASSEMBLY.
Refer to figure 9-2 and reassemble
the stowage tool box in the reverse order of
the numbers assigned. Pay particular
attention to the following:
a. Align cover (5) so that seal (1) makes
full contact on stowage box (6) prior to
tightening nuts (2).
9-16.
INSTALLATION.
Refer to figure 9-1 and install
stowage-tool box assembly in base assembly. Pay particular attention to the
following:
a. Install stowage tool box and secure
with screws (16), nuts (17), and washers
(18), leaving nuts finger tight.
Inspect paint for damage.
REPAIR.
a. Straighten dented and distorted parts
using suitable tools.
b. Align stowage tool box cover so that
it is flush with base assembly and tighten
nuts.
Change 8
9-5
P-8-627-34
TM-07464A-35
T.O. 35 C2-3-442-2
TM 5-6115-457-34
Section III.
9-17.
FUEL TANK ASSEMBLY
GENERAL.
The baffled fuel tank stores fuel for
generator set operation and is located within
the base assembly. The fuel tank assembly
consists of a fuel level transmitter, plate
assembly, and a needle valve. The fuel
level transmitter senses the fuel level in the
fuel tank and transmits a signal to the fuel
gauge on the control cubicle, which indicates a reading corresponding to that of the
fuel level transmitter. The needle valve
permits draining of the fuel tank and
removal of water and sediment from the
tank.
REMOVAL.
9-18.
Refer to figure 9-1 and remove the
fuel tank as follows:
a. Refer to Operator and Organizational
Maintenance Manual and drain fuel tank.
b. Disconnect stowage tool box (19) by
removing screws (16), nuts (17), and
washers (18).
c. Remove filler panels (14, 15, and 23),
bracket (26), and rear tank stops (29).
d. Loosen clamp and remove fuel filler
hose from fuel tank.
e. Disconnect electrical connector from
fuel tank fuel level transmitter.
f. Tag and disconnect fuel and vent
lines from fuel tank and plug lines.
a. Mark alignment marks on plate (4)
and fuel tank (15) to insure proper
reassembly.
9-20. CLEANING.
a. Remove old gaskets (5) using a suitable scraper.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protect ion required. Good general
ventilation is normally adequate.
b. Clean parts and exterior of fuel tank
with an approved cleaning solvent and dry
thoroughly.
c. Clean interior of fuel tank with clean
fuel oil. Agitate fuel tank to loosen sediment and pour fuel from tank. Repeat procedure until all sediment is removed from
tank .
WARNING
Steam cleaning creates hazardous noise
levels and severe bum and eye injury
potential. Eye, skin and ear protection required.
d. If sediment can not be removed by
performing step c. or fuel tank is to be
repaired by welding, steam clean tank to
remove sediment or to purge tank of fuel
vapors.
g. Remove fuel tank straps (52).
h. Remove the fuel tank (53) from the
base through the stowage-tool box opening.
9-19. DISASSEMBLY.
Refer to figure 9-3 and disassemble
fuel tank assembly in the order of index
numbers assigned. Pay particular attention
to the following:
9-6
Change 8
e. Clean old sealant from pipe threads
using a wire brush.
9-21.
INSPECTION.
a. Shake transmitter float to check for
fuel in float which would indicate a crack or
hole in float.
P-8-627-34
TM-07464A-35
Figure 9-3.
Legend to figure 9-3:
1. Adapter
2, Adapter
3. Screw (14)
4. Plate
5. Gasket
6. Nut (5)
7.
7A.
7B.
7C.
7D.
8.
T
O
35C2-3-442-2
TM 5-6115-457-34
Fuel tank assembly, exploded view
Screw (5)
Preformed packing
Lug
Wire
Lug
Fuel level transmitter
b. Using a multimeter, perform resistance test on fuel level transmitter. Resis tance shall be 0.00 to 0.50 ohms at empty
(down) position, and 29.50 to 31.50 ohms at
full (up) position.
9.
10.
11.
12.
13.
14.
15.
Gasket
Cap
Hook
Needle valve
Coupling
Nipple
Fuel tank
from bottom of fuel level transmitter
flange. At empty (down), the float shall be
7.50 to 7.62 inches from bottom of ‘fuel
level transmitter flange.
d. Check fuel tank for leaks as follows:
c. Connect transmitter float to fuel
level transmitter and check float movement.
At full (up), float shall be 0.44 to 0.50 inch
1. Plug all fuel tank openings except
one. Connect a suitable low pressure
Change 8
9-7
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
regulated air supply to remaining fuel
tank opening.
2. Slowly apply 0.5 PSI air pressure
to fuel tank.
3. Apply a soapy water solution to
fuel tank and check for bubbles that would
indicate leaks. Mark leaks, if any.
4. Reduce air pressure to zero.
Remove test equipment from tank. Remove
soapy water solution from fuel tank.
e . Connect a suitable pressure supply
and gage to needle valve. Turn on pressure
supply and bleed test equipment by opening
valve. Close valve. Slowly apply 150 PSI
and check for external and internal leakage.
Reduce pressure to zero and remove test
equipment from valve.
f. Check transmitter float linkage for
distortion.
g. Inspect for damaged threads.
h. Inspect paint for damage.
REPAIR.
9-22.
WARNING
Do not weld fuel tank unless tank
has been steam cleaned and it is
filled with water.
a. Repair cracks and holes in fuel tank
as follows:
WARNING
Steam cleaning creates hazardous noise
levels and severe bum and eye injury
Eye, skin and ear protecpotential.
tion required.
1. Steam clean tank to remove fuel
vapors.
2 . Fill tank with water.
WARNING
Welding operations produce heat,
highly toxic fumes, injurious
radiation, metal slag and airborne particles. Welding goggles, with proper tinted lenses,
apron or jacket and welder's
boots are required.
3. Weld crack or holes.
9-8
Change 8
Large
damaged area may be repaired by welding
a suitable patch over area.
4. Remove water from fuel tank and
dry interior of tank thoroughly.
5. Check repaired areas for leakage
as specified in paragraph 9-21, step d.
b. Straighten distorted transmitter float
linkage using suitable tools.
c. Repair damaged fuel tank threads
using a suitable tap. Fill tap grooves with
grease to catch cuttings. Remove all
cuttings from fuel tank.
d. Remove damaged paint with a suitable
scraper. Blend in edges, prime, and paint
damaged areas.
9-23. REASSEMBLY.
Refer to figure 9-3 and reassemble
fuel tank assembly in the reverse order of
index numbers assigned. Pay particular
attention to the following:
—
a. Apply thread sealing compound conforming to Military Specification MIL-S45180, type III, to pipe threads prior to
reassembly.
b. Make sure alignment marks on fuel
tank (15) and plate (4) are aligned when plate
is installed.
9-24. INSTALLATION.
Refer to figure 9-1 and install the
fuel tank as follows:
a. Install fuel tank (53) in base (61)
through stowage tool box opening, making
sure needle valve is toward opening. Position and hold tank against forward stops
and install rear tank stops (29), bracket
(26), and filler panels (14, 15, and 23).
P-9-TM-457-35
TM-07464A-35
b. Install and secure fuel tank straps
(52), making sure that thick end of bevel
washers (50) are on top.
T.O. 35C2-3-442-2
TM 5-6115-457-34
d. Connect fuel filler hose to fuel tank
and secure with clamp.
e. Install stowage tool box (19).
c. Connect fuel and vent lines to fuel
tank. Connect electrical connector to
fuel level transmitter.
f. Refer to Operator and Organizational
Maintenance Manual and service fuel tank.
9-9/(9-10 blank)
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
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CHAPTER 9A
PAINT AND MARKING REQUIREMENTSAFTER OVERHAUL
9A-1.
GENERAL,
a. (AF Only) Paint and markings on
the generator sets shall be in accordance
with AFR 35-1-3.
9A-2.
NOISE LEVEL WARNING.
a. The noise level warning sign shall
be stenciled on the top half of both
rear (generator end of set) side doors,
in accordance with Figure 9A-1.
Figure 9A-1. Noise Level Warning Sign
Change 2
9A-1/(9A-2
Blank)
P-8-627-34 T. O. 35C2-3-442-2
TM 5-6115-457-34
TM-07464A-35
CHAPTER 10
TEST AFTER OVERHAUL
Section I. PRETEST CHECKS AND ADJUSTMENTS
10-1.
10-2.
GENERAL.
Pretest checks and adjustments
shall be performed prior to test after overhaul cf the generator set. To perform the
pretest checks and adjustments, proceed as
follows :
PRETEST CHECKS
— — AND
. .
ADJUSTMENTS
— .
a. Perform engine assembly run-in and
adjustments paragraph 2-237.
b. Perform alignment of electric governor actuator unit (precise generator sets
only), refer to paragraph 6-246.
Section II. TEST AFTER OVERHAUL
10-3.
GENERAL.
All tests should be performed under
the following conditions:
a. All tests shall be made at ambient
temperatures.
b. AII test instrumentation will be in
accordance with Military Standardization
Handbook MIL-HDBK-705 and Military
Standard MIL-ST D-705, as applicable.
c . Temperatures will be measured by
means of appropriately located thermocouples and properly calibrated read-out
devices. Thermocouples will be insulated
from contact with other metals. Temperatures will be recorded in degrees Farenheit
or Centigrade, depending on the instrument
scale, but will be reduced in degrees Farenheit in all cases. Barometric pressure will
be measured by a mercurial barometer,
which will be corrected for the temperature of the scale, the mercury for vapor
pressure and for the location of the barometer with regard to altitude and latitude.
Ameroid barometers will not be used.
d. Pretest adjustments shall be completed prior to starting test procedures,
refer to paragraph 10-2.
e . Operational procedures required in
support of the individual test specified
herein shall be performed as outlined in the
Operator and Organizational Maintenance
Manual.
f. Record test results as required by
local instructions.
10-4.
START AND STOP TEST .
Test the generator set for evidence
of abnormal start and stop conditions by
Change 8 10-1
P-8-627-34
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
set and vary the load as indicated in
step c.
performing the start and shutdown procedures as outlined in the Operator and
Organizational Maintenance Manual. The
generator set should be capable of starting
promptly at any ambient temperatures in
the range of +125°F to -25°F without
external heat.
c. Record the master instrument reading and the readings of the meters at the
following percentages of rated load: 1/4,
2/4, 3/4, 4/4, and 5/4 percent.
a. Operate generator set at rated
speed, voltage, and no-load for 15 minutes,
then discontinue operation.
d, The accuracy of the instruments
should be such that the maximum error
will not exceed the following parameters:
b. Operate generator set at rated
speed, voltage, and no-load for 15 minutes.
Discontinue operation by de-energizing the
DC circuit breaker.
1 . V o l t m e t e r - 2-1/2 percent of full
scale except not greater than 5 volts between 115 and 125 volts, not greater than
10 volts between 200 and 250 volts.
c. Repeat start-stop procedures two
additional times. If any malfunction is
noted, make necessary repairs before subjecting the generator set to the remaining
tests.
10-5.
INSTRUMENT CHECK.
Test the generator set ammeter,
voltmeter, and frequency meter for accuracy by comparing them with master
instruments.
2. Ammeter -2 percent of full
scale.
3. Kilowatt meter -2 percent of
full scale.
4. Frequency meter - 0.25 percent
at any point on scale.
10-6.
LOW OIL PRESSURE TRIP TEST .
Perform this test under an artificially produced condition as follows:
NOTE
This test shall be done in conjunction with other tests.
a. Adjust the meters to zero as outlined
in the Operator and Organizational M ainte nance Manual.
NOTE
This test shall be repeated at all
rated frequencies and at voltages
of 120/208 and 240/416.
b. Connect the generator set to
a variable load. Operate the generator
10-2 Change 8
a. Install a test adapter with a gage for
measuring pressure to the lubricating oil
pressure switch, a valve for shutting off
flow to pressure switch, and a valve for
bleeding off pressure. Operate the generator set at rated speed and no load.
b. Purge air from system through the
bleed valve. Close valve and record operating pressure.
CAUTION
If unit fails to shut down when oil
pressure is below 15 ± 3 PSI, the
test should be discontinued and
corrective action taken.
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
c. Close pressure shutoff valve and
slowly bleed pressure from system until the
generator set shuts down and LOW OIL
PRESSURE fault locator indicator illuminates. Record pressure. The generator
set shutdown and LOW OIL PRESSURE
fault locator indicator shall occur simultaneously at 15 ± 3 PSI.
d. Remove test components from generator set.
10-7. HIGH COOLANT TEMPERATURE
TRIP TEST.
Perform the high coolant temperature trip test as follows:
a. Remove coolant temperature transmitter from front of engine thermostat
housing and install thermocouple in its
place.
CAUTION
If the engine fails to shut down when
222 °F is reached, drop the load and
unblock the radiator to cool engine.
b. Operate unit at rated speed, block
air passing through the radiator and apply
sufficient load to raise the unit temperature
to the trip point of 217 ± 3°F. The high
coolant temperature switch shall actuate at
214° to 220° F, causing the load contactor to
open, the engine to shut down, and the
COOLANT HIGH TEM P fault indicator to
illuminate.
c . Remove the rmocouple and replace
coolant temperature transmitter.
10-8.
b. Disconnect electrical connector from
day tank fuel solenoid valve.
c. Operate the generator set at rated
voltage, frequency and at full load until
day tank float valve switch actuates, causing
the load contactor to open, the engine to
shut down and the NO FUEL fault indicator
to illuminate.
d. Start generator set and as soon as
engine starts, lift red battle short switch
guard and position switch to ON. Operate
generator set for one minute at rated voltage, frequency and fuel load. Generator
set should operate for one minute without
running out of fuel. Shut down generator
set, but do not de-energize DC circuit
breaker.
e. Connect electrical connector to day
tank fuel solenoid valve. Position start-runstop to RUN and fill day tank. Position
battle short switch and guard to OFF position and de-energize DC circuit breaker.
