GENERATOR SET, SKID MOUNTED, TACTICAL QUIET, 30 kW, 50

*ARMY TM 9-6115-644-24
AIR FORCE TO 35C2-3-446-12
MARINE CORPS TM 09249A/09246A-IN
TECHNICAL MANUAL
FIELD AND SUSTAINMENT MAINTENANCE MANUAL
FOR
GENERATOR SET, SKID MOUNTED, TACTICAL QUIET,
30 kW, 50/60 Hz, MEP-805A
(NSN: 6115-01-274-7389) (EIC: VG5)
GENERATOR SET, SKID MOUNTED, TACTICAL QUIET,
30 kW, 400 Hz, MEP-815A
(NSN: 6115-01-274-7394) (EIC: VN5)
*SUPERSEDURE NOTICE - This manual supersedes TM-9-6115-644-24, TO 35C2-3-446-12 & TM 09249A/09246A-IN dated 30 April 1995.
Date of issue for the revised manual is: 15 May 2010.
DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENTS OF THE ARMY, AIR
FORCE AND HEADQUARTERS, U.S. MARINE CORPS
15 MAY 2010
PCN: 184 092490 00
TM 9-6115-644-24
WARNING SUMMARY
FIRST AID
For First Aid information, refer to FM 4-25.11.
SAFETY SUMMARY
5 SAFETY STEPS TO FOLLOW IF SOMEONE IS THE VICTIM OF ELECTRICAL
SHOCK:
DO NOT TRY TO PULL OR GRAB THE INDIVIDUAL.
IF POSSIBLE, TURN OFF THE ELECTRICAL POWER.
IF YOU CANNOT TURN OFF THE ELECTRICAL POWER, PULL, PUSH OR LIFT THE
PERSON TO SAFETY USING A DRY WOODEN POLE OR A DRY ROPE OR SOME
OTHER INSULATING MATERIAL.
SEND FOR HELP AS SOON AS POSSIBLE.
AFTER THE INJURED PERSON IS FREE OF CONTACT WITH THE SOURCE OF
ELECTRICAL SHOCK, MOVE THE PERSON A SHORT DISTANCE AWAY AND IMMEDIATELY START ARTIFICIAL RESUSCITATION.
a
TM 9-6115-644-24
WARNING SUMMARY - Continued
WARNING AND CAUTION STATEMENTS
Warning and Caution statements have been strategically placed throughout this text prior to operating
procedures, practices, or conditions considered essential to the protection of personnel (WARNING) or equipment
and property (CAUTION).
A WARNING or CAUTION will apply each time the related step is repeated. Prior to starting any task the
WARNINGs or CAUTIONs included in the text for that task must be reviewed and understood. Refer to the
materials list at the beginning of the appropriate manual section for materials used during maintenance of this
equipment. This warning summary contains the WARNINGs and CAUTIONs included in the manual. The detailed
warnings for hazardous materials only are listed separately in the warning summary as the "Hazardous Materials
Warnings" section.
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can
cause injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. Make sure generator set is
completely shut down and free of any power source before attempting any repair or maintenance
on the set, or when connecting or disconnecting load cables. Failure to comply with this warning
can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set
and make sure it is free of any power source before attempting any repair or maintenance on the
set, or when connecting or disconnecting load cables. Failure to comply with this warning can
cause injury or death to personnel.
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
Shut down generator set before performing inspection of wiring. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
Ensure nuts on ground terminals are properly secured creating a good ground. Failure to comply
with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when the generator set is in operation. DO NOT touch live voltage
connections. Never attempt to connect or disconnect load cables or paralleling cables while the
generator set is running. Failure to comply with this warning can cause injury or death to
personnel.
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TM 9-6115-644-24
WARNING SUMMARY - Continued
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Prior to making any connections for parallel operation, ensure that there is no input to the load
and that the generator sets are shut down. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
If it is necessary to move a generator set which has been operating in parallel with another
generator set, shut down remaining generator set connected to the load, prior to removing load
and ground cables. Failure to comply with this warning can cause injury or death to personnel.
WARNING
Power is available when the main contactor is open. Avoid accidental contact. Failure to comply
with this warning can cause injury or death to personnel.
WARNING
High voltage power is available when the main contactor is closed. Avoid accidental contact with
live components. Ensure load cables are properly connected and the load cable door is shut
before closing main contactor. Ensure load is turned off before closing main contactor. Ensure
that soldiers working with/on loads connected to the generator set are aware that main contactor
is about to be closed before closing main contactor. Failure to comply with this warning can
cause injury or death to personnel.
WARNING
Slave receptacle (NATO connector) is electrically live at all times and is unfused. The Battery
Disconnect Switch does not remove power from the slave receptacle. NATO slave receptacle
has 24 VDC even when Battery Disconnect Switch is set to OFF. This circuit is only dead when
the batteries are fully disconnected. Disconnect the batteries before performing maintenance on
the slave receptacle. Failure to comply with this warning can cause injury or death to personnel.
WARNING
Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection
are required when working in contact with diesel fuel. Avoid repeated or prolonged contact.
Provide adequate ventilation. Operators are to wash exposed skin and change chemical soaked
clothing promptly if exposed to fuel. Failure to comply with this warning can cause injury or death
to personnel.
WARNING
Fuels used in the generator set are flammable. Do not smoke or use open flames when
performing maintenance. Failure to comply with this warning can cause injury or death to
personnel, and damage to the generator set.
c
TM 9-6115-644-24
WARNING SUMMARY - Continued
WARNING
Fuels used in the generator set are flammable. When filling the fuel tank, maintain
metal-to-metal contact between filler nozzle and fuel tank opening to eliminate static electrical
discharge. Failure to comply with this warning can cause injury or death to personnel, and
damage to the generator set.
WARNING
Hot engine surfaces from the engine and generator circuitry are possible sources of ignition.
When hot refueling with DF-1, DF-2, JP5 or JP8, avoid fuel splash and fuel spill. Do not smoke
or use open flame when performing refueling. Remember PMCS is still required. Failure to
comply with this warning can cause injury or death to personnel, and damage to the generator
set.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/or liquids can result in burns and scalding. Shut down generator set, and allow system to
cool before performing checks, services and maintenance, or wear gloves and additional
protective clothing and goggles as required. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
In extreme cold weather, skin can stick to metal. Avoid contacting metal items with bare skin in
extreme cold weather. Failure to comply with this warning can cause injury to personnel.