10-9. SHORT CIRCUIT TRIP TEST.
Perform the short circuit trip test
as follows:
a. Connect a load bank capable of supplying 450 percent of rated current to the
generator set load terminals. Reactive
load may be used to obtain the required
current.
LOW FUEL LEVEL TRIP TEST.
Perform the low level trip test as
follows :
a. Energize DC circuit breaker and
position start-run-stop switch to RUN to
fill day tank. When day tank is full, the
electric fuel transfer pumps will change
pitch indicating they are bypassing fuel
internally.
b. Adjust short circuit load to draw
350 percent of rated current.
c. Operate the generator set at rated
voltage, rated speed, and rated load.
d. Apply short circuit load of 350 percent
rated current (total of 450 percent of rated
current) to the generator set in one step.
10-3
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
CAUTION
If output contactor fails to open,
instantaneously remove short
circuit.
e. The output contactor shall actuate
instantaneously when current exceeds
425 ± 25 percent of rated current, causing
the SHORT CIRCUIT fault indicator to
illuminate.
2. Repeat step b. , reduce voltage
between 65 to 103 volts. The load contactor
shall open in 6 ± 2 seconds, causing the
UNDER VOLT fault locator to illuminate.
3. Repeat steps b. , 4. 1., and 4.2.
two additional times.
10-11. UNDER FREQUENCY TRIP TEST
(PRECISE GENERATOR SETS
ONLY).
10-10. OVER AND UNDER VOLTAGE
TRIP TEST .
Perform the under frequency trip
test as f ollows:
Perform the over and under voltage
trip tests as follows:
a. Operate the generator set at no load,
rated frequency, and rated voltage with load
contactor closed.
a. Connect a voltmeter between T9 and
T12 of the monitored 120 volt phase.
b. Operate the generator set at no load,
rated frequency, and rated voltage with load
contactor closed.
c. OVER VOLTAGE TRIP TEST.
Raise voltage until the engine shuts down and
OVER VOLT fault locator indicator illuminates. Record the voltage. The over voltage relay shall actuate when the voltage
exceeds 153 ± 3 volts for more than
200 milliseconds causing the load contactor
to open within 1 second, the engine to shutdown and the OVER VOLT fault indicator to
illuminate.
b. Lower frequency until the UNDER
FREQ fault locator indicator illuminates.
The load contactor should open, causing the
UNDER FREQ fault locator indicator to
illuminate when the frequency drops to the
values indicated below:
50 hertz operation - 46 ± 1 hertz
60 hertz operation - 55 ± 1 hertz
400 hertz operation - 370 ± 5 hertz
10-12. PHASE SEQUENCE CHECK.
Perform the phase sequence check
as follows:
d. UNDER VOLTAGE TRIP TEST
(PRECISE GENERATOR SETS ONLY),
a. Connect a suitable phase sequence
indicator to generator set load terminals as
following rotation of set.
1. Repeat step b. , lower voltage
until the UNDER VOLT fault locator indicator illuminates. Record voltage. The
load contactor shall open immediately when
voltage drops below 48 volts, causing the
UNDER VOLT fault locator indicator to
illuminate.
b. Operate generator set and determine
phase sequence by observing the indicator.
The AC output connections shall be of the
proper rotation, compare test results with
the AC system simplified schematic, figure 1-4 for 50/60 hertz generator sets or
figure 1-5 for 400 hertz generator sets.
10-4
P-9-TM-457-35
TM-07464A-35
c. If generator set is equipped with an
AC output receptacle box, check phase
sequence of each receptacle for proper
rotation.
10-14,
T.O. 35C2-3-442-2
TM 5-6115-457-34
FREQUENCY ADJUSTMENT
RANGE TEST.
Perform the frequency adjustment
range test as follows:
10-13. PHASE BALANCE TEST.
a.
PRECISE GENERATOR SETS.
Perform the phase balance test as
follows :
1. Operate generator set at full load.
a. Operate generator set at 240/416
volts, rated speed and no load. Adjust
voltage as necessary until average voltage
is 240 volts line to neutral. Measure each
line to neutral voltage to the nearest0O.1 volt
at load terminals and record.
NOTE
Load must be balanced. Record all
three line to neutral voltages and
obtain the average value. Reduce
or raise voltage as required, by
the amount that the previously
computed average differs from
rated voltage. The average of the
three phase voltages should be
equal to rated voltage.
b. Measure and record each of the line
to neutral voltages.
c . The maximum difference in the three
line-to-neutral voltage under all balanced
loads at rated voltage and speed shall not
exceed one percent rated voltage and speed
shall not exceed one percent rated line-toneutral voltage. That is, no phase voltage
shall differ from the average by more than
1.2 volts.
d. Formula to compute percentage of
voltage unbalance is as follows:
2. Slowly adjust frequency from 58 to
62 hertz (for 50/60 hertz operation) and
390 to 420 hertz (for 400 hertz operation).
Clockwise rotation shall increase frequency.
Voltage shall remain at rated value throughout the frequency range. The frequency
rheostat shall allow frequency adjust over
the following ranges at any load:
50 hertz operation - Between 48 and 52
hertz but not below
45 hertz.
60 hertz operation - Between 58 and 62
hertz but not above
65 hertz.
400 hertz operation - Between 390 and 420
hertz but not below
370 hertz or above
430 hertz,
b. UTILITY GENERATOR SETS.
1. Operate generator set at full
speed by adjusting manual speed control.
Record frequency.
2. Turn manual speed control knob
90 degrees. Record frequency. A 90 degree
turn of the manual speed control knob shall
not cause a change in frequency greater
than 1 percent.
100 x maximum deviation from average
(T1-N) + 3 (T2-N)
+ (T3-N)
3. Repeat step 2. a number of
times, both raising and lowering frequency.
10-5
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
4. Rapidly decrease engine speed by
turning the manual speed control knob to its
lowest possible speed obtainable. Increase
engine speed by turning the manual speed
control knob to its maximum speed obtainable, The manual speed control shall be
adjustable from idle (approximately
1400 RPM) to 2250 ± 25 RPM.
10-15. REGULATOR RANGE TEST.
10-16. EXCITER REGULATOR AND GOVERNOR STABILITY AND TRANSIENT
RESPONSE TEST .
Perform the exciter regulator and
governor stability and transient response
test as follows:
a. Operate generator set at 240/416 volts
at full load until temperatures have
stabilized.
Perform the regulator range test as
follows:
a. Operate generator set at 240/416 volts
at full load. Adjust voltage for 480 volts
(for 50/60 hertz operation) and 458 volts (for
400 hertz operation). Record voltage and
speed. Adjust voltage for 395 volts (for
50/60 or 400 hertz operation. Record voltage and speed.
b. Reduce load to zero. Adjust voltage
for maximum attainable voltage. Record
voltage and speed. Adjust voltage for mini mum voltage attainable. Record voltage and
speed.
c. The generator set shall operate at
any load between no load and full load at the
following line-to-line voltages:
b. Drop and apply the load a sufficient
number of times to make sure that the voltage and frequency are within the prescribed
band .
c . The governor shall be set at isochronous regulation for precise generator sets
and at 2.9 to 3 percent for uti Iity generator
sets. Adjust voltage to rated value. No
further adjustments shall be made during
this test. The recorders in the test circuit
are now started.
d. Perform the following load switching
sequence starting with full load, waiting
approximately 30 seconds between each load
change:
Adjust load to full load and starting from
no load: full load - 0 - full load - 0 full load -0
1. Between 380 and 426 volts for
50 hertz operation.
Adjust load to 3/4 load and starting from
no load: 3/4 -0-3/4-0-3/4-0
2. Between 375 and 489 volts for
60 hertz operation.
Adjust load to 1/2 load and starting from
no load: 1/2 -0-1/2-0-1/2-0
3. Between 395 and 458 volts for
400 hertz operation.
Adjust load to 1/4 load and starting from
no load: 1/4 - 0 - 1 / 4 - 0 - 1 / 4 - 0
10-6
T.O. 35C2-3-442-2
P-9-TM-457-35
TM-07464A-35 TM 5-6115-457-34
e. The frequency and voltage requirements are indicated below:
utility
Precise
Frequency
Steady State Band (30 see)
0.5 p e r c e n t
2 percent
Recovery Time
3 seconds
4 seconds
Overshoot and Undershoot (Apply Full Load)
6.0 percent
4 percent
Regulation
0.25 percent
2 to 3 percent
Precise
Voltage
Utility
Steady State Band (30 sec)
1.0 p e r c e n t
2 percent
Regulation
1.0 percent
3 percent
10-17. LONG TERM STEADY STATE
STABILITY TEST .
Perform the long term steady state
stability test as follows:
a. Operate the generator set at rated
speed, voltage, and full load for a period of
four hours.
b. Record voltage and frequency at start
and f ini ah of the four ham period. The long
term steady deviation at constant loads
from no load to full load shall be as follows:
1. The bandwidth shall remain within
1 percent (for precise generator sets) and
3 percent (for utility sets) of the rated
frequency.
2. The bandwidth shall remain within
2 percent (for precise generator sets) and
4 percent (for utility generator sets) of the
rated voltage.
10-18. PARALLEL OPERATION AND
REVERSE POWER TEST.
a. PARALLEL OPERATION. Perform
the parallel operation test as follows:
1. Operate two or more generator
sets in parallel at 240/416 volts at no load,
refer to Operator and Organizational Maintenance Manual.
2. If necessary, make fine adjustments to governors and exciter regulator
paralleling controls, with generator sets
operating in parallel and at no load.
3. Precise generator sets shall
divide load in accordance with the following
as system load at rated power factor is
varied between zero and 100 percent (and
vice versa) of the combined rating of the
connected sets:
(a) Real power division. - A t
no time shall the difference between the
average individual kilowatt outputs of the
three sets, when supplying the system load,
be greater than ten percent of the kilowatt
rating of one set.
(b) Power exchange. - At any
constant system load up to the combined
rating of the sets in parallel, power exchange between the sets shall not exceed
10 percent of the KW rating of one set.
Power exchange is the difference between
change 7
10-7
P-9-TM-457-35
TM-07464A-35
T.O. 35 C2-3-442-2
TM 5-6115-457-34
the maximum and minimum power output
delivered by one set, for constant system
load conditions.
(c) Reactive power division. At no time shall the difference in average
reactive KVA supplied by any three sets
differ by more than ten percent of the
reactive KVA rating of one set. For the
above requirements, the initial system load
shall be equally divided between the sets,
both as to active and reactive components;
thereafter, there shall be no adjustments
to governors, voltage regulators, or any
other component as system load is changed.
When voltage regulators are not interconnected between sets, the above requirements shall apply also, except that voltage
droop not exceeding three percent may be
introduced through the voltage regulator
reactive droop compensating circuits.
4. Utility generator sets shall divide
load in accordance with the following system
load at rated power factor is varied between
20 and 100 percent (and vice versa) of the
combined rating of the connected sets:
(a) Real power division. - At
no time shall the difference between the
average individual kilowatt outputs of the
three sets, when supplying the system load,
be greater than ten percent of the kilowatt
rating of one set.
(b) Power exchange. - At any
constant system load up to the combined
rating of the sets in parallel, power
exchange between the sets shall not exceed
10 percent of the KW rating of one set.
Power exchange is the difference between the
the maximum and minimum power output
delivered by one set, for constant system
load conditions.
10-8
(c) Reactive power division. At no time shall the difference in average
reactive KVA supplied by any three sets
differ by more than ten percent of the
reactive KVA rating of one set. For the
above requirements, the initial system load
shall be equally divided between the sets,
both as to active and reactive components;
thereafter, there shall be no adjustments
to governors, voltage regulators, or any
other components as system load is
changed.
b. REVERSE POWER TEST. Perform
the reverse power test as follows:
1. Operate two generators sets in
parallel at no load with load contractors
closed, refer to Operator and organizational
Maintenance Manual,
2. Lower speed of generator set
being tested until the REVERSE POWER
fault locator indicator illuminates. Record
value of kilowatt load at which the load
contactor opens. The load contactor shall
open when power flow into the generator sets
exceeds 20 percent of rated value, causing
the REVERSE POWER fault locator indicator to illuminate.
10-19. ENGINE EFFICIENCY TEST.
Perform the engine efficiency test
as follows:
a. Operate the generator set at full
rated load, speed, and voltage. Check the
engine exhaust for excessive smoke and
density of smoke.
b. The engine shall deliver 125 percent
of rated load for five minutes. Engine
exhaust smoke should be just visible at
100 percent load.
P-8-627-34 T. O. 35C2-3-442-2
TM 5-6115-457-34
TM-07464A-35
CHAPTER 11
FUEL BURNING WINTERIZATION KIT REPAIR INSTRUCTIONS
Section I. CONTROL BOX
11-1.
GENERAL.
The control box is located to the
right of the control cubicle and consists of
an ON-OFF switch, a circuit breaker,
press-to-test indicator light, and two
receptacles for interconnection. The ONOFF switch permits starting of the heater
and a means of stopping the heater. When
the switch is positioned to OFF, the heater
motor will continue to operate for a period
of approximately 4-1/2 minutes, to purge
heated air and fuel from heater. The circuit breaker is a manual reset type; it
protects the heater circuitry in case of an
overload. The press-to-test indicator light
illuminates to show that the heater is in
operation, it is also a means of checking
system electrical power.
11-2.
b. Remove connectors (5 and 8). If
necessary, remove wires from connectors.
c. Remove cover (10) from frame (26).
d. Remove lens (11), indicator light (15),
circuit breaker (21), switch (25) and component board assembly (25 B).
11-4.
DISASSEMBLY,
Refer to figure 11-1 and disassemble control box in the order of index numbers assigned. Pay particular attention to
the following:
CLEANING.
a. Clean electrical components with a
cloth moistened with an approved cleaning
solvent, and dry thoroughly.
REMOVAL.
Refer to Operator and Organizational Maintenance Manual and remove
control box.
11-3.
a. Remove screws (1) and pull plate (2)
aside. Tag and disconnect wiring from
plate components.
WARNING
Cleaning Solvents are f lammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
b. Clean metal components with an
approved cleaning solvent and dry
thoroughly.
CAUTION
Prolonged use of soldering equipment could cause damage to components due to excessive heat.
NOTE
Disassemble control box only to
the extent necessary to effect
repair.
11-5.
INSPECTION.
a. Inspect connectors and each wire for
continuity. Refer to table 11-1. Inspect
connectors for damaged threads; bent,
loose, or missing pins; and for shorts to
case and surrounding pins.
Change 8 11-1
P-8-627-34
TM-07464A-35
T. O. 35C2-3-442-2
TM 5-6115-457-34
Figure 11-1.
Fuel burning winterization kit control box,
exploded view
11-2
Change 8
T.O. 35 C2-3-442-2
TM 5-6115-457-34
P-9-TM-457-35
TM-07464A-35
Legend to figure 11-1:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Screw (2)
Plate
11.
Nut assembly (4) 12.
13.
Screw (4)
14.
Connector
Nut assembly (4) 15.
16.
Screw (4)
17.
Connector
18.
Screw (2)
Table 11-1.
Cover
Lens
Nut
Washer
Lamp
Indicator
Terminal
Terminal
Terminal
light
lug (2)
lug (2)
lug (3)
19.
20.
21.
22.
23.
24.
25.
25A.
25B.
Terminal lug
25C. Screw
Nut
25D. Spacer
Circuit breaker
25E. Diode
Nut
25F. Terminal
Washer
26. Frame
Tab washer
Switch
Screw
Component board assembly
Fuel Burning Winterization Kit Control Box Wire Termination Data
WIRE
LENGTH
INCHES
FROM
T ERMI NATION
NOTE
J26A
3
J27A
3
1
3
J26A
3
DS1-1
3, 4
2
4
J26B
3
S1-1
5
2
5
J26C
3
J27C
3
1
3-1/2
J26D
3
S1-6
6
1
6
J26E
3
CB-1
7
1
3-1/2
J26B
3
S1-3
5
2
6
J27D
3
DS1-2
3, 4
2
5
J27E
3
C B-2
7
1
6
CB-2
8
DS1-3
3, 4
2
3
CB-2
8
S1-4
5
2
3
OTES: 1.
2.
3.
4.
5.
6.
7.
8.
9.
TO
TERMINATION
NOTE
WIRE
TYPE
Wire is M5086/2-12-9 per MIL-W-5086/2.
Wire is M5086/2-16-9 per MIL-W-5086/2.
Solder.
Make good mechanical connection before soldering.
Secure end with terminal lug, MS25036-106.
Secure end with terminal lug, MS25036-111.
Secure end with terminal lug, MS25036-156.
Secure end with terminal lug, MS25036-153.
Refer to Operator and Organizational Maintenance Manual for wiring
diagram.
Change 1
11-3
P-9-TM-457-35
TM-07464A-35
T.O. 35 C2-3-442-2
TM 5-6115-457-34
b. Inspect switch, indicator light, and
circuit breaker for continuity. Refer to
figure 1-29.
11-7.
REASSEMBLY.
c. Inspect terminal lugs for security
and c onditi on.
Refer to figure 11-1 and reassemble control box in the reverse order of
index numbers assigned. Pay particular
attention to the following:
d. Inspect components for dents,
cracks, and distortion.
a. When installing switch (25), insert
tab of tab washer (24) into hole of plate (2).
11-6.
b. Install circuit breaker (21), indicator light (15), and lens (11).
REPAIR.
NOTE
c. Install connectors (5 and 8) with key
located on the top.
Figure 1-29 is the fuel burning
winterization kit and wiring diagram contained in Operator and
Organizational Maintenance
Manual.
a. Repair or replace defective control
box wiring in accordance with table 11-1.
b. Repair dents and distortion using
proper tools.
d. Attach cover (10) to frame (26).
e. Connect wiring and check for proper
connection, refer to table 11-1.
11-8.
INSTALLATION.
Refer to Operator and Organi zational Maintenance Manual and install control box.
Section II. HEATER
11-9.
GENERAL.
The heater is a fuel burning type
designed to pre-heat the engine for starting
at low temperatures down to -65°F by circulating heated coolant through the engine.
The heater consists of a blower motor,
fuel regulator valve, limit switch, igniter,
flame switch, and a coolant pump. The
blower motor and fan assembly provides
air for combustion; it is also a means for
driving the coolant pump. The fuel regulator valve permits the fuel to be turned on
and off; it also regulates the fuel flow to
the burner. The igniter, which is a high
11-4
resistance glow plug, is used to vaporize
and ignite the fuel. The flame switch controls the electrical supply to the igniter,
blower motor and indicator lamp; its operation is determined by temperature. Recirculation of heated coolant is provided by
the coolant pump at a rate of 80 to 100 GPH.
Coolant is circulated around the heater
combustion chamber where it is heated and
then is circulated through the engine.
11-10. REMOVAL.
Refer to Operator and Organizational
Maintenance Manual and remove heater.
P-8-627-34
TM-07464A-35
11-11. DISASSEMBLY.
Refer to figure 11-2 and disassem-
ble heater in the order of index numbers
assigned. Pay particular attention to the
following:
a . R e m o v e c o v e r ( 1 ) . T a g and di sconnect wires.
CAUTION
Use care when removing quartz
rod (14) as it is easily broken if
dropped.
b. Remove receptacle assembly (3),
terminal block (5), and flame switch
assembly (8).
c. Remove igniter (18), gasket
(19),
NOTE
Do not remove regulator
valve assembly (21) until
after casting (40) has been
removed.
d. Remove burner assembly (48), and
motor and pump assembly (55) as a
complete assembly.
NOTE
Coolant pump (56) cannot be removed as a complete assembly.
The unit must be disassembled during removal as the pump rotor (67)
is secured to the motor shaft by a
set screw (66).
e . Before disassembly of coolant pump,
make an alignment mark across adapter
(68), cam ring (63), and plate (58) for correct alignment during reassembly.
T O 35 C2-3-442-2
TM 5-6115-457-34
11-12. CLEANING.
a. Clean electrical components with a
cloth moistened with an approved cleaning
solvent, and dry thor oughly.
b. Remove carbon desposits from burner
assembly using a suitable wire brush.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
Compressed air used for cleaning and
drying purposes can create airborne
particles that may enter the eyes.
Pressure shall not exceed 30 psig.
Eye protection is required.
c. Clean orifice assembly by forcing
filtered compressed air through orifice in
the reverse flow direction.
d. Clean parts with an approved cle an ing solvent, and dry thoroughly.
11-13. INSPECTION.
a. Inspect components for cracks,
dents, distortion, burrs, nicks, and damaged threads.
b. Inspect insulation for damage.
c. Inspect springs for condition.
Inspect spring (60, figure 11-2). Using a
suitable spring compressor, apply a load
of 1 ± 0.1 pounds and compress spring (60)
to a working length of 0.750 inch. Spring
should measure 1.164 inches free length
after test.
d. Inspect receptacle assembly for
loose connections and bent or broken te rminal pins. Check for short to case and
surrounding pins. Check for continuity
between wires and terminal pins.
e. Inspect orifice assembly for proper
orifice opening. Opening should be
0.012 inch diameter.
f. Inspect regulator valve assembly (21)
as follows:
1. Check resistance of solenoid coil;
resistance should be 150 ohms.
Change 8
11-5
P-8-627-34
TM-07464A-35
T O 35 C2-3-442-2
TM 5-6115-457-34
Figure 1 1 - 2 .
11-6
Change 8
Fuel burning winterization kit heater,
exploded view
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Legend to figure 11-2:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Cover
Screw (4)
Receptacle assembly
Screw (4)
Terminal block
Screw (2)
Limit switch
Flame switch assembly
Adjusting screw
Washer
Adjusting spring
Tension spring
Spring pad
Quartz rod
Screw (2)
Micro-switch
Switch frame assembly
Igniter
Gasket
Tube assembly
Regulator valve assembly
Plug
Orifice assembly
Body
Sintered filter
Gasket
Screw (2)
Set screw
Set screw
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
Fuel pre-heater
assembly
Regulator valve
assembly
Screw (6)
Bracket (2)
Elbow
Screw (8)
Cover
Grommet
Screw (3)
Screw (5)
Casing
Hose (2)
Clamp (4)
Lockwire
Screw (2)
Retainer
Vaporizer
Screw (4)
Burner assembly
Set screw
Fan
Plate
Screw (2)
Inlet
Elbow (2)
Motor and pump
assembly
56. Coolant pump assembly
57. Screw (4)
58. Plate
59. Plug
60. Spring
61. Ball
62. O-ring
63. Cam ring
64. O-ring
65. Blade (4)
66. Set screw
67. Rotor
68. Adapter
69. Seal assembly
70. Seal cage
71. O-ring
72. Seal washer
73. Seal spring
74. Decal
75. Blower motor assembly
76. Brush cap (2)
77. Brush and spring (2)
78. Screw
79. Name plate
80. Drain plug
81. clamp (2)
82. Bracket (2)
83. Heat exchanger
2.
Test fuel flow. Connect filtered
7 PSI fuel supply to regulator valve, and
apply 24 VDC to valve solenoid.
5. Remove 24 VDC from valve
solenoid, and check for leakage through
valve.
3. Using a stop watch, time the fuel
flow into a graduated container. Flow
should measure 21 to 23 cubic centimeters
per minute (approximately 1/4 pint in five
minutes).
6. Remove test equipment from
valve. Replace valve that will not provide
proper fuel flow or one that leaks when
voltage is removed.
4. If fuel flow rate is not within
these tolerances, adjust valve. Turn adjusting screw clockwise to increase flow rate o r
counterclockwise to decrease flow rate.
g. Inspect flame switch assembly (8) as
foil ow s :
1. Inspect frame for loose pivot
points.
11-7
P-9-TM-457-35
TM-07464A-35
T.O. 35 C2-3-442-2
TM 5-6115-457-34
2. Check continuity of micro-switch
(16) as follows:
(a) Depress the micro-switch
button. This will be the ignition or start
position of the switch. Continuity should be
indicated between the two NO terminals and
also between each of the NO terminals and
the common terminal. There should be an
open circuit between the two NC terminals
and also between the common terminal and
the two NC terminals.
(b) Release the micro-switch
button. This will be the run position of the
micro-switch. Continuity should be indicated between the two NC terminals and the
common terminal. There should be an open
circuit between the NO ignition or start terminals and between the NO terminals and
the common terminal.
j . Inspect heat exchanger and burner
assembly for warpage and burned area.
k. Inspect sintered filter for blockage.
1. Using a suitable dial indicator, check
end play on shaft of blower motor assembly.
Grasp short shaft end and rotate in either
direction, at the same time moving in and
out. The end play should not exceed 0.010
to 0.025 inch.
m. Inspect adapter for damaged or
scored face, warped condition, and dam aged seal face. Inspect for motor shaft
bore wear. Refer to figure 11-3 for limits.
n. Inspect seal cage for scored or dam-
aged seal face.
o. Inspect rotor and blades for damage
and wear. Refer to figure 11-3 for limits.
h. Inspect igniter as follows:
1. Inspect for broken coil or short.
2. Check igniter for proper resistance; resistance should be 1 ohm.
p. Inspect cam ring for damaged or
scored bore. Inspect for warped condition.
Both faces must be parallel within 0.001 inch
T. I. R.
q. Inspect plate (58, figure 11-2) for
WARNING
damaged or scored face.
11-14. R E P A I R .
To prevent burns, do not touch
igniter during test, and allow enough
time for it to return to ambient
temperature before removing test
equipment.
3. Connect 24 VDC power source and
an ammeter to igniter terminal. Ground
igniter. Apply 24 VDC to igniter. The
igniter should draw 10.5 amperes and heat
to a bright red color in a few seconds.
i. Inspect fan for loose or damaged
blades.
11-8
a. Seal face of adapter (68, figure 11-2)
and seal face of seal cage (71) can be
dressed to remove minor nicks, scratches
or scoring. Remove only material necessary to clean up seal face. Seal face must
be parallel with rotor side of adapter within
0.001 inch per inch. Replace either part if
imperfections cannot be dressed cut.
b. Straighten distorted parts using
suitable tools.
c. Remove burrs or nicks using a stone
or file.
P-9-TM-457-35
TM-07464A-35
T. O. 35C2-3-442-2
TM 5-6115-457-34
NOTE
The coolant pump (56) cannot be
assembled completely and installed
as a separate unit. It is assembled
as it is installed on the short shaft
end of the motor.
a. Apply a thin film of grease to o-rings
(62, 64, and 70) and seal cage (71).
b. Install seal spring (73) and seal
washer (72) over end of motor shaft. Place
o-ring (70) in seal cage (71); then install
seal cage over end of motor shaft with seal
face facing outward.
c. Install pump adapter (68) over motor
shaft and align holes with tapped holes in
motor.
NOTE
Make certain that adapter (69) and
cam ring (63) are tightly compressed together when determining the 0.002 inch clearance,
otherwise a false reading will be
obtained.
Figure 11-3. Coolant pump wear limits
11-15. REASSEMBLY.