WARNING
Operating the generator set exposes personnel to a high noise level. Hearing protection must be
worn when operating or working near the generator set when the generator set is running.
Failure to comply with this warning can cause hearing damage to personnel.
WARNING
Exhaust discharge contains deadly gases including carbon monoxide. DO NOT operate
generator set in enclosed areas unless exhaust discharge is properly vented outside. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Hot exhaust gases can ignite flammable materials. Allow room for safe discharge of hot gases
and sparks. Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
Top housing panels and exhaust system can get very hot. When performing DURING PMCS,
wear gloves and additional protective clothing as required. Failure to comply with this warning
can cause severe burns and injury to personnel.
d
TM 9-6115-644-24
WARNING SUMMARY - Continued
WARNING
Exercise extreme caution when performing DURING PMCS checks inside engine compartment.
Avoid contact with moving or hot engine parts. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
When running, winterization heater has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow heater to cool before performing maintenance. Wear gloves and
additional protective clothing as required. Failure to comply with this warning can cause injury or
death to personnel.
WARNING
Each battery weighs more than 70 pounds (32 kg) and requires a two-person lift. Lifting batteries
can cause back strain. Ensure proper lifting techniques are used when lifting batteries. Failure to
comply with this warning can cause injury to personnel.
WARNING
Batteries give off a flammable gas. Do not smoke or use open flame when performing
maintenance. Failure to comply with this warning can cause injury or death to personnel, and
damage to the generator set.
WARNING
Battery acid can cause burns to unprotected skin. Wear safety goggles and chemical gloves and
avoid acid splash while working on batteries. Failure to comply with this warning can cause injury
to personnel.
WARNING
When disconnecting or removing batteries, disconnect the negative lead that connects directly to
the grounding stud first; disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply with this warning can
cause injury to personnel.
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
Many components require a two-person lift. Lifting heavy components can cause back strain.
Ensure proper lifting techniques are used when lifting heavy components. Failure to comply with
this warning can cause injury to personnel.
WARNING
Solvent used to clean parts is potentially dangerous to personnel and property. Clean parts in a
well-ventilated area. Avoid inhalation of solvent fumes. Wear goggles and rubber gloves to
protect eyes and skin. Wash exposed skin thoroughly. Do not smoke or use near open flame or
excessive heat. Failure to comply with this warning can cause injury to personnel, and damage
to the equipment.
WARNING
Do not operate generator set while servicing radiator. Failure to comply with this warning can
cause injury to personnel and damage to the equipment.
e
TM 9-6115-644-24
WARNING SUMMARY - Continued
WARNING
Fan has sharp blades. Use caution and wear gloves when removing or installing belts. Failure to
comply with this warning can cause injury to personnel.
WARNING
Oil filter base and housing springs are under tension and can act as projectiles when being
removed. Use eye protection when removing springs. Failure to comply with this warning can
cause injury to personnel.
WARNING
The high pressure oil system operates at high temperature and pressure. Contact with hot oil
can result in burns and scalding. Shut down generator set, and allow system to cool before
performing checks, services, and maintenance. Wear heat resistant gloves and avoid contacting
hot surfaces. Do not allow hot oil or components to contact skin or hands. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
components have been heated. Wear additional protective clothing as required. Failure to
comply with this warning can cause injury to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
If not shielded, hot exhaust pipe can ignite flammable wall materials. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
An unwrapped exhaust pipe can cause injury if touched. Failure to comply with this warning can
cause injury to personnel.
WARNING
Always remove radiator cap slowly to permit any pressure to escape. Failure to comply with this
warning can cause injury to personnel.
WARNING
Avoid breathing fumes generated by soldering. Eye protection is required. Good general
ventilation is normally adequate. Failure to comply with this warning can cause injury to
personnel.
WARNING
CARC paint is a health hazard, and is irritating to eyes, skin, and respiratory system. Wear
protective eyewear, mask, and gloves when applying or removing CARC paint. Failure to comply
with this warning can cause injury to personnel.
WARNING
Eye protection is required when working with compressed air. Compressed air can propel
particles at high velocity and injure eyes. Do not exceed 15 psi pressure when using
compressed air. Failure to comply with this warning can cause injury to personnel.
f
TM 9-6115-644-24
WARNING SUMMARY - Continued
WARNING
High pressure steam can blow particles or chemicals into eyes, can cause severe burns, and
creates hazardous noise levels. Wear protective eye, skin, and hearing protection when using
high pressure steam. Failure to comply with this warning can cause injury to personnel.
WARNING
The generator set, engine, and generator are extremely heavy and require an assistant and a
lifting device (forklift, overhead lifting device) with sufficient capacity. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
Rated capacity of overhead hoist should be at least 1,500 pounds (680 kg). Do not use a hoist
with less capacity. Failure to comply with this warning can cause injury or death to personnel,
and damage to equipment.
WARNING
Keep hands and feet from underside of engine and generator while using lifting device to remove
them from the skid base. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Support components when removing attaching hardware or component may fall. Failure to
comply with this warning can cause injury to personnel, and damage to equipment.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
WARNING
Cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye
protection are required when working in contact with cleaning solvent. Avoid repeated or
prolonged contact. Work in ventilated area only. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
Cleaning compound is toxic. Avoid prolonged breathing of vapors. Use only in a well-ventilated
area. Failure to comply with this warning can cause injury to personnel.
WARNING
Conversion coating material is toxic to eyes, skin, and respiratory tract. Skin and eye protection
are required when working in contact with conversion coating material. Avoid repeated or
prolonged contact. Work in ventilated area only. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
Hot metal surfaces can cause burns to skin. Wear protective gloves and eye protection when
applying heat to generator housing. Failure to comply with this warning can cause injury to
personnel.
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TM 9-6115-644-24
WARNING SUMMARY - Continued
WARNING
Use protective gloves when handling heated rectifier hub. Failure to comply with this warning
can cause injury to personnel.
WARNING
Do not use the engine starter to turn the flywheel. Failure to comply with this warning can cause
injury to personnel.
WARNING
Catch fuel in suitable container. Keep spilled fuel away from hot engine and all fires. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Do not attempt to perform any maintenance tasks on the Winterization Kit while the generator
set is operating. Failure to comply with this warning can cause injury or death to personnel.
WARNING
Disconnect negative battery cable from right battery and the positive battery cable from the left
battery before doing the following procedures. Reconnect cables in reverse order. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Muffler and flex hoses can get very hot. Allow them to cool before touching them. Failure to
comply with this warning can cause severe burns and injury to personnel.