Refer to figure 11-2 and reassemble
heater in the reverse order of index numbers assigned. Pay particular attention to
the following:
d. Install pump rotor (67) on motor
shaft and temporarily tighten rotor set
screw (66). Place o-ring (64) in groove of
pump adapter (68). Place cam ring (63) in
position aligning scribe mark. With motor
shaft end play taken up in direction of pump,
make certain there is at least 0.002 inch
clearance between outer face of cam ring
(63) and outer face of rotor (67). Move
rotor back or forth as necessary to produce
this clearance; then tighten set screw (66).
e. Install rotor blades (65) in rotor
slots, making sure that grooves in blades
face away from direction of rotation, Pump
rotates counterclockwise when viewing
end of port plate (58).
f. Place o-ring (62) in groove of port
(58); then position plate against
11-9
P-9-TM-457-35 T.O. 35C2-3-442-2
TM 5-6115-457-34
TM-07464A-35
cam ring (63), Align scribe marks, and
tighten screws (57) evenly.
g. Test coolant pump assembly (56).
Refer to paragraph 11-16, step a.
p. Adjust flame switch (8), refer to
paragraph 11-16, step b.
q. Install cover (l).
11-16.
h. After coolant pump has been reassembled and tested, flush with corrosive
preventive compound, Military Specification
MIL-C-6529, and drain.
COMPONENT TEST AND
ADJUSTMENTS.
The following procedures cover
testing and adjustments of individual
components.
NOTE
Make certain that the lead wire
from blower motor assembly (75)
is on the side of the blower
opposite the name plate.
i. Assemble motor and pump assembly
(55), inlet (53), plate (51), and fan (50)
before installing into burner assembly (48).
j. Install burner assembly (48) and
casing (40).
k. Install cover (36).
1. Install regulator valve assembly (21),
gasket (19), and igniter (18).
a. Coolant Pump Assembly. Coolant
pump assembly (56, figure 11-2) should be
tested before being reinstalled in the heater.
Test coolant pump assembly as follows:
1. Connect motor and pump assembly to equipment as shown in figure 11-4.
2. Turn power switch to ON and
run-in unit for approximately 15 minutes.
3. Test relief valve by closing
manual shut-off valve. Discharge pressure
should not exceed 30 to 35 PSI when valve
is closed. Open and close valve a few
times to check consistency of valve performance. Replace relief valve spring if
pressure exceeds 30 to 35 PSI.
CAUTION
Use care when installing quartz
rod (14) as it is easily broken if
dropped.
m. After installing quartz rod (14),
gently raise the rod up and down to see if it
moves freely in the stainless tube. Also
make sure at least 1/32 inch extends out of
tube when rod is resting on bottom.
n. Install flame switch assembly (8) and
terminal block (5).
o. Install receptacle assembly (3) with
key located on the top.
11-10
4. To check pump for rated flow and
pressure, adjust valve in discharge line
until a reading of 2 PSI is obtained on pressure gauge.
5. Using a suitable timer, check for
rated flow of 80 GPH minimum at 2 PSI discharge pressure. Amperage draw should
not exceed 6 amperes during this test.
6. Check motor RPM using a strobe
light. Motor shaft speed should be 8500 RPM.
7. Observe smoothness of operation
of both pump and motor. Seal leakage of
1 cubic centimeter per hour (seal may show
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 11-4. Coolant pump test set-up
signs of dampness) is maximum when pump
is operating at 2 PSI discharge pressure.
8. Turn power supply to OFF; then
remove discharge line and fitting from OUT
port. Plug this port and apply 40 PSI hydrostatic pressure for 20 minutes. No leakage
shall be evident during this test.
9.
2. Turn adjusting screw (9)
counterclockwise until motor starts.
3. Then turn adjusting screw clockwise until motor stops.
4. Turn adjusting screw clockwise
an additional 1/2 (180 degrees) turn.
Remove test equipment.
5. Remove power supply.
b. Flame Micro-Switch. Check microswitch (16, figure 11-2) as follows:
11-17.
1. Connect a 24 VDC power supply to
heater receptacle, positive to pin C and
negative to pin A.
Refer to Operator and Organizational Maintenance Manual and install
heater.
INSTALLATION.
11-11/(11-12 blank)
P-9-TM-457-35
T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
CHAPTER 12
ELECTRIC WINTERIZATION KIT REPAIR INSTRUCTIONS
Section I. CONTROL BOX
12-1.
GENERAL.
The control box contains the operating controls of the electric winterizati on
kit. Incorporated in the box are the on-off
switch, fuse, step down transformer, full
wave diode rectifier, and heater indicator.
The switch turns kit components on or off
and the fuse protect kit components from
excessive current. The step down transformer converts input voltage from external
power supply to 33 VAC which in turn is
converted to approximately 24 VDC by the
full wave diode rectifier for coolant pump
operation. The indicator illuminates
whenever the kit is in operation.
12-2.
REMOVAL.
Refer to Operator and Organizational Maintenance Manual and remove the
control box.
1.2-3.
Figure 12-1. Electric winterization kit
control box, test setup
TEST.
NOTE
Figure 1-30 is the electric winterization kit schematic.
12-4.
DISASSEMBLY .
Refer to figure 12-2 and disassemble electric winterization kit control box in
the order of index numbers assigned. Pay
particular attention to the following:
a. Prior to control box disassembly,
test box as specified in paragraph 12-3 and
then disassemble control box only to the
extent necessary to accomplish repair.
a. Connect control box to test equipment
as illustrated in figure 12-1.
b. Remove cover (2). Tag and disconnect harness wires from components and
remove harnesses (3 and 9).
b. Perform test procedures as specified
in table 12-1.
c. Tag diodes (11) with location and
polarity and remove diodes from terminal
strip by removing terminal strip screws.
12-1
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
12-2
Table 12-1.
P-8-627-34 T.O. 35C2-3-442-2
TM-07464A-35
TM 5-6115-457-34
Figure 12-2.
Electric winterization kit control box,
exploded view
Change 8
12-3
P-8-627-34
TM-07464A-35
T.O. 35 C2-3-442-2
TM 5-6115-457-34
Legend to figure 12-2:
1. Screw (6)
2. Cover
3. Harness
4. Nut (4)
5. Screw (4)
6. Nut (4)
7. Screw (4)
8. Cover
9. Harness
10. Terminal lug (8)
11. Diode (4)
12. Nut (2)
13. Screw (2)
12-5. CLEANING.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Terminal board
Nut (4)
Screw (4)
Transformer
Nut (2)
Lock washer (2)
Screw (2)
Resistor
Setscrew
Knob
Screw (3)
Switch
a. Clean electrical components with a
clean lint-free cloth moistened in an
approved cleaning solvent and dry
thoroughly.
WARNING
Cleaning Solvents are f lammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
b. Clean remaining parts in an approved
cleaning solvent and dry thoroughly.
12-6.
INSPECTION.
a. Inspect sheet metal parts for cracks,
distortion, dents, and bent corners.
b. Check threads for damage
c. Inspect terminal board for damaged
or cracked insulation.
NOTE
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
Cap
Fuse
Nut (2)
Screw (2)
Plate
Fuse holder
Lens
Lamp
Nut
Washer
Light housing
Chassis
e. Check switch, lamp, light, fuse, and
fuse holder for continuity.
f. Check forward and reverse resistance of diodes. Measured from anode (+)
to cathode (-), value should be low.
Reverse meter leads, value should be
infinity.
g. Inspect transformer for burrs and
defective insulation. Apply 240 VAC to
transformer terminals 1 and 2. Check
output at terminals 3 and 4, output should
be 33 VAC.
h. Inspect harness (3, figure 12-2)
wires for continuity, refer to figure 12-3.
i. Inspect harness (9, figure 12-2)
connectors for bent, loose, or missing
pins. Check each harness wire for continuity from wire ends to connector pins.
Check connector pins for shorts to case
and surrounding pins. Refer to figure
12-4.
12-7. REPAIR.
a. Straighten dented or distorted parts
using proper tools.
Figure 1-30 is the schematic for
the electric winterization kit.
b. Repair or rebuild defective harness
(3, figure 12-2) as illustrated in figure
12-3.
d. Check resistor for proper resistance
value, value should be 2.47K ohms.
c. Repair or rebuild defective harness
(9, figure 12-2) as illustrated in figure 12-4.
12-4
Change 8
P-9-TM-457-35
TM-07464A-35
T. O. 35C2-3-442-2
TM 5-6115-457-34
Figure 12-3. Electric winterization kit control box
wiring harness
12-5
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 12-4. Electric winterization kit control box
connector wiring harness
12-6
P-8-627-34
TM-07464A-35
12-8.
REASSEMBLY.
Refer to figure 12-2 and reassemble
the electric winterization kit control box in
the reverse order of index numbers assigned. Pay particular attention to the following:
a. Install connectors of harness (9) with
keyways on top.
NOTE
b. Prior to installing cover (2), refer
to figure 1-30 and check wiring for proper
connection.
c. After reassembly, test control box
as specified in paragraph 12-3.
12-9.
Refer to Operator and Organizational Maintenance Manual for
electric winterization kit wiring
diagram.
T O 35C2-3-442-2
TM 5-6115-457-34
INSTALLATION .
Refer to Operator and Organizational Maintenance Manual and install the
control box.
Section II. ELECTRIC HEATER
12-10.
GENERAL.
The electric heater is utilized to
preheat generator set engine coolant during
cold weather operation. The heater consists of a removable heating element,
intake head with integral check valve and
coolant tank. The check valve insures that
the coolant tank is always full and heating
element is submerged in coolant. The
heating element heats the coolant in the
tank which is in turn circulated through the
engine coolant system.
12-11.
REMOVAL.
Refer to Operator and Organizational Maintenance Manual and remove the
electric heater.
12-12.
DISASSEMBLY.
Refer to figure 12-5 and disassemble the electric heater in the order of index
numbers assigned.
Figure 12-5. Electric winterization kit
electric heater, exploded view
Legend to figure 12-5:
1.
2.
3.
4.
5.
6.
Screw
Cover
End Plug
Heating element
Screw (6)
Washer (6)
7. Intake head and
check valve
assembly
8. Gasket
9. Tank
10. Plug
Change 8
12-7
P-8-627-34
TM-07464A-35
12-13.
T O 35C2-3-442-2
TM 5-6115-457-34
C LEANING.
WARNING
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
a. Remove hand coolant deposits from
components by boiling components a minimum of 30 minutes in solution of one pound
baking soda to each gallon of water.
b. Clean old gasket from intake head
and check valve assembly and tank using a
suitable scraper.
gouge surfaces.
Exercise care not to
c. Clean parts with an approved cleaning solvent and dry thoroughly.
12-14.
INSPECTION.
a. Inspect threads for damage.
b. Inspect parts for cracks and damaged gasket surfaces.
c. Check flap of check valve for freedom of movement and for proper seating on
intake head.
Do not handle heating element during test and permit element to cool
prior to removing test equipment.
d. Connect single phase 240 volts, 50,
60, or 400 hertz power supply to heating
element terminals. Connect suitable ammeter and wattmeter in series with heating
element and power supply. Apply 240 VAC
and observe ammeter and wattmeter.
Heating element should draw 10.8 amperes
and 2500 watts. Remove test equipment,
replace defective heating element.
12-15. REASSEMBLY.
Refer to figure 12-5 and reassemble the electric heater in the reverse order
of index numbers assigned. Pay particular
attention to the following:
a. Apply thread sealing compound conforming to Military Specification MIL-S45180, type III, to threads of end plug (3)
and plug (9) prior to installation.
b. When installing intake head and
check valve assembly (7), make sure that
hole with arrow is on top.
12-16. INSTALLATION .
Refer to Operator and Organiz ational Manual and install the
electric heater.
Section III. COOLANT PUMP
12-17.
GENERAL.
The coolant pump consists of a
pump and motor assembly which operates
on 24 VDC and provides a minimum of
80 gallons per hour at 2 PSI. The motor is
a continuous duty type and rotates in a
clockwise direction as viewed from the pump
end. The motor is rated at 20 to 32 VDC,
3.3 amperes with a maximum of 7500 RPM.
12-8
Change 8
The motor is equipped with an internal
bypass and feed thru capacitor for radio
suppression and voltage and current protection. The pump is a rotor type with a
built in relief valve that is set at 30 to
35 PSI. If coolant pressure reaches 30 to
35 PSI, the relief valve ball is unseated
and coolant is permitted to bypass internally within the pump until pressure is
reduced to 30 PSI.
P-8-627-34 T.O. 35 C2-3-442-2
TM-07464A-35
TM 5-6115-457-34
12-18.
REMOVAL.
Refer to Operator and Organizati onal Maintenance Manual and remove
coolant pump.
12-19. TEST .
a. Connect coolant pump to test equipment as illustrated in figure 11-4, except
test equipment fuse rating should be
4 amperes.
b. Perform test procedure specified in
paragraph 11-16, step a. Test results during test should be the same as provided in
test procedure except motor amperage
draw should not exceed 3.3 amperes in
step a. 5. and motor RPM in step a. 6.
should be 7500.
12-20. DISASSEMBLY.
Refer to figure 12-6 and disassemble the coolant pump in the order of index
numbers assigned. Pay particular attenti on to the following:
a. Mark alignment marks on port plate
(6), cam ring (8), adapter (13), and motor
(23) prior to disassembly to insure proper
reassembly.
WARNING
Avoid breathing fumes generated by
unsoldering/soldering. Eye protection is required.
b. Move shell (22) away from motor
and unsolder wire (20) from pump.
c. Replace all packings.
12-21. CLEANING.
a. Clean wire and motor with a clean
lint-free cloth moistened in an approved
cleaning solvent and dry thoroughly.
WARNING
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
Compressed air used for cleaning and
drying purposes can create airborne
particles that may enter the eyes.
Pressure shall not exceed 30 psig.
Eye protection is required.
b. Clean brush and spring assembly and
brush openings with filtered low pressure
compressed air.
c. Clean remaining parts in an approved cleaning solvent and dry thoroughly.
1.2-22.