WARNING
Engine exhaust fumes contain deadly poisonous gases.
Severe exposure can cause death or permanent brain damage.
Exhaust gases are most dangerous in places with poor airflow. Best defense against
exhaust gas poisoning is very good airflow.
To protect yourself and your partners, always obey the following rules:
•
DO NOT run engine indoors unless you have VERY GOOD AIRFLOW.
•
DO NOT idle engine for a long time unless there is VERY GOOD AIRFLOW.
•
Be alert at all times. Check for smell of exhaust fumes.
•
REMEMBER: Best defense against exhaust gas poisoning is VERY GOOD AIRFLOW.
•
Exhaust gas poisoning causes dizziness, headache, loss of muscle control, sleepiness,
coma, and death. If anyone shows signs of exhaust gas poisoning, get ALL
PERSONNEL clear of exhaust area. Make sure they have lots of fresh air. KEEP THEM
WARM, CALM, AND INACTIVE. GET MEDICAL HELP. If anyone stops breathing, give
artificial respiration. See FM 4-25.11 for first aid.
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TM 9-6115-644-24
LIST OF EFFECTIVE PAGES / WORK PACKAGES
NOTE: This manual supersedes TM-9-6115-644-24, TO 35C2-3-446-12 & TM 09249A/09246A-IN dated 30
April 1995. Date of issue for the revised manual is: 15 May 2010. Zero in the "Change No."
column indicates an original page or work package.
Date of issue for revision is:
Revision 15 MAY 2010
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USA
*ARMY TM 9-6115-644-24
AIR FORCE TO 35C2-3-446-12
MARINE CORPS TM 09249A/09246A-24/2
HEADQUARTERS,
DEPARTMENTS OF THE ARMY, AIR FORCE AND
HEADQUARTERS, U.S. MARINE CORPS
WASHINGTON, D.C., 15 MAY 2010
TECHNICAL MANUAL
FIELD AND SUSTAINMENT MAINTENANCE MANUAL
GENERATOR SET, SKID MOUNTED, TACTICAL QUIET,
30 kW, 50/60 Hz, MEP-805A
(NSN: 6115-01-274-7389) (EIC: VG5)
GENERATOR SET, SKID MOUNTED, TACTICAL QUIET,
30 kW, 400 Hz, MEP-815A
(NSN: 6115-01-274-7394) (EIC: VN5)
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
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please let us know. Reports, as applicable by the requiring Service, should be submitted as follows:
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(b) (MC) Submit notice of discrepancies or suggested changes on a NAVMC 10772. The NAVMC may be
submitted via the Internet using URL: http://192.156.19.109/ar/mcefs.nsf. Once the form is completed click
on file in the tool bar at top of screen, scroll to "Send" and select "Page by email", and enter
SMB.LOG.Tech.Pubs.fct@usmc.mil, this will come in to the Pubs Sections mailbox. This method of
submittal does not require a Common Access Card (CAC) to access the form. The
https://pubs.ala.usmc.mil/front.htm urn will allow access to the Albany Publications web site where the form
can be filled out and be submitted by electronic mail to mbmatcommarlogbases@logcom.usmc.mil. A paper
copy NAVMC 10772 can be mailed in an envelope addressed to Commander, Marine Corps Systems
Command (LOG/TP), 814 Radford Blvd, Suite 20343, Albany, GA 31704-0343. Problems or questions
regarding the NAVMC 10772 program should be reported by calling DSN 567-7628, DSN 567-6439 or DSN
567-5017.
(d) (F) Air Force - By Air Force AFTO Form 22 (Technical Manual (TM) change Recommendation and Reply) in
accordance with paragraph 6-5, Section VI, TO 00 5 1 directly to prime ALC/MST.
A reply will be furnished to you.
*SUPERSEDURE NOTICE - This manual supersedes TM-9-6115-644-24, TO 35C2-3-446-12 & TM 09249A/09246A-IN dated 30 April
1995. Date of issue for the revised manual is: 15 May 2010.
DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.
i
TM 9-6115-644-24
TABLE OF CONTENTS
Page No.
WP Sequence No.
How to Use This Manual
Chapter 1 - General Information, Equipment Description and Theory of Operation
General Information .............................................................................................................................. WP 0001
Scope .................................................................................................................................................0001-1
Maintenance Forms, Records, and Reports.......................................................................................0001-1
Reporting Equipment Improvement Recommendation (EIR) .............................................................0001-1
Figure 1. Generator Set, 30 kW, Tactical Quiet..................................................................................0001-2
Destruction of Army Materiel to Prevent Enemy Use .........................................................................0001-3
Corrosion Prevention and Control (CPC) ...........................................................................................0001-3
Levels of Maintenance........................................................................................................................0001-3
Preparation for Storage or Shipment..................................................................................................0001-3
List of Abbreviations/Acronyms ..........................................................................................................0001-3
Nuclear, Biological, Chemical.............................................................................................................0001-3
Equipment Description and Data .......................................................................................................... WP 0002
Equipment Description .......................................................................................................................0002-1
Equipment Data..................................................................................................................................0002-1
Table 1. Tabulated Data. ....................................................................................................................0002-1
Location and Description of Major Components.................................................................................0002-4
Figure 1. Generator Set Components ................................................................................................0002-4
Equipment Differences .......................................................................................................................0002-6
Equipment Data..................................................................................................................................0002-6
Table 2. Performance Characteristics. ...............................................................................................0002-6
Generator Assembly Technical Description .......................................................................................0002-7
Figure 2. Brushless Generator Schematic..........................................................................................0002-8
Theory of Operation .............................................................................................................................. WP 0003
Principles of Operation .......................................................................................................................0003-1
Figure 1. Fault System .......................................................................................................................0003-3
Fuel System........................................................................................................................................0003-3
Figure 2. Generator Set Fuel System.................................................................................................0003-5
Generator Set Cooling System...........................................................................................................0003-6
Figure 3. Generator Set Cooling System............................................................................................0003-6
Engine Cooling System ......................................................................................................................0003-7
Figure 4. Engine Cooling System .......................................................................................................0003-7
Engine Lubrication System.................................................................................................................0003-8
Figure 5. Engine Lubrication System..................................................................................................0003-8
Engine Air Intake and Exhaust System ..............................................................................................0003-9
Figure 6. Engine Air Intake and Exhaust System ...........................................................................
....0003-10
Output Supply System....................................................................................................................
....0003-11
Figure 7. Output Supply System.....................................................................................................
....0003-12
Generator Set Controls...................................................................................................................
....0003-13
Figure 8. Engine Starting System...................................................................................................
....0003-14
Governor Control System ...............................................................................................................
....0003-15
Figure 9. Governor Control System................................................................................................
....0003-16
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TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Voltage Regulation System ............................................................................................................
....0003-17
Figure 10. Voltage Regulation System ...........................................................................................
....0003-17
Radio Interference Suppression .....................................................................................................
....0003-17
Chapter 2 - Troubleshooting Procedures
Troubleshooting Index .......................................................................................................................... WP 0004
Purpose of Troubleshooting Table .....................................................................................................0004-1
Troubleshooting Procedures................................................................................................................. WP 0005
Chapter 3 - Maintenance Instructions
Service Upon Receipt ........................................................................................................................... WP 0006
Table 1. Coolant. ................................................................................................................................0006-2
Table 2. Fuel.......................................................................................................................................0006-3
Table 3. Lubricating Oil.......................................................................................................................0006-4
Figure 1. Base Mounting Measurements............................................................................................0006-5
Figure 2. Minimum Enclosure Clearance Measurements...................................................................0006-8
Table 4. Fabricated/Assembled Parts. ...............................................................................................0006-8
PMCS Introduction................................................................................................................................ WP 0007
PMCS, Including Lubrication Instructions ............................................................................................. WP 0008
Special Lubrication Instructions..........................................................................................................0008-1
Table 1. Preventive Maintenance Checks and Services for MEP-805A and MEP-815A. ..................0008-1
Removal and Installation of Major Components, Engine and Generator Assembly: Removal,
Installation............................................................................................................................................. WP 0009
General...............................................................................................................................................0009-1
Removal .............................................................................................................................................0009-1
Installation ..........................................................................................................................................0009-3
Figure 1. Engine and Generator Assembly ........................................................................................0009-5
Removal and Installation of Major Components, Engine Assembly: Removal, Installation,
Replacement......................................................................................................................................... WP 0010
Engine Assembly................................................................................................................................0010-1
Removal .............................................................................................................................................0010-1
Figure 1. Top Housing Panel..............................................................................................................0010-3
Figure 2. Filler Hose and Panel Assembly .........................................................................................0010-4
Figure 3. Overflow Bottle Assembly ...................................................................................................0010-5
Figure 4. Top Housing Section Assembly ..........................................................................................0010-6
Figure 5. Radiator Assembly ..............................................................................................................0010-6
Figure 6. Rear Housing Panel ............................................................................................................0010-7
Figure 7. Fuel Filler Hoses and Panel Assembly................................................................................0010-8
Figure 8. Left Side Housing Panels ....................................................................................................0010-8
Figure 9. Air Cleaner Hose and Tube Assembly ................................................................................0010-9
Figure 10. Oil Drain Hose ...................................................................................................................0010-9
Figure 11. Left Side Engine ............................................................................................................
....0010-10
Figure 12. Right Side Engine..........................................................................................................
....0010-11
Figure 13. Load Output Terminal Board .........................................................................................
....0010-11
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TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Figure 14. Radiator Mounting Bracket............................................................................................
....0010-12
Installation ......................................................................................................................................
....0010-13
Replacement ..................................................................................................................................
....0010-15
Figure 15. Engine Components (Left Side) ....................................................................................
....0010-16
Figure 16. Engine Components (Right Side)..................................................................................
....0010-17
Maintenance of DC Electrical System, Battery and Slave Receptacle Cables: Inspection, Removal,
Cleaning, Repair, Installation ................................................................................................................ WP 0011
Inspection ...........................................................................................................................................0011-2
Removal .............................................................................................................................................0011-2
Cleaning .............................................................................................................................................0011-2
Repair .................................................................................................................................................0011-2
Installation ..........................................................................................................................................0011-3
Figure 1. Batteries and Cables. ..........................................................................................................0011-3
Maintenance of DC Electrical System, Batteries: Testing, Removal, Inspection, Servicing,
Installation............................................................................................................................................. WP 0012
Testing................................................................................................................................................0012-1
Table 1. State of Charge with Specific Gravity Corrected to 80 °F (27 °C). .......................................0012-1
Table 2. Specific Gravity Temperature Corrections............................................................................0012-1
Removal .............................................................................................................................................0012-2
Inspection ...........................................................................................................................................0012-3
Servicing.............................................................................................................................................0012-3
Installation ..........................................................................................................................................0012-3
Maintenance of DC Electrical System, Nato Slave Receptacle: Inspection, Removal, Installation ...... WP 0013
Inspection ...........................................................................................................................................0013-1
Removal .............................................................................................................................................0013-1
Installation ..........................................................................................................................................0013-1
Figure 1. NATO Slave Receptacle and Cables. .................................................................................0013-2
Maintenance of Housing, Access Doors: Removal, Inspection, Repair, Installation............................. WP 0014
Removal .............................................................................................................................................0014-1
Inspection ...........................................................................................................................................0014-2
Repair .................................................................................................................................................0014-2
Installation ..........................................................................................................................................0014-2
Figure 1. Generator Set Access Doors...............................................................................................0014-3
Maintenance of Housing, Control Box Top Panel: Removal, Inspection, Repair, Installation............... WP 0015
Removal .............................................................................................................................................0015-1
Inspection ...........................................................................................................................................0015-2
Repair .................................................................................................................................................0015-2
Installation ..........................................................................................................................................0015-2
Figure 1. Control Box Top Panel. .......................................................................................................0015-3
Maintenance of Housing, Top Housing Section: Removal, Inspection, Repair, Installation ................. WP 0016
Removal .............................................................................................................................................0016-1
Inspection ...........................................................................................................................................0016-2
Repair .................................................................................................................................................0016-2
iv
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TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Installation ..........................................................................................................................................0016-3
Figure 1. Generator Set Top Housing Section (Sheet 1 of 2).............................................................0016-4
Figure 1. Generator Set Top Housing Section (Sheet 2 of 2).............................................................0016-5
Maintenance of Housing, Front Housing Section: Removal, Inspection, Repair, Installation ............... WP 0017
Removal .............................................................................................................................................0017-1
Inspection ...........................................................................................................................................0017-2
Repair .................................................................................................................................................0017-2
Installation ..........................................................................................................................................0017-3
Figure 1. Generator Set Front Housing Section. ................................................................................0017-4
Maintenance of Control Box Assembly, Rear Housing Section: Removal, Inspection, Repair,
Installation............................................................................................................................................. WP 0018
Removal .............................................................................................................................................0018-1
Inspection ...........................................................................................................................................0018-2
Repair .................................................................................................................................................0018-3
Figure 1. Generator Set Rear Housing Section..................................................................................0018-4
Installation ..........................................................................................................................................0018-5
Maintenance of Control Box Assembly, Control Box Assembly: Inspection, Removal, Repair,