INSPECTION.
a. Inspect springs for cracks, distortion, and broken ends.
b. Test relief valve spring for proper
spring rate using a suitable spring tester.
Spring rate should be 1 pound ± 0.1 pound
at 0.750 inch working length. After rate
test, check spring for proper free length
of approximately 1.164 inches.
c. Test seal spring for proper spring
rate. Spring rate should be 2.5 pounds
± 0.25 pound at 0.25 inch working length.
After rate test, check spring for proper
free length of approximately 0.470 inch.
d. Inspect relief valve ball and ball
seat in port plate for grooves, scratches,
and nicks .
e. Inspect parts for cracks, damaged
contact surfaces, signs of scuffing, nicks,
and burrs.
f. Inspect threads for damages.
g. Inspect pump components for wear,
refer to figure 11-3.
h. Inspect brush and spring assembly
brushes for cracks, chips, and wear by
comparing brush with new brush. Replace
brush and spring assembly if brush is
worn to half its original length.
Change 8
12-9
P-8-627-34
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
Electric winterization kit coolant pump,
exploded view
k. Connect 24 VDC and ammeter to
i. Rotate motor shaft and check for
motor
terminal and ground motor. Check
smoothness of rotation, rough spots, and
motor RPM using a suitable strobe light.
excessive side play. Using a suitable dial
Motor should draw a maximum of 3.3 amindicator, check motor shaft end play.
peres and RPM should be approximately
End play should be 0.010 to 0.025 inch.
7500.
Check motor shaft for wear, shaft
12-23. REPAIR.
should be 0.3125 ± 0.0005 inch diameter
and 0.286 ± 0.005 inch from flat. Check
a. Remove nicks and burrs using a
shaft for grooves on packing contact surface.
stone or file.
j . Check capacitor for open or short.
b. Repair loose nameplate using a
Figure 12-6.
suitable adhesive.
12-10
Change 8
P-8-627-34
TM-07464A-35
T O 35C2-3-442-2
TM 5-6115-457-34
Legend to figure 12-6:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Nameplate
Plug
Relief valve spring
Relief valve ball
Screw (4)
Port plate
Packing
Cam ring
Blade (4)
12-24.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Setscrew
Rotor
Packing
Adapter
Seal cage
Packing
Washer
Seal spring
Brush cap (2)
REASSEMBLY.
Refer to figure 12-6 and reassemble the coolant pump in the reverse order
of index numbers assigned. Pay particular
attention to the following:
WARNING
Avoid breathing fumes generated by
unsoldering/soldering. Eye protection is required.
a. Solder wire (20) to motor and position shell (22) on motor to ensure water
tight seal.
19.
20.
21.
22.
23.
24.
25.
26.
27.
d. Position spring (17), washer (16),
packing (15), seal cage (14), adapter (13),
and assembled rotor (11) on motor shaft.
Align motor setscrew opening with flat of
motor shaft. Slide components toward
motor, compressing spring (17) and install
setscrew (10).
e. Install remaining components.
Tighten screws (5) evenly to prevent side
loading components.
f. Test coolant pump as specified in
paragraph 12-19.
12-25.
b. Apply a thin film of grease to packings (7, 12, and 15) and seal cage (14) so
that packing will move in groove to form
proper seal at time of reassembly. Positi on packings in grooves.
Brush and spring assembly (2)
Wire
Shell
Shell
Motor
Screw (4)
Plate
Gasket
Capacitor
INSTALLATION.
Refer to Operator and Organizational Maintenance Manual and install
coolant pump.
c. Install blades (9) in rotor (11).
Align alignment marks.
12-11/(12-12 blank)
T O 35C2-3-442-2
P-8-627-34
TM-07464A-35 TM 5-6115-457-34
CHAPTER 13
DUMMY LOAD KIT REPAIR INSTRUCTIONS
Section I. DUMMY LOAD KIT
13-1.
GENERAL.
The dummy load kit is a balanced
three phase, four wire, resistive type load
bank. The kit is rated for approximately
48 KW with increments loads of approximately 12 KW. It is capable of operating with
either 50/60 hertz or 400 hertz generator
sets. The kit consists of a control box, resistive heater elements, and wiring enclosed
in a ventilated housing. The kit is designed
to operate at either 120/208 or 240/416 output voltages. The kit's load is created by
the heater elements, as selected by the load
switch. The control box and its components
are described in Section II of this chapter.
b. Tag, disconnect, and remove leads
(28) from heater elements (33). Remove
heater elements (33), resistor brackets
(38, 43, and 48) from frame (70).
c. Remove control box cover (57), tag
and disconnect wire harnesses (52 and 53)
from control box components.
d. Separate control box (63), fire wall
(61), panel (62), and end panels (67, 68, and
69) from frame (70).
e. Refer to paragraph 13-22 for disassembly procedures for the control box.
13-4.
13-2.
CLEANING
REMOVAL.
Refer to Operator and Organizational
Maintenance Manual and remove dummy
load kit.
a. Clean electrical components with a
clean lint-free cloth moistened with an approved cleaning solvent and dry thoroughly.
WARNING
13-3.
DISASSEMBLY.
Refer to figure 13-1 and disassembly
dummy load kit in the order of index numbers assigned. Pay particular attention to
the following.
NOTE
Disassemble dummy load kit only to
the extent necessary to effect repair,
a. Remove cover assembly (6), side
panels (17) channels (18 and 19) and end
panels (23, 24, and 25) from frame (70).
Cleaning Solvents are flammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
b. Clean metal parts in an approved
cleaning solvent and dry thoroughly.
13-5.
INSPECTION AND TEST.
a. Inspect parts for cracks, dents, and
distortion.
b. Inspect threads for damage.
Change 8
13-1
T O 35C2-3-442-2
P-8-627-34
TM-07464A-35 TM 5-6115-457-34
Figure 13-1. Dummy load kit, exploded view (sheet 1 of 2)
13-2
Change 8
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 13-1. Dummy load kit, exploded view (sheet 2 of 2)
13-3
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Legend to figure 13-1.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10,
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26,
27.
28.
29.
30.
31.
32.
33.
34.
35.
13-4
Eye bolt (2)
Screw (6)
Lock washer (6)
Nut (8)
Screw (8)
Cover
Nut (8)
Screw (8)
Bracket (4)
Nut (12)
Screw (12)
Splash pan (2)
Side rail (2)
Screw (18)
Lock washer (18)
Washer (18)
Side panel (6)
Channel (2)
Channel (2)
Screw (6)
Lock washer (6)
Washer (6)
End panel
End panel
End panel
Nut (96)
Washer (96)
Lead (10)
Strap (49)
Nut (96)
Lock washer (96)
Screw (96)
Heater Element (48)
Nut (4)
Washer (4)
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
Screw (4)
Washer (4)
Resistor bracket (4)
Nut (4)
Washer (4)
Screw (4)
Washer (4)
Resistor bracket (4)
Nut (4)
Washer (4)
Screw (4)
Washer (4)
Resistor bracket (4)
Nut (6)
Screw (6)
Clamp (6)
Wire harness
Wire harness
Screw (12)
Lock washer (12)
Washer (12)
Control box assembly cover
Screw (4)
Lock washer (4)
Washer (4)
Fire wall
Panel
Control box
Screw (6)
Lock washer (6)
Washer (6)
End panel
End panel
End panel
Frame
P-8-627-34
T O 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
NOTE
Dummy load kit wiring diagram is
contained in the Operator and Organizational Maintenance Manual.
c. Refer to figure 13-2 and 13-3 and
check each harness wire for continuity.
Check harness wires for loose terminal
lugs and defective installation.
d. A quick test of heater elements may be
accomplished without disassembly of dummy
load bank. Measure resistance between
terminal points 1, 7, 13, 19, 25, 31, 37,
43, 49, 55, 61 and 67 to neutral lead LO
on dummy load bank terminal board.
Resistance valves should be approximately
(1.75 ohms 120/208 voltage connection or
(7 ohms 240/416 voltage connections). Refer to figure 1-31.
WARNING
Do not touch heater elements during
test and permit elements to cool
prior to removing test equipment.
e. Test resistance of each heater element, resistance should be 11 to 14 ohms.
Test each heater element by connecting a
120 VAC; 50, 60, or 400 hertz power supply
a n d a 0 - 10 ampere AC ammeter to heater
element terminals. Turn on power supply,
heater element should draw 8.3 amperes.
Remove test equipment.
f. Inspect fire wall for deterioration,
cracks, and damaged ends.
g. Inspect paint for deterioration,
cracks, and damaged ends.
13 -6. REPAIR.
WARNING
Welding operations produce heat,
highly toxic fumes, injurious
radiation, metal slag and airborne particles. Welding goggles, with proper tinted lenses,
apron or jacket and welder’s
boots are required.
a. Repair cracks by welding.
b. Straighten dented or distended parts
using suitable tools.
c. Remove damaged paint. Blend in
edges, prime, and paint damaged areas.
d. Repair damaged harnesses as specified in figure 13-2 or 13-3.
13-7. WIRING HARNESS REBUILD.
a. Rebuild dummy load
wiring harness as specified
b. Rebuild dummy load
wiring harness as specified
13-8. REASSEMBLY.
kit
in
kit
in
right side
figure 13-2.
left side
figure 13-3.
Refer to figure 13-1 and reassemble
dummy load kit in the reverse order of index numbers assigned. Pay particular
attention to the following:
a. Install end panels (67, 68, and 69)
on frame (70).
b. Position wire harnesses (52 and 53)
on frame (70) and secure with clamps (51)
screws (50) and nuts (49).
c. Reassemble control box as specified
in paragraph 13-28.
d. Install control box (63), fire wall (61),
and panel (62) on frame (70). Connect wire
harnesses (52 and 53) to control box components. Install control box cover (57) on
control box assembly (63).
NOTE
Dummy load kit wiring diagram is
contained in the Operator and Organizational Maintenance Manual.
e. Install heater elements (33) and leads
(28). Leave screws (32) at center frame
loose to permit expansion and travel of
heater elements (33). Check wiring for
proper connection.
f. Install end panels (23, 24, and 25),
channels (18 and 19), side panels (17), and
cover assembly.
13-9. INSTALLATION.
Refer to Operator and Organizational
Maintenance Manual and install dummy load
kit.
Change 8
13-5
Change 8
T O 35C2-3-442-2
P-8-627-34
TM-07464A-35 TM 5-6115-457-34
13-6
Figure 13-2.
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 13-2. Dummy load kit right side wiring harness (sheet 2 of 2)
13-7
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
13-8
Figure 13-3.
P-8-627-34 T O 35C-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 13-3. Dummy load kit (left side) wiring harness (sheet 2 of 2)
Change 8
13-9
T O 35C2-3-442-2
P-8-627-34
TM-07464A-35 TM 5-6115-457-34
Section II. CONTROL BOX
13-10. GENERAL.
a. Control Box. The control box contains the operating controls of the dummy
load kit. The box incorporates a harness,
load selector switch, load removal
switch, voltage change terminal board,
load dumping relay, transformer, diodes,
resistors, capacitors, relay, transistors
and contractors.
b. Load Dumping Relay (K5). The
relay contains controls necessary to
automatically remove dummy load kit from
operation when the automatic load removal
switch is positioned to ON. With the switch
in the ON position the dummy load kit is
removed from operation when the generator set load exceeds 50 percent, After
automatic load removal the relay must
be manually reset by positioning automatic
load removal switch to BY-PASS RESET.
13-11. LOAD DUMPING RELAY (K5).
13-12. REMOVAL. Refer to figure 13-4
and remove the load dumping relay as
follows :
a. Disconnect cover (11) from frame
(91) by removing screws (9) and washers
(10).
b. Tag and disconnect harness (51)
wires from load dumping relay (45).
c. Disconnect load dumping relay (45)
by removing screws (44).
b. Perform test specified in table 13-1.
13-14. DISASSEMBLY. Refer to figure
13-6 and disassemble load dumping relay
to the extent necessary to effect repair as
follows :
a. Remove relay, relay socket, and
terminal strip by removing screws, washers, and nuts.
WARNING
Avoid breathing fumes generated by
unsoldering/soldering. Eye protection is required.
b. Unsolder components from their
connection points exercising care not to
apply excessi ve heat to components.
13-15. CLEANING. Clean parts with a
clean lint free cloth moistened in an approved cleaning solvent and dry thoroughly.
13-16. INSPECTION.
a. Inspect component side of circuit
board for damage, burns, di scolored areas,
and signs of overheating. Check components
for security.
b. Inspect printed circuits of board for
breaks and damage.
13-17. REPAIR. Repair printed circuits
by soldering a jumper wire accross defective area exercising care not to apply
excessive heat to components. Make sure
solder joints do not project more than 0.094
inch beyond surface of board.
13-18. REASSEMBLY. Refer to figure
13-6. and reassembly load dumping relay
as follows:
13-13. TEST AND BENCH TEST.
a. Connect test equipment to the load
dumping relay as illustrated in figure 13-5.
13-10
Change 8
a. Solder components to their connection points exercising care not to apply
excessive heat to components.
P-9-TM-457-35 T. O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 13-4. Dummy load kit control box, exploded view (sheet 1 of 2)
Change 4
13-11
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 13-4. Dummy load kit control box, exploded view (sheet 2 of 2)
13-12
Change 1
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Legend to figure 13-4:
1 .
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
15A.
15B.
15C.
15D.
15E.
15F.
15G.
15H.
15J.
15K.
15L.
15M.
15N.
15P.
15Q.
15R.
15S.
15T.
16.
17.
18.
19.