Installation............................................................................................................................................. WP 0019
Inspection ...........................................................................................................................................0019-1
Removal .............................................................................................................................................0019-1
Repair .................................................................................................................................................0019-2
Installation ..........................................................................................................................................0019-2
Figure 1. Control Box Assembly .........................................................................................................0019-3
Maintenance of Control Box Assembly, Panel Lights: Inspection, Removal, Disassembly, Assembly,
Installation............................................................................................................................................. WP 0020
Inspection ...........................................................................................................................................0020-1
Removal .............................................................................................................................................0020-1
Disassembly .......................................................................................................................................0020-2
Assembly ............................................................................................................................................0020-2
Installation ..........................................................................................................................................0020-2
Figure 1. Control Panel Lights ............................................................................................................0020-3
Maintenance of Control Box Assembly, Press-to-Test Lights: Inspection, Testing, Removal,
Installation............................................................................................................................................. WP 0021
Inspection ...........................................................................................................................................0021-1
Testing................................................................................................................................................0021-1
Removal .............................................................................................................................................0021-1
Installation ..........................................................................................................................................0021-2
Maintenance of Control Box Assembly, Synchronizing Lights: Inspection, Removal, Installation ........ WP 0022
Inspection ...........................................................................................................................................0022-1
Removal .............................................................................................................................................0022-1
Installation ..........................................................................................................................................0022-2
Maintenance of Control Box Assembly, Fuel Level Indicator: Inspection, Testing, Removal,
Installation............................................................................................................................................. WP 0023
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TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Inspection ...........................................................................................................................................0023-1
Testing................................................................................................................................................0023-1
Removal .............................................................................................................................................0023-2
Figure 1. Control Panel Indicators ......................................................................................................0023-4
Installation ..........................................................................................................................................0023-5
Maintenance of Control Box Assembly, Temperature Indicator: Inspection, Testing, Removal,
Installation............................................................................................................................................. WP 0024
Inspection ...........................................................................................................................................0024-1
Testing................................................................................................................................................0024-1
Removal .............................................................................................................................................0024-2
Installation ..........................................................................................................................................0024-3
Maintenance of Control Box Assembly, Oil Pressure Indicator: Inspection, Testing, Removal,
Installation............................................................................................................................................. WP 0025
Inspection ...........................................................................................................................................0025-1
Testing................................................................................................................................................0025-1
Removal .............................................................................................................................................0025-2
Installation ..........................................................................................................................................0025-3
Maintenance of Control Box Assembly, Time Meter (Total Hours): Inspection, Testing, Removal,
Installation............................................................................................................................................. WP 0026
Inspection ...........................................................................................................................................0026-1
Testing................................................................................................................................................0026-1
Removal .............................................................................................................................................0026-1
Installation ..........................................................................................................................................0026-2
Maintenance of Control Box Assembly, Battery Charge Ammeter: Inspection, Testing, Removal,
Installation............................................................................................................................................. WP 0027
Inspection ...........................................................................................................................................0027-1
Testing................................................................................................................................................0027-1
Removal .............................................................................................................................................0027-1
Installation ..........................................................................................................................................0027-2
Maintenance of Control Box Assembly, Frequency Meter (Hertz): Inspection, Testing, Removal,
Installation............................................................................................................................................. WP 0028
Inspection ...........................................................................................................................................0028-1
Testing 50/60 Hz ................................................................................................................................0028-1
Testing 400 Hz ...................................................................................................................................0028-2
Removal .............................................................................................................................................0028-2
Installation ..........................................................................................................................................0028-3
Maintenance of Control Box Assembly, Ammeter (Percent Rated Current): Inspection, Testing,
Removal, Installation............................................................................................................................. WP 0029
Inspection ...........................................................................................................................................0029-1
Testing................................................................................................................................................0029-1
Removal .............................................................................................................................................0029-2
Installation ..........................................................................................................................................0029-3
vi
TM 9-6115-644-24
TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Maintenance of Control Box Assembly, Kilowattmeter (Percent Power): Inspection, Testing,
Removal, Installation............................................................................................................................. WP 0030
Inspection ...........................................................................................................................................0030-1
Testing................................................................................................................................................0030-1
Removal .............................................................................................................................................0030-2
Installation ..........................................................................................................................................0030-3
Maintenance of Control Box Assembly, AC Voltmeter (Volts AC): Inspection, Testing, Removal,
Installation............................................................................................................................................. WP 0031
Inspection ...........................................................................................................................................0031-1
Testing................................................................................................................................................0031-1
Removal .............................................................................................................................................0031-2
Installation ..........................................................................................................................................0031-3
Maintenance of Control Box Assembly, Master Switch: Inspection, Removal, Testing, Installation ..... WP 0032
Inspection ...........................................................................................................................................0032-1
Removal .............................................................................................................................................0032-1
Testing................................................................................................................................................0032-2
Installation ..........................................................................................................................................0032-2
Figure 1. Control Panel Switches .......................................................................................................0032-4
Maintenance of Control Box Assembly, Ether Switch: Inspection, Removal, Testing, Installation ....... WP 0033
Inspection ...........................................................................................................................................0033-1
Removal .............................................................................................................................................0033-1
Testing................................................................................................................................................0033-2
Installation ..........................................................................................................................................0033-3
Maintenance of Control Box Assembly, Voltage Adjust Potentiometer: Inspection, Removal, Testing,
Installation............................................................................................................................................. WP 0034
Inspection ...........................................................................................................................................0034-1
Removal .............................................................................................................................................0034-1
Testing................................................................................................................................................0034-2
Installation ..........................................................................................................................................0034-3
Maintenance of Control Box Assembly, Frequency Adjust Potentiometer: Inspection, Removal,
Testing, Installation ............................................................................................................................... WP 0035
Inspection ...........................................................................................................................................0035-1
Removal .............................................................................................................................................0035-1
Testing................................................................................................................................................0035-2
Installation ..........................................................................................................................................0035-3
Maintenance of Control Box Assembly, Battle Short Switch: Inspection, Testing, Removal,
Installation............................................................................................................................................. WP 0036
Inspection ...........................................................................................................................................0036-1
Testing................................................................................................................................................0036-1
Removal .............................................................................................................................................0036-2
Installation ..........................................................................................................................................0036-3
Maintenance of Control Box Assembly, AC Circuit Interrupter Switch: Inspection, Testing, Removal,
Installation............................................................................................................................................. WP 0037
vii
TM 9-6115-644-24
TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Inspection ...........................................................................................................................................0037-1
Testing................................................................................................................................................0037-1
Removal .............................................................................................................................................0037-2
Installation ..........................................................................................................................................0037-3
Maintenance of Control Box Assembly, Parallel-Unit Switch: Inspection, Removal, Testing,
Installation............................................................................................................................................. WP 0038
Inspection ...........................................................................................................................................0038-1
Removal .............................................................................................................................................0038-1
Testing................................................................................................................................................0038-2
Installation ..........................................................................................................................................0038-3
Maintenance of Control Box Assembly, VM-AM Transfer Switch: Inspection, Removal, Testing,
Installation............................................................................................................................................. WP 0039
Inspection ...........................................................................................................................................0039-1
Removal .............................................................................................................................................0039-1
Testing................................................................................................................................................0039-2
Installation ..........................................................................................................................................0039-2
Maintenance of Control Box Assembly, Panel Lights Switch: Inspection, Removal, Testing,
Installation............................................................................................................................................. WP 0040
Inspection ...........................................................................................................................................0040-1
Removal .............................................................................................................................................0040-1
Testing................................................................................................................................................0040-2
Installation ..........................................................................................................................................0040-3
Maintenance of Control Box Assembly, Emergency Stop Switch Assembly: Inspection, Removal,
Testing, Installation ............................................................................................................................... WP 0041
Inspection ...........................................................................................................................................0041-1
Removal .............................................................................................................................................0041-1
Testing................................................................................................................................................0041-2
Installation ..........................................................................................................................................0041-3
Maintenance of Control Box Assembly, Reactive Current Adjust Rheostat: Inspection, Testing,
Removal, Installation............................................................................................................................. WP 0042
Inspection ...........................................................................................................................................0042-1
Testing................................................................................................................................................0042-1
Removal .............................................................................................................................................0042-2
Installation ..........................................................................................................................................0042-3
Maintenance of Control Box Assembly, Load Sharing Adjust Rheostat: Inspection, Testing,
Removal, Installation............................................................................................................................. WP 0043
Inspection ...........................................................................................................................................0043-1
Testing................................................................................................................................................0043-1
Removal .............................................................................................................................................0043-2
Installation ..........................................................................................................................................0043-3
Figure 1. Control Box Components ....................................................................................................0043-3
Maintenance of Control Box Assembly, Overspeed Reset Switch: Inspection, Testing, Removal,
Installation............................................................................................................................................. WP 0044
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TM 9-6115-644-24
TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Inspection ...........................................................................................................................................0044-1
Testing................................................................................................................................................0044-1
Removal .............................................................................................................................................0044-1
Installation ..........................................................................................................................................0044-2
Maintenance of Control Box Assembly, Frequency Select Switch (MEP-805A): Inspection, Testing,
Removal, Installation............................................................................................................................. WP 0045
Inspection ...........................................................................................................................................0045-1
Testing................................................................................................................................................0045-1
Removal .............................................................................................................................................0045-1
Installation ..........................................................................................................................................0045-2
Maintenance of Control Box Assembly, Convenience Receptacle: Inspection, Testing, Removal,
Installation............................................................................................................................................. WP 0046
Inspection ...........................................................................................................................................0046-1
Testing................................................................................................................................................0046-1
Removal .............................................................................................................................................0046-1
Installation ..........................................................................................................................................0046-2
Maintenance of Control Box Assembly, Ground Fault Circuit Interrupter: Inspection, Testing,
Removal, Installation............................................................................................................................. WP 0047
Inspection ...........................................................................................................................................0047-1
Testing................................................................................................................................................0047-1
Removal .............................................................................................................................................0047-1
Installation ..........................................................................................................................................0047-2
In-line Fuse Installation.......................................................................................................................0047-4
Figure 1. In-Line Fuse Installation ......................................................................................................0047-4
Maintenance of Control Box Assembly, Malfunction Indicator Panel: Inspection, Testing, Removal,
Installation............................................................................................................................................. WP 0048
Inspection ...........................................................................................................................................0048-1
Testing................................................................................................................................................0048-1
Removal .............................................................................................................................................0048-1
Installation ..........................................................................................................................................0048-2
Maintenance of Control Box Assembly, Battery Charger Fuse: Removal, Inspection, Installation ....... WP 0049
Removal .............................................................................................................................................0049-1
Inspection ...........................................................................................................................................0049-2
Installation ..........................................................................................................................................0049-2
Maintenance of Control Box Assembly, DC Control Power Circuit Breaker: Inspection, Testing,
Removal, Installation............................................................................................................................. WP 0050
Inspection ...........................................................................................................................................0050-1
Testing................................................................................................................................................0050-1
Removal .............................................................................................................................................0050-1
Installation ..........................................................................................................................................0050-3
Maintenance of Control Box Assembly, AC Voltage Regulator: Inspection, Testing, Removal,
Installation............................................................................................................................................. WP 0051
Inspection ...........................................................................................................................................0051-2
ix
TM 9-6115-644-24
TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Testing................................................................................................................................................0051-2
Table 1. Voltage Adjustment Range (MEP-805A). .............................................................................0051-3
Table 2. Voltage Adjustment Range (MEP-815A). .............................................................................0051-4
Removal .............................................................................................................................................0051-4
Installation ..........................................................................................................................................0051-5
Maintenance of Control Box Assembly, Frequency Transducer: Inspection, Testing, Removal,
Installation............................................................................................................................................. WP 0052
Inspection ...........................................................................................................................................0052-1
Testing................................................................................................................................................0052-1
Removal .............................................................................................................................................0052-2
Installation ..........................................................................................................................................0052-3
Maintenance of Control Box Assembly, Kilowatt Transducer: Inspection, Testing, Removal,
Installation............................................................................................................................................. WP 0053