Screw (6)
Washer (6)
Upper panel
Nut (4)
Screw (3)
Lower panel
Rivet (4)
Instruction plate
Screw (12)
Washer (12)
Cover
Nut (12)
Screw (12)
Washer (12)
Contactor (4)
Deleted
Deleted
Deleted
Deleted
Deleted
Deleted
Deleted
Deleted
Deleted
Deleted
Deleted
Deleted
Deleted
Deleted
Deleted
Deleted
Deleted
Deleted
Deleted
Nut (4)
Washer (4)
Screw (4)
Transformer
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
Lead (3)
Nut (3)
Screw (3)
Lock washer (6)
Capacitor (3)
Screw (4)
Bridge rectifier
assembly
Nut (2)
Washer (2)
Screw (2)
Terminal board
Nut (4)
Washer (4)
Diode (2)
Diode (2)
Terminal lug (2)
Terminal lug (4)
Lead (4)
Screw (4)
Washer (4)
Spacer (4)
Insulated plate (2)
Heatshield
Heatshield
Screw (3)
Load dumping
relay K5
Spacer (3)
Grommet (2)
Nut (4)
Screw (4)
Cover and chain
Harness
Nut (14)
Screw (10)
Washer (10)
Reconnection
board assembly
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
Nut (4)
Washer (4)
Screw (4)
Washer (4)
Setscrew
Knob
Nut
Load selector
switch
Tab waste
Nut
Lens
Lamp
Nut
Light
Washer
Nut
Nut
Washer
Automatic load
removal switch
Tab washer
Nut
Control board panel
Nut (52)
Link (26)
Nut (’78)
Lock washer (78)
Rear link (13)
Nut (’78)
Terminal stud (78)
Nut (4)
Nut (4)
Washer (4)
Nut (4)
Load stud (4)
Terminal board
Frame
Change 4
13-13
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
13-14
Figure 13-5.
Table 13-1.
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
13-15
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
13-16
Table 13-1.
P-8-627-34 T O 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
b. Secure relay, relay socket, and
terminal strip in position and secure with
screws, washers, and nuts.
c. After replacement of components on
the printed circuit board, coat the board
with protective coating, conforming to
Military Specification MIL-I-46058, grade
S, type PUR, 0.0050 minimum thickness.
The coating shall be applied so that it
anchors the components to the board.
Terminals utilized for connection to external
circuits shall not be coated.
13-19. INSTALLATION. Refer to figure
13-4 and install the load dumping relay as
follows :
a. Connect load dumping relay (45) to
frame (91) and secure with screws (44).
NOTE
Dummy load kit wiring diagrams
is contained in the Operator and
Organizational Maintenance Manual.
b. Connect electrical wiring to relay.
Check wiring for proper connection.
c. Install cover (11) and secure with
screws (9) and washers (10).
13-20. CONTROL BOX.
13-21. REMOVAL, Refer to figure 13-1
and remove control box as follows:
WARNING
Figure 13-6. Dummy load kits load
dumping relay (K5).
Legend to figure 13-6.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Screw
Spacer
Screw (2)
Lock washer (2)
Relay
Relay socket
Screw (2)
Spacer (2)
Terminal board
Diode (2)
Resistor
Capacitor
Resistor
Resistor
Diode
Zener diode
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Resistor
Variable resistor
Resistor
Transistor
Transistor pad
Resistor
Resistor
Transistor
Transistor pad
Resistor
Resistor
Resistor
Diode
Transistor
Transistor pad
Board
b. Tag and disconnect frame harness
wires from control box components.
Make sure dummy load kit is not
connected to generator set prior to
performing maintenance.
a. Disconnect cover (57) by removing
serews (54), and washers (55 and 56).
c. Disconnect control box (63) from
frame (70) by removing screws (58) and
washers (59 and 60).
Change 8 13-17
P-8-627-34
T O 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
WARNING
13-22. DISASSEMBLY. Refer to figure
13-4 and disassemble control box in the
order of index number assigned. Pay
particular attention to the following.
Cleaning Solvents are f lammable and
moderately toxic to skin, eyes and
respiratory tract. Eye and skin
protection required. Good general
ventilation is normally adequate.
NOTE
Disassemble control box only to the
extent necessary to effect repair.
b. Clean metal parts in an approved
cleaning solvent and dry thoroughly.
13-24. INSPECTION.
a. Remove cover (11). Tag and disconnect harness (51) wires from components.
b. Disassemble load dumping relay as
specified in paragraph 13-14, only after
performing test specified in paragraph 13-13.
c. To remove leads (20) from capacitors.
(24), remove screws and washers securing
leads to capacitor terminal.
d. Tag lead (37) with location prior to
removal to insure proper reassembly.
e. Remove nut (12), screw (13) and
washer (14). Remove contactor (15)
from control box.
NOTE
Steps f. through h. deleted.
i. Note position of rear links (82) prior
to removal to insure proper reassembly.
a. Inspect harness wires for defective
or loose terminal lugs and defective insulation. Check each wire for continuity,
refer to figure 13-7. Check connects for
bent, loose, or missing pins and for shorts
from case to pins and pins to surrounding
pins.
NOTE
Figure 1-31 is the dummy load kit
schematic.
b. Check switches and light assembly
for continuity.
13-25. TEST.
a . Test for continuity between contractors
K1, K2, K3, and K4 terminals L1 to T1, L2
to T2, and L3 to T3; there should not be
continuity. Connect a 24 VDC ± 4 volt, 5
ampere power supply and 0 - 5 ampere
ammeter to contactor terminals Cl and C3.
Turn on power supply and observe ammeter.
Ammeter should indicate 4.5 amperes pullin current and 0.9 amperes holding current.
Check for continuity between terminals L1
to T1, L2 to T2, and L3 to T3; there should
be continuity. Turn off power supply.
13-23. CLEANING.
a. Clean electrical components with a
clean lint-free cloth moistened in an approved cleaning solvent and dry thoroughly.
13-18
Change 8
b. Test resistance of transformer
windings. Check between terminals 1 and 2,
3 and 4, and 5 and 6; resistance should be
6.5, 7, and 0.06 ohms respectively. Check
Figure 13-7.
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
13-19
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 13-7. Dummy load kit control box harness (sheet 2 of 3)
insulation resistance using a 500 volt megger, resistance should be greater than 1
magohm. Connect a 50, 60, or 400 hertz
0.5 ampere power supply to terminals 1
and 2 of transformer. Connect a 0-3
ampere ammeter in series with power supply and terminal 1. Connect a 0-50 VAC
voltmeter accross transformer terminals
5 and 6. Turn on power supply, ammeter
should indicate less than 0.05 amperes and
13-20
Change 1
voltmeter should indicate 35 volts. Connect
power supply and ammeter to terminals 3
and 4 with ammeter in series with terminal
3. Turn on power supply, ammeter should
indicate less than 0.05 amperes and voltmeter should indicate 35 volts, Remove
test equipment from transformer.
c. Test forward and reverse resistante of diodes. Measured from anode (t)
P-8-627-34 T O 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
Figure 13-7. Dummy load kit control box harness (sheet 3 of 3)
to cathode (-), value should be low. Reverse meter leads, value should be
infinity.
d. Test load dumping relay K5 as
specified in paragraph 13-13.
e. Inspect parts for cracks, breaks,
distortion and dents.
f. Inspect threads for damage.
13-26.
REPAIR.
WARNING
Welding operations produce heat,
highly toxic fumes, injurious
radiation, metal slag and airborne particles. Welding goggles, with proper tinted lenses,
apron or jacket and welder’s
boots are required.
a. Repair cracked metal parts by welding.
b. Straighten damaged or distorted
sheet metal parts using suitable tools.
c. Repair wiring harness as specified
in figure 13-7.
Change 8
13-21
T O 35C2-3-442-2
P-8-627-34
TM-07464A-35 TM 5-6115-457 -34
13-27. WIRING HARNESS REBUILD. Rebuild dummy load kit control box harness as
specified in figure 13-7.
h. Prior to installing cover (11) check
harness (51) wires and rear links (82) for
proper connection.
13-28. REASSEMBLY. Refer to figure
13-4 and reassemble control box assembly
in the reverse order of index numbers
a s s i g n e d . Pay particular attention
to the following.
i. Coat all solder connections withfungus resistant varnish conforming to
Military Specification MIL-U-173B prior
to installing cover (n).
a. Reassemble load dumping relay (45)
as specified in paragraph 13-18.
b. When installing links (79), set links
for desired voltage output, refer to
Operator and Organizational Maintenance
Manual.
NOTE
Steps c. through g. deleted.
13-29. INSTALLATION. Refer to figure
13-1 and install control box as follows.
NOTE
Control box cover must be
removed prior to installation.
a. Position panel (62), firewall (61),
and control box (63) on frame (70) and
secure with screws (58) and washers (59
and 60).
NOTE
Dummy load bank wiring diagram is
contain in Operater and Organizational
Maintenance Manual.
b. Connect frame harness wires to
control box components. Check wires for
proper connection.
NOTE
Dummy load kit wiring diagram is
contain in Operator and Organizational Maintenance Manual.
c. Install cover (57) and secure switch
screws (54) and washers (55 and 56).
All data on pages 14-1 through 14-8,
including figures 14-1 and 14-2 deleted.
13-22
Change 8
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
APPENDIX A
REFERENCES
A-1.
FIRE PROTECTION.
TB5-4200-200-10
A-2.
A-3.
A-4.
A-5.
Hand Portable Fire Extinguisher Approved for Army Users
LUBRICATION.
C91001L
Fuels, Lubricants, Oils and Waxes
L05-6115-458-I.2
End Item Lubrication Order
PAINTING.
T.O. 35-1-3
Painting and Marking of USAF Aerospace Ground Equipment
TM 9-213
Painting Instructions for Field Use
RADIO SUPPRESSION.
MIL-STD-461
Radio Interference Suppression
TM 11-483
Radio Interference Suppression
MAINTENANCE.
T.0. 00-25-225
Repair of External Power Cables, Aerospace Ground
Equipment
T.O. 00-25-234
General Shop Practice Requirements for the Repair,
Maintenance and Test of Electronic Equipment
T.O. 1-1-1
Cleaning of Aerospace Equipment
T.O.1-1A-14
T.O. 1-1A-15
Installation Practices for Aircraft Electric and Electronic Wiring
General Maintenance Instruction for Support Equipment
T.O. 31-1-75
General Maintenance Practices
T.O. 35-1-11
Organization, Intermediate and Depot Level Maintenance
for FSC 6115 Non-Airborne Equipment
T.O. 35-1-12
Compounds and Procedures for Cleaning Aerospace Ground
Equipment
T.O. 35-1-26
Repair/Replacement Criteria for FSC 6115 Aerospace
Ground Equipment
Change 7 A-1
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
A-6.
A-2
T.O. 35-1-524
USAF Equipment Registration Number System Applicable to
FSC 6115 Equipment
TM 9-1870-1
Care and Maintenance of Pneumatic Tires
TB ORD 651
Use of Antifreeze Solutions and Cleaning Compounds in
Engine Cooling Systems
TM 38-750
The Army Maintenance Management System.
TM 5-6115-458-12
Operator and Organizational Maintenance Manual
TM 5-6115-458-35
Intermediate (Field) (Direct and General Support) and Depot
Maintenance Manual
TM 5-6115-458-25P
Organizational, Intermediate (Field) (Direct Support and
General Support) and Depot Maintenance Repair Parts and
Special Tools Lists
TM 9-2920-232-34
Starter Motor Field Maintenance Manual
TM 9-6140-200-15
Operation and Organizational Field and Depot Maintenance
Storage Batteries, Lead Acid Type
TM 5-764
Electric Motor and Generator Repair
MIL-HDBK-705
Military Standardization Handbook, Generator Sets,
Electrical Measurements and Instruments
MIL-I-6868
Inspection Process, Magnetic Particle
MIL-I-25135
Inspection Materials, Penetrant
MIL-STD-120
Gauge Inspection
MIL-STD-454
Standard General Requirements for Electronic Equipment
MIL-STD-705
Generator Sets, Engine-Driven Methods of Test and
Instructions
MIL-STD-1261 (MR)
Welding Procedures for Construction Steels
MIL-T-27730
Tape, Antiseize, Polytetrafluoroethy lene, with Dispenser
MS 33540
Safety Wiring and Cotter Pinning, General Practices for
SHIPMENT AND STORAGE.
T.O. 35-1-4
Processing and Inspection of Aerospace Ground Equipment
for Storage and Shipment
T. O. 38-1-5
Processing and Inspection of Non-Mounted, Non-Aircraft
Gasoline and Diesel Engines for Storage and Shipment
TB 740-90-1
Administrative Storage of Equipment
T.O. 35C2-3-442-2
P-9-TM-457-35
TM-07464A-35 TM 5-6115-457-34
A-7.
TB 740-93-2
Preservation of USAM EC Mechanical Equipment for
Shipment and Storage
TM 38-230
Preservation, Packaging and Packing of Military Supplies
and Equipment
MIL-S-207
Sulfuric Acid, Electrolyte: Packaging, Packing, and
Marking for Shipment and Storage of
DESTRUCTION OF MATERIEL.
TM 750-244-3
Procedures for Destruction of Equipment to Prevent
Enemy Use
A-3/(A-4 blank)
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
ALPHABETICAL INDEX
Paragraph
A. C. Current Meter (M-8) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test on Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.C. Output Receptacle Box-Deleted
Accessory Drive Group
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base Assembly
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Group
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
....
Change 3
6-23
6-25
6-26
6-28
6-27
6-24
6-24b
8-153
8-152
8-150
8-154
8-157
8-156
8-151
8-155
8-15
8-14
8-12
8-16
8-20
8-18
8-13
8-17
8-19
9-4
9-3
9-1
9-5
.9-8
.
9-7
9-2
9-6
8-207
8-206
8-204
8-208
8-211
8-210
8-205
8-209
I-1
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
ALPHABETICAL INDEX (Continued)
Paragraph
Circuit Breaker Assembly (CB2) . .
Cleaning . . . . . . . . . . . .
Disassembly . . . . . . . . . .