Inspection ...........................................................................................................................................0053-1
Testing................................................................................................................................................0053-1
Removal .............................................................................................................................................0053-2
Installation ..........................................................................................................................................0053-3
Maintenance of Control Box Assembly, Shunt: Inspection, Testing, Removal, Installation .................. WP 0054
Inspection ...........................................................................................................................................0054-1
Testing................................................................................................................................................0054-1
Removal .............................................................................................................................................0054-2
Installation ..........................................................................................................................................0054-3
Maintenance of Control Box Assembly, Overvoltage/Undervoltage Relay: Inspection, Testing,
Removal, Installation............................................................................................................................. WP 0055
Inspection ...........................................................................................................................................0055-1
Testing................................................................................................................................................0055-1
Removal .............................................................................................................................................0055-2
Installation ..........................................................................................................................................0055-3
Maintenance of Control Box Assembly, Short Circuit/Overload Relay: Inspection, Testing, Removal,
Installation............................................................................................................................................. WP 0056
Inspection ...........................................................................................................................................0056-1
Testing................................................................................................................................................0056-1
Figure 1. Test Circuit ..........................................................................................................................0056-2
Removal .............................................................................................................................................0056-2
Installation ..........................................................................................................................................0056-3
Maintenance of Control Box Assembly, Permissive Paralleling Relay: Inspection, Testing, Removal,
Installation............................................................................................................................................. WP 0057
Inspection ...........................................................................................................................................0057-1
Testing................................................................................................................................................0057-1
Figure 1. Permissive Paralleling Relay Test Setup ............................................................................0057-2
Removal .............................................................................................................................................0057-2
Installation ..........................................................................................................................................0057-3
x
TM 9-6115-644-24
TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Maintenance of Control Box Assembly, Reverse Power Relay: Inspection, Testing, Removal,
Installation............................................................................................................................................. WP 0058
Inspection ...........................................................................................................................................0058-1
Testing................................................................................................................................................0058-1
Figure 1. Reverse Power Relay Test Setup .......................................................................................0058-2
Removal .............................................................................................................................................0058-2
Installation ..........................................................................................................................................0058-3
Maintenance of Control Box Assembly, Voltage Sensing Relay: Inspection, Testing, Removal,
Installation............................................................................................................................................. WP 0059
Inspection ...........................................................................................................................................0059-1
Testing................................................................................................................................................0059-1
Removal .............................................................................................................................................0059-1
Installation ..........................................................................................................................................0059-2
Maintenance of Control Box Assembly, Relays: Inspection, Testing, Removal, Installation ................ WP 0060
Inspection ...........................................................................................................................................0060-1
Testing................................................................................................................................................0060-1
Removal .............................................................................................................................................0060-1
Installation ..........................................................................................................................................0060-2
Maintenance of Control Box Assembly, Governor Control Unit (GCU): Inspection, Troubleshooting
Procedures, Testing, Adjustment, Removal, Installation, Replacement ............................................... WP 0061
Inspection ...........................................................................................................................................0061-2
Troubleshooting Procedures ..............................................................................................................0061-2
Testing................................................................................................................................................0061-2
Adjustment..........................................................................................................................................0061-4
Figure 1. Fuel Injection Pump High Idle Speed Adjustment ...............................................................0061-4
Removal .............................................................................................................................................0061-6
Installation ..........................................................................................................................................0061-7
Replacement ......................................................................................................................................0061-7
Maintenance of Control Box Assembly, Control Box Wiring Harness: Inspection, Testing, Repair,
Removal, Installation............................................................................................................................. WP 0062
Inspection ...........................................................................................................................................0062-2
Testing................................................................................................................................................0062-2
Repair .................................................................................................................................................0062-2
Removal .............................................................................................................................................0062-3
Installation ..........................................................................................................................................0062-4
Figure 1. Control Box Components ....................................................................................................0062-5
Maintenance of Control Box Assembly, Diagnostic Connector: Inspection, Removal, Installation ....... WP 0063
Inspection ...........................................................................................................................................0063-1
Removal .............................................................................................................................................0063-1
Installation ..........................................................................................................................................0063-2
Figure 1. Diagnostic Connector Pin Positions ....................................................................................0063-3
Table 1. Diagnostic Connector Connection Points. ............................................................................0063-3
Maintenance of Control Box Assembly, Parallel Connector: Inspection, Removal, Installation............ WP 0064
xi
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TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Inspection ...........................................................................................................................................0064-1
Removal .............................................................................................................................................0064-1
Installation ..........................................................................................................................................0064-2
Maintenance of Control Box Assembly, Load Measuring Unit: Inspection, Removal, Installation,
Testing, Replacement ........................................................................................................................... WP 0065
Inspection ...........................................................................................................................................0065-2
Removal .............................................................................................................................................0065-2
Installation ..........................................................................................................................................0065-3
Testing................................................................................................................................................0065-3
Replacement ......................................................................................................................................0065-4
Maintenance of Control Box Assembly, Resistor-Diode Assembly: Inspection, Testing, Removal,
Repair, Installation ................................................................................................................................ WP 0066
Inspection ...........................................................................................................................................0066-1
Testing................................................................................................................................................0066-1
Figure 1. Diode Identification..............................................................................................................0066-2
Removal .............................................................................................................................................0066-2
Repair .................................................................................................................................................0066-3
Installation ..........................................................................................................................................0066-3
Maintenance of Control Box Assembly, Control Panel: Inspection, Removal, Repair, Installation ....... WP 0067
Inspection ...........................................................................................................................................0067-1
Removal .............................................................................................................................................0067-1
Repair .................................................................................................................................................0067-2
Installation ..........................................................................................................................................0067-3
Figure 1. Control Box Panels..............................................................................................................0067-4
Maintenance of Control Box Assembly, Control Panel Frame: Inspection, Removal, Repair,
Installation............................................................................................................................................. WP 0068
Inspection ...........................................................................................................................................0068-1
Removal .............................................................................................................................................0068-1
Repair .................................................................................................................................................0068-2
Installation ..........................................................................................................................................0068-3
Maintenance of Control Box Assembly, Control Box Side Panels: Inspection, Removal, Repair,
Installation............................................................................................................................................. WP 0069
Inspection ...........................................................................................................................................0069-1
Removal .............................................................................................................................................0069-1