Inspection . . . . . . . . . . .
Installation . . . . . . . . . .
Reasembly . . . . . . . . . .
Repair . . . . . . . . . . . . .
Test . . . . . . . . . . . . . .
Test on Equipment . . . . . . .
Connecting Rods and Pistons Group
Cleaning . . . . . . . . . . . .
Disassembly . . . . . . . . . .
General . . . . . . . . . . . .
Inspection . . . . . . . . . . .
Installation . . . . . . . . . .
Reassembly . . . . . . . . . .
Removal . . . . . . . . . . . .
Repair . . . . . . . . . . . . .
Control Assembly . . . . . . . . .
Cleaning . . . . . . . . . . . .
Disassembly . . . . . . . . . .
Inspection . . . . . . . . . . .
Installation . . . . . . . . . .
Reassembly . . . . . . . . . .
Removal . . . . . . . . . . . .
Repair . . . . . . . . . . . . .
Control Box Relay Assembly (A-4)
Cleaning . . . . . . . . . . . .
Disassembly . . . . . . . . . .
Inspection . . . . . . . . . . . .
Installation . . . . . . . . . .
Reassembly . . . . . . . . . .
Removal . . . . . . . . . . . .
Repair . . . . . . . . . . . . .
Test . . . . . . . . . . . . . .
Test on Equipment . . . . . . .
Control Cubicle . . . . . . . . . . .
Adjustment . . . . . . . . . . .
I-2
Change 3
6-147A
6-147E
6-147D
6-147F
6-1471
6-147H
6-147G
6-147C
6-147B
8-215
8-214
8-212
8-216
8-219
8-218
8-213
8-217
4-18
4-21
4-20
4-22
4-25
4-24
4-19
4-23
6-14
6-13
6-17
6-19
6-22
6-21
6-15b
6-20
6-16
6-15
6-29
6-39
P-9-TM-457-35
TM-07464A-35
T.O. 35 C2-3-442-2
TM 5-6115-457-34
ALPHABETICAL INDEX (Continued)
Paragraph
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-32
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . .
6-31
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-38
Reassembly . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .6-36
Rebuild . . . . . . . . . . . . . . . . . . . .. . . . ..... . . . . . . . . . . .
6-35
Repair . . . . . . . . . . . . . . .....
6-34
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . .6-37
Test on Equipment . . . . . . . . . . . . . . . .... . . . . . . . . . . . . . . 6-30
. . . .
Removal . . . . . . . . . . .. .. . ... . . . . . . . . . . . . . . . . . . . . . . . 6-30b
.
Control Cubicle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Installation . . . . . . . . . . . . . . . . . . . ... . ... . . . . . . . . . . . . . . .
2-6b
Removal . . . . . . . .
2-6a
Convenience Receptacle Assembly
50/60 Hertz Convenience Receptacle Assembly . . . . . . . . . . . . . . . . . . . . 6-58
Cleaning . .... . . . . . . . . . . .
. . . 6-61
.
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
.
Installation . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .6-65
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Removal . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . 6-59
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-63
. . . . .
400 Hertz Convenience Receptacle Assembly . . . . . . . . . . . . . . . . . . . . .
6-66
Cleaning . . . . . . . . . . . . . . ... ... . ... . . ... . . . . .6-69
. . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68
. .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..O
6-70
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-73
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-67
Repair . . . . . . . . . . .
. . . . .
6-71
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
Crankshaft Group and Main Bearings
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-223
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-222
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-220
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
8-224
Installation . . . . . . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . 8-227
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
.
.
8-226
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-221
Repair . . . . . . . . . . .....
....
.
.
.
.
.
.
.
.
....
8-225
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
0
.
.
.
.
.
.
.
.
.
.
. * . * . . .
0
.
.
.
. *
.
.
.
.
.
. . . * . .
.
.
.
.
.
.
.
.
.
.
.
*
.
.
0......
.
.
.
.
.
●
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
0
.
.
.
.
.
.
.
.
.
I-3
T.O. 35C2-3-442-2
P-9-TM-457-35
TM-07464A-35 TM 5-6115-457-34
ALPHABETICAL INDEX (Continued)
Paragraph
Crankshaft Pulley, Damper and Timing Gear
Cover Group
8-128
Cleaning
. . . . . . . . . . . . . . . . . . . . . . . . .
.
.
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-127
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-125
. . . .
8-129
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-132
. . . . .
8-130
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-126
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
..
.
.
.
.
.
.
.
.
.
.
Removal
R e p a i r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-130
.
.
.
.
Cylinder Block and Covers Group
.
.
.
.
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-231
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-230
. .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-228
.
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-232
. . .
. . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-235
8-234
Reassembly . . . . . . . . . . . . . . . . . . . . .. . . .
. .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-229
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-233
.
Cylinder Head Group
. .
Cleaning . . . . . ..
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-191
8-190
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-188
.
8-192
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-195
8-194
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-189
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-193
Day Tank Assembly
8-40
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .....
8-41
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
8-43
Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-39
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-42
Repair . .
D.C. Circuit Breaker Box
6-43
Cleaning . . . . . . . . . . . . .
6-42
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
6-44
. . . . . . . . . . . . . . . . . . . . . .
Inspection
6-47
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-46
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
,
.
0
0
0
0
.
.
.
.
0
.
0
.
.
.
.
.
.
0
.
.
0
.
*
.
.
●
I-4
*
*
.
. . 0 . * . .
*
.
. .
*
* * * . . *
*
*
*
*
*
* * * * * * *
.
●
*
*
*
*
*
*
.
.
.
.
.
.
.
.
.
.
P-9-TM-457-35 T.O. 35 C2-3-442-2
TM-07464A-35 TM 5-6115 -457-34
ALPHABETICAL INDEX (Continued)
Paragraph
6-41
Removal ... ... . . . . . . . . . . . . . . ...
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 6-45
.
6-86
D.C. Relay Assembly (A-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . .6-90
. .
6-89
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. 6-91
.
.
.
Inspection . . . . . . . . . . . . ..
6-94
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-93
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-92
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .
6-88
6-87
6-87b
13-4
13-3
13-1
13-5
13-9
13-8
13-2
13-7
13-20
13-23
13-22
13-24
13-29
13-28
13-21
13-26
13-25
13-27
13-10
13-10a
13-10b
13-11
13-15
13-14
13-16
13-19
13-18
13-12
I-5
.
.
P-9-TM-457-35
TM-07464A-35
T.O. 35 C2-3-442-2
TM 5-6115-457-34
ALPHABETICAL INDEX (Continued)
13-17
13-13
6-122
6-121
6-120
6-123
6-126
6-125
6-124
6-119
6-119b
5-3
5-1
5-4
5-6
5-5
5-2
12-5
12-4
12-1
12-6
12-9
12-8
12-2
12-7
12-3
12-21
12-20
12-17
12-22
12-25
12-24
12-18
12-23
12-19
I-6
Change 3
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
ALPHABETICAL INDEX (Continued)
Paragraph
Electric Winterization Kit, Electric Heater
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Components
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Harness Group
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Test After Overhaul
Engine Assembly Run-in and Adjustments . . . . . . . . . . . . . . . . . . . . . . . .
Pre-run-in Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Run-in . . . . . . . . . . . . . . . . . . . . . . . . ...... . . . . . . . . . . . . .
Utility Governor Speed Setting Adjustment . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exciter-Regulator
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ...
12-13
12-12
12-10
12-14
12-16
12-15
12-11
2-8
2-8b
2-8a
8-3
8-1
8-5
8-4
8-2
8-8
8-6
8-9
8-11
8-10
8-7
8-237
8-237a
8-237c
8-237b
8-236
6-84
6-78
6-77
6-74
6-79
6-83
6-82
6-81
6-80
6-76
I-7
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
ALPHABETICAL INDEX (Continued )
6-75
6-75b
8-160
8-158
8-161
8-163
8-159
8-162
8-33
8-32
8-30
8-34
8-37
8-36
8-31
8-35
6-52
6-51
6-48
6-53
6-56
6-55
6-54
6-50
6-49
6-49b
8-199
8-198
8-196
8-200
8-203
8-202
8-197
8-201
1-2
6-8
6-10
6-11
I-8
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
ALPHABETICAL INDEX (Continued)
Paragraph
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test on Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Burning Winterization Kit Control Box
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Burning Winterization Kit Heater
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Test and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . .
.
.
.
.
.
.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
Repair
Fuel Injection Group
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . .
. . . .
. .
. .
.
. . . . .
.
. . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . ..
Inspection
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Group
Cleaning
. . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection
. . . . . . . . . . . . . . . . . ....
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal
. . . . . . . . . . . . . . . . .. .. .... . . . .... ...
Repair . . . . . . . . . . .
. . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
6-13
6-12
6-9
6-9b
11-4
11-3
11-1
11-5
11-8
11-7
11-2
11-6
11-12
11-16
11-11
11-9
11-13
11-17
11-15
11-10
11-14
8-144
8-143
8-141
8-145
8-148
8-147
8-142
8-146
8-149
8-64
8-63
8-61
8-65
8-68
8-67
8-62
8-66
I-9
P-9-TM-457-35 T. O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
ALPHABETICAL INDEX (Continued)
Paragraph
Fuel Tank Assembly
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .... . . . . . . . . . . . . . .
Reassembly
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General
Control Cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reconnection Board Assembly, Load Contactor, Load
Board Assembly, and Transformer Assembly . . . . . . . . . . . . . . . . . . . .
Removal and Installation of Major Components
and Auxiliaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutter and Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........
Generator Assembly Repair
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... .
High Potential Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON Equipment Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair or Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Actuator Unit (precise Sets Only)
Cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . .
. 0
1-10
Change 3
. . , . . .
. .
* . * . . .
. .
* . . . * .
.
9-20
9-19
9-17
9-21
9-24
9-23
9-18
9-22
6-1
1-3
4-1
6-136
2-5
4-17
2-4
2-7
2-7b
2-7a
7-4
7-3
7-1
7-8
7-5
7-9
7-2
7-2b
7-7
7-6
8-111
8-110
8-108
8-112
8-116
8-114
8-113
8-115
8-109
8-109b
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115 -457-34
ALPHABETICAL INDEX (Continued)
Paragraph
Housing Frame
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Housing Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Rear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Pump (Precise Sets Only)
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Pump Drive Group
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Inspection
. . . . . . . ... . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Tank (Precise Sets Only)
Cleaning . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . ... . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . ...
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
.
.
. .
Lifting Frame Assembly
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . .....
3-3
3-1
3-lb
3-la
3-lc
3-4
3-6
3-2
3-5
8-95
8-93
8-96
8-99
8-94
8-97
8-98
8-103
8-102
8-100
8-104
8-107
8-106
8-101
8-105
8-88
8-87
8-85
8-89
8-92
8-91
8-86
8-90
3-10
3-9
3-7
3-11
3-14
I-11
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
ALPHABETICAL INDEX (Continued)
Paragraph
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . .....
Load Board Assembly
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly . . . . . . . . ....... . . . . . . . . . . . . . . . ...
Load Contactor
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
Test on Equipment . . . . . . . . . . . . . . . . . . . . . . . . . ... . ....
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .... . ..... ..
Load Measurement Unit
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . ............
Test on Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode I Relay Box Assembly
Bench Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . . . . ... . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Bench Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
On Equipment Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . ......
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Mode H Relay Box Assembly
Bench Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . ...
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... . ..
Inspection
. . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . ...... .. .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I-12 Change 3
3-13
3-8
3-12
6-150
6-151
6-152
6-149
6-147
6-146
6-145
6-145b
6-216
6-215
6-212
6-217
6-220
6-219
6-218
6-214
6-213
6-213b
6-97
6-99
6-98
6-85
6-100
6-103
6-96
6-96b
6-102
6-101
6-129
6-131
6-130
6-104
6-132
6-135
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115 -457-34
ALPHABETICAL INDEX (Continued)
Paragraph
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test on Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Cooler Group
Cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan Group and Related Parts
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection
. . . . . . . . . . . . . . . . . . . . . ...
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Group
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . .
. . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair .
.
.
.
. . . .
. .
. . . . . . . . . . . . . .
Organzational, Intermediate (Field) (Direct Support and General
Support) and Depot Maintenance Repair Parts . . . . . . . . . . . . . . . . . . . . . .
Overload Relay (K-14)
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test on Equipment
. . . . . . . . . . . . . . ..... . . . ...
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overspeed Shutdown Device
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operational Test
Overspeed Switch
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Major Speed Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minor Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-134
6-133
6-128
6-128b
8-80
8-79
8-77
8-81
8-84
8-83
8-78
8-82
8-167
8-166
8-164
8-168
8-171
8-170
8-165
8-169
8-175
8-174
8-172
8-176
8-179
8-178
8-173
8-177
2-2
6-177
6-176
6-175
6-175b
8-110
8-112
8-114
8-114
8-115
8-51
8-51a
8-51b
Change 7 I-13
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
ALPHABETICAL INDEX (Continued)
Paragraph
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overvoltage Relay (K-3)
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
On Equipment Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Permissive Paralleling Relay 400 Hertz (K16)
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
On Equipment Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precise Governor Control Unit (A23)
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .
Rebuild . . .
. .
.
. . .
. .
. . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . ... . ..
Test and Removal . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . ...... . . . ...
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precise Relay Box
Cleaning . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. ..... . . . . . . . . . . . . .. ....
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
......
General . . . . . . . . . . . . . ... . . . ........ . . . . ..... . ..
Instillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . .... . ....... . . . ...... . ....... . . . . . ... . . ....
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test ........ . . ...... . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . .......
Test and Removal
. . . .
.
. . . . .
.
.
. . .
.
. . . . .
.
Removal . . . ...... . ..... . . . ...... . ..... . . . . . . . . . . ..
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pretest Checks and Adjustments . . . . . . . . . . . . . . . .
...... . . . ....
Radiator . . . . . ..... . ....... . . . . . ..... . . . . . . . . . . . . . ..... . ...
Cleaning
. . . . ...... . . ..... . . . . . . . . . . . . ....... . . . ......
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-14
Change 3
8-47
8-46
8-44
8-48
8-52
8-50
8-45
8-49
6-165
6-163
6-163b
6-164
6-117
6-115
6-l15b
6-116
6-211
6-205
6-204
6-201
6-206
6-210
6-209
6-208
6-207
6-203
6-202
6-202b
6-196
6-195
6-187
6-200
6-199
6-198
6-194,
6-197
6-193
6-193b
10-1
10-2
4-8
4-12
4-11
4-13
4-16
4-15
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
ALPHABETICAL INDEX (Continued)
Paragraph
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair
Test . . ............. . . . . . . ... . ........ . . . . . . . . . . . . . . . . . . . . . . .
.......
Radiator Upper and Lower Shroud and Shroud Plate . . . . . . . . .
Cleaning . . . . . . . . . . . ........ . . . . . . . . . . . . . . . . . . . . . ....... . . ...... ..
Inspection . . . ...... . . ...... . ....... . . . . . . .... . . . ..... . ....
Installation . . . . . . . . . . . . . . ....... . . . . ...... . . . . . . .... . .....
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . ...... . . . ... . . . . . ..... . ....... . . . . . ..... . .......
Reconnection Board Assembly
Cleaning . ........ . ........ . . . . ...... . . . ....... . . . . . . . . . . . . . ...
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . ..... . ...... . . . . . . .... . ....... . ..
Reassembly . . . . ..... ....... . . . . . . . . . . . . . . ..... . ...... . . . . . . ...
Removal . . . . . . . . . . . . . . . . . . . . . . . . ....... . ...,... . . . . . . . . . . . . . ..
Reverse Power Relay (K15)
Installation .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .
On Equipment Test . . . . . . . . . . . . . . ..... . . ........ . . ...... .....
Removal . ....... . . . . . . . . . . . . ....... . . . . . . . . . . . . . . . . . . . . . . . ..
Scope
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . . . . . . ... . ......
Short Circuit Relay (K-13)
Installation . . . . . . . . . . . . . . . . .... . . . . . . . . . . . . ....... . . . . . . .... . . . . . .
Test on Equipment . . . . . . . . . . . . ....... . . . . . . . . . . . . . . . . . . . . . . ...... . . . .
Removal . ... . . . ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutter
. . . . ..... . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . .... . . . . . . ..
Cleaning . . . . ...... . . . . . . . . . . . . . . . ...... . . ........ . . . . . . . . . . . . ......
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . ....... . . ...... . . . . . . . . . . . . . ....... . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . ........ . . ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specially Designed (Fabricated) Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . ..... . . ......
Special Tools and Equipment
Starting Motor
Cleaning . . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . .. . . . . . .. .. .....
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . ..... . . . . . . . . . .. . . . . . . . . ..... . . . . ....... . . ..
Installation . ....... . . . . ..... . ...... . . . . . . . . . . . ...... . . . . . ...
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . ...... . . . . . . . . . . . . . . . . . . . . . . . . . ....... . . . . . . . . . . . . . . . .
Removal . . ....... . . . . . . . . . . . . . . . . . . . . . . . . ...... . . ....... . .....
. . . . . . . . . . . . . ..... . ........ . ....... . ........ . ....
Repair
. . . . . . . . . . . . . . . .... . . ....... ...,.... . . ....... . . ...
Testing
Armature End Play Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No Load Test . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . ..... . . . . . . . . . . .
Pinion Position Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Winding Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change 3
4-9
4-14
4-10
4-2
4-4
4-5
4-7
4-3
4-6
6-140
6-139
6-141
6-143
6-142
6-138
6-169
6-167
6-167b
1-1
6-173
6-171
6-171b
4-26
4-29
4-28
4-30
4-33
4-32
4-27
4-31
2-3
2-1
8-24
8-23
8-25
8-29
8-21
8-27
8-22
8-26
8-28
8-28e
8-28b
8-28f
8-28c
I-15
I
I
I
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
ALPHABETICAL INDEX (Continued)
Paragraph
Stall Torque Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . .8-28d
Stowage Tool Box
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9-12
Disassembly . .
.
. .
. . . .
. .
. .....
. . . . ....
. .. . . 9-11
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9-9
Inspection .. . . .. . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9-14
Tabulated Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Tachometer Drive Group
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8-56
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 8-57
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 8-60
Reassembly . . . . . . . . . . . . . . . .
. . . . . . . . . . . .. . . . . . . . . . 8-59
Removal . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. .. . . . . . . . . . . . . . . . 8-54
Repair
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58
Tactical Relay Box
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-182
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . ..... . . . . . . . . . . . . . . ...... . 6-181
General . . . . . .
. . ...... .
. ...... . . . . .....
. . . . . . . . . . . . . 6-161
Inspection and Test . . . . . . . . . . . . . . ..... . . . . . . . . . . . . . ...... . . . . . . ... 6-183
Installation . . . . . . .... . . . . . . . . . . . . . . . . . . ... . . ........ . . ........ . . . . . . 6-186
Reassembly . . . . . . .... . ........ . . ..... . . . . ..... . . . . . . . . . . . . . . . . 6-185
Repair . . . . . . . . . . . .... ....... . . . . . . . . . . . ...... . ...... .. 6-184
Test . . . . . . . . . . . . ...... ...... . ...... . . . . . . . . . . . . . . . . . . . . . . . 6-180
Test on Equipment . . . . . ..... . . . . . . . . . . . . . . . . . .... . . ...... . ...... 6-179
Removal . ....... . . . . . . . . . . . ..... . . ....... . . . . ...... ... 6-179b
Test After Overhaul
Engine Efficiency Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...10-19
Exciter Regulator and Governor Stability and
Transient Response Test . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Frequency Adjustment Range Test . . . . . . . ... . . . . . . . . . . . . . ..... . . . . . . . . 10-14
Precise Generator Sets . . . . . . . . . . . . . ........ . . . . . ..... . . . . . . .... . . . . . 10-14a
Utility Generator Sets . . ..... . . ...... . . . . . . . ... . . . . . . . . . . . . ... 10-14b
General . . ....... . . . . . . . . . . . ...... . ........ . . . . . . . . . . . . . . . . ... 10-3
High Coolant Temperature Trip Test . . . . . . . .
. . . . . . . . . . . . . . 10-7
Instrument Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 10-5
Long Term Steady State Stability Test . . . . . . . . . . . . . . . . . . . . . . . . . ...... . . 10-17
Low Fuel Level Trip Test ........ ...... . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Low Oil Pressure Trip Test . . . . . . . . . . . . . . . . . . . . . . . . . . ...... . ...... 10-6
Over and Under Voltage Trip Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...10-10
Over Voltage Trip Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..l0-l0c
Under Voltage Trip Test (Precise Sets Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10d
Parallel Operation and Reverse Power Test . . . . . . . . . . . ..... . . ...... 10-18
Parallel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18a
I-16
Change 3
P-9-TM-457-35
TM-07464A-35
T.O. 35C2-3-442-2
TM 5-6115-457-34
ALPHABETICAL INDEX (Continued)
Paragraph
Reverse Power Test . . ....... ........ . . . . . . . . . . . . . . . . . . . . . . . . . .
Phase Balance Test . . . . . . .... . . ..... . . . . . . . . . . . . . . . . .... . . . ...
Phase Sequence Check . . . . . . . . . . . . . . . . . . . . . . . . ...... . . . . . . ...
Regulator Range Test . . . . .... . . ...... . . . . . . . . . . . . . ....... . . . . . . .
Start and Stop Test . ....... . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Short Circuit Trip Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... . . . .
Under Frequency Trip Test (Precise Set Only) . . . . . .
...... . . . .
Thermal Watt Converter . . ..... . . . . . . . ... . . . . . . .... . . . . . . . . . .
Cleaning
. . . . . . . . . . . . . ...... . . . . ..... . . ........ . ....... .. ...
Inspection . . . ....... . . . . . . . . . . . . . . . . . . . . . . . .. . ... . .
Installation . . . . ..... . . . . ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . . . . . ..
Test on Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . ..... . . ...... . . . . . . . ... . ...
Transformer Assembly
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .
Disassembly . ....... . . ........ . . . . . . . . . . . . . ........ . . . . . . ....
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. . . .. . . . . . . . . . . .
Installation . . ....... . . . ...... . ....... . ........ . . . . . . . . . . . . ...
Reassembly . . ....... . ....... . . . . . . . . . . . ....... . . . . . . . . . . . . ..
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . ....... . ......
Repair . . . . .... . . . . . . . . . . . . . ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger Group
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......
General . . . . . . . . . . . . . ..... . . . . . . . . . . . . . . ...... . ....... . . . .
Inspection .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . ...... . . . . . . . . . . . . . . ....... . . . . .... . ........ ... ....
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Under Frequency Relay 50/60 Hertz (K-12)
Installation . . ....... . ....... . . . . . . .... . ....... . . . . ..... . . . . .
Test . ..... . . . . ...... . . . . . . . . . . . . . ...... . . ........ . . ......
Test on Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . .
......
..... . . ........ . . . . . .
Under Frequency Relay 400 Hertz (K12)
Bench Test . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ... . . . ..
Installation . . . . . . . . . . . . . . . . . . ... . . ...... . . . . . . . . . . . . . ........ . . . . . .
On Equipment Test . . . . . ..... . . . . ..... . . . . . . . . . . . . . . ..... ......
Removal . . . ....... . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. .. . ..
Undervoltage Relay 400 Hertz (K1l)
Installation
....... . . . . . . . . . . . . ...... . . . . . . .... . . ...... ..
On Equipment Test
. . . . . . . . . . . . ...... ....... . . ........ . . ......
Removal . . . . . . . . . . . . . ....... . . . . . . . . . . . . . . . . . . . . . . . . . ....... .
Test . . ........ . . . . . . . . . . . . . ...... . . . . . . . . . . . . . . . . . . . . . . ...... .
Utility Governor Group
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . ... .. . . . . . ..
Governor Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Utility Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
Change 3
10-18b
10-13
10-12
10-15
10-4
10-9
10-11
6-2
6-4
6-5
6-7
6-6
6-3
6-3b
6-156
6-155
6-157
6-160
6-159
6-154
6-158
8-72
8-71
8-69
8-73
8-76
8-75
8-70
8-74
6-191
6-190
6-189
6-189b
6-108
6-109
6-107
6-107b
6-113
6-111
6-lllb
6-112
8-136
8-136b
8-136a
I-17
I
I
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115-457-34
ALPHABETICAL INDEX (Continued)
Paragraph
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .
Utility Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Utility Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Drive Housing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Utility Governor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Utility Governor and Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Utility Governor . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
............... .. ................ .......... ........ .. ..
Repair
Governor Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Utility Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Cover and Valve Mechanism Group
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ...
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . .
Repair . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .
Water Pump Group
Cleaning . . . . . . . . . . . . . . . .. . . . . . . . . . . .. .. . ... . . . . . . . . ..
Disassembly . . . . . . . . . . . . . . .
. . .. . . . . . . . . .
.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . .. . . . . . . . . .
Inspection . . . . . . . . . . . . . .. . . . . . .... . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Mounting Kit . . . . .
........... . ........ .... ...... ... ...
Installation . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .
All data on pages I-19 through 1-20, deleted.
1-18
Change 3
8-135
8-135b
8-135a
8-133
8-137
8-137b
8-137a
8-140
8-140a
8-140b
8-140c
8-140d
8-139
8-139b
8-139a
8-134
8-138
8-138b
8-138a
8-183
8-182
8-180
8-184
8-187
8-186
8-181
8-185
8-120
8-119
8-117
8-121
8-124
8-123
8-118
8-122
2-9
2-9b
2-9a
P-9-TM-457-35 T.O. 35C2-3-442-2
TM-07464A-35 TM 5-6115 -457-34
ALPHABETICAL INDEX (Continued)
Paragraph
Under Frequency Relay 400 Hertz (K12)
Bench Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
On Equipment Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-108
6-114
6-107
6-107b
Undervoltage Relay 400 Hertz (Kll)
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
On Equipment Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Utility Governor Group
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Governor Drive Housing.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Utility Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Drive Housing . . . . . . . . . . . . . . . . . . .
Utility Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Drive Housing.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Utility Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Drive Housing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .
Utility Governor Adjustment. . . . . . . . . . . . . . . . . . . . .
Utility Governor and Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Governor Drive Housing . . . . . . . . . . . . . . . . . . . . .
Utility Governor . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Drive Housing . . . . . . . . . . . . . . . . . . . . . .
Utility Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
6-113
6-111
6-lllb
6-112
8-136
8-136b
8-136a
8-135
8-135b
8-135a
8-133
8-137
8-137b
8-137a
8-140
8-140a
8-140b
8-140c
8-140d
8-139
8-139b
8-139a
8-134
8-138
8-138b
8-138a
Change 7 I-19/(1-20B1ank)
By Order of the Secretaries of the Army, the Navy, end the Air Force:
Official:
VERNE L. BOWERS
Major General, United States Army
The Adjutant General
CREIGHTON W. ABRAMS
General, United States Army
Chief of Staff
A. R. MARSCHALL
Rear Admiral, CEC, USN
commander, Naval Facilities
Engineering Commend
Official:
DWIGHT W. COVELL, Colonel, USAF
Director of Administration
JOHN D. RYAN, General, USAF
Chief of Staff
Distribution:
Army:
To be distributed in accordence with DA Form 12-25D, direct end genera! support maintenance
requirements for Generator Sets: 60KW, 60 HZ Precise Power, 60 KW, 400 HZ Precise Power, 60 KW,
60 HZ Utility.
MARCORPS CODE:
AGC
PIN : 013538-000
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