Repair .................................................................................................................................................0069-2
Installation ..........................................................................................................................................0069-3
Maintenance of Control Box Assembly, Control Box Tray (Bottom): Inspection, Removal, Repair,
Installation............................................................................................................................................. WP 0070
Inspection ...........................................................................................................................................0070-1
Removal .............................................................................................................................................0070-1
Repair .................................................................................................................................................0070-2
Installation ..........................................................................................................................................0070-3
xii
TM 9-6115-644-24
TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Maintenance of Air Intake and Exhaust System, Muffler and Exhaust Pipe: Inspection, Removal,
Installation............................................................................................................................................. WP 0071
Inspection ...........................................................................................................................................0071-1
Removal .............................................................................................................................................0071-1
Figure 1. Muffler and Exhaust Pipe ....................................................................................................0071-3
Installation ..........................................................................................................................................0071-4
Maintenance of Air Intake and Exhaust System, Air Restriction Indicator: Inspection, Removal,
Installation............................................................................................................................................. WP 0072
Inspection ...........................................................................................................................................0072-1
Removal .............................................................................................................................................0072-1
Installation ..........................................................................................................................................0072-2
Maintenance of Air Intake and Exhaust System, Air Cleaner Assembly: Inspection, Servicing,
Removal, Installation............................................................................................................................. WP 0073
Inspection ...........................................................................................................................................0073-1
Servicing.............................................................................................................................................0073-1
Removal .............................................................................................................................................0073-1
Installation ..........................................................................................................................................0073-2
Figure 1. Air Cleaner Assembly..........................................................................................................0073-3
Maintenance of Air Intake and Exhaust System, Air Cleaner Element: Removal, Inspection,
Installation............................................................................................................................................. WP 0074
Removal .............................................................................................................................................0074-1
Inspection ...........................................................................................................................................0074-2
Installation ..........................................................................................................................................0074-2
Maintenance of Air Intake and Exhaust System, Air Cleaner Tubing and Breather: Inspection,
Servicing, Removal, Installation............................................................................................................ WP 0075
Inspection ...........................................................................................................................................0075-1
Servicing.............................................................................................................................................0075-1
Removal .............................................................................................................................................0075-2
Installation ..........................................................................................................................................0075-2
Maintenance of Coolant System, Coolant System: Testing, Servicing ................................................. WP 0076
Testing................................................................................................................................................0076-1
Servicing.............................................................................................................................................0076-2
Figure 1. Coolant System ...................................................................................................................0076-2
Maintenance of Coolant System, Radiator Filler Hose and Panel Assembly: Removal, Inspection
and Cleaning, Installation...................................................................................................................... WP 0077
Removal .............................................................................................................................................0077-1
Inspection and Cleaning .....................................................................................................................0077-2
Installation ..........................................................................................................................................0077-2
Figure 1. Radiator Cap .......................................................................................................................0077-3
Maintenance of Coolant System, Fan Guards: Inspection, Removal, Installation ................................ WP 0078
Inspection ...........................................................................................................................................0078-1
Removal .............................................................................................................................................0078-1
Figure 1. Fan Guards and Coolant Recovery System........................................................................0078-3
xiii
TM 9-6115-644-24
TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Installation ..........................................................................................................................................0078-3
Maintenance of Coolant System, Upper Coolant Hose: Removal, Inspection and Cleaning,
Installation............................................................................................................................................. WP 0079
Removal .............................................................................................................................................0079-1
Inspection and Cleaning .....................................................................................................................0079-2
Installation ..........................................................................................................................................0079-2
Maintenance of Coolant System, Lower Coolant Hose: Removal, Inspection and Cleaning,
Installation............................................................................................................................................. WP 0080
Removal .............................................................................................................................................0080-1
Inspection and Cleaning .....................................................................................................................0080-2
Installation ..........................................................................................................................................0080-2
Maintenance of Coolant System, Coolant Overflow and Drain Hoses: Removal, Inspection,
Installation............................................................................................................................................. WP 0081
Removal .............................................................................................................................................0081-1
Inspection ...........................................................................................................................................0081-1
Installation ..........................................................................................................................................0081-2
Maintenance of Coolant System, Radiator: Removal, Inspection and Cleaning, Repair,
Installation............................................................................................................................................. WP 0082
Removal .............................................................................................................................................0082-1
Inspection and Cleaning .....................................................................................................................0082-2
Repair .................................................................................................................................................0082-3
Installation ..........................................................................................................................................0082-3
Maintenance of Coolant System, Generator Set Cooling Fan: Removal, Inspection, Installation ........ WP 0083
Removal .............................................................................................................................................0083-1
Inspection ...........................................................................................................................................0083-2
Installation ..........................................................................................................................................0083-2
Maintenance of Coolant System, Fan Belt: Inspection, Testing and Adjustment, Removal,
Installation............................................................................................................................................. WP 0084
Inspection ...........................................................................................................................................0084-1
Figure 1. Fan Belt ...............................................................................................................................0084-2
Testing and Adjustment......................................................................................................................0084-2
Removal .............................................................................................................................................0084-2
Installation ..........................................................................................................................................0084-3
Maintenance of Coolant System, Coolant Recovery System: Inspection, Removal, Installation.......... WP 0085
Inspection ...........................................................................................................................................0085-1
Removal .............................................................................................................................................0085-1
Installation ..........................................................................................................................................0085-2
Maintenance of Fuel System, Low Pressure Fuel Lines and Fittings: Removal, Installation ................ WP 0086
Removal .............................................................................................................................................0086-1
Installation ..........................................................................................................................................0086-2
Maintenance of Fuel System, Auxiliary Fuel Pump: Inspection, Testing, Removal, Installation ........... WP 0087
Inspection ...........................................................................................................................................0087-1
xiv
TM 9-6115-644-24
TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Testing................................................................................................................................................0087-1
Removal .............................................................................................................................................0087-1
Installation ..........................................................................................................................................0087-2
Figure 1. Fuel Tank Filler Neck and Low Pressure Fuel System .......................................................0087-3
Maintenance of Fuel System, Fuel Tank Filler Neck: Removal, Inspection, Installation....................... WP 0088
Removal .............................................................................................................................................0088-1
Inspection ...........................................................................................................................................0088-2
Installation ..........................................................................................................................................0088-2
Maintenance of Fuel System, Fuel Drain Valve: Removal, Installation ................................................ WP 0089
Removal .............................................................................................................................................0089-1
Installation ..........................................................................................................................................0089-2
Maintenance of Fuel System, Fuel Level Sender: Inspection, Removal, Testing, Installation.............. WP 0090
Inspection ...........................................................................................................................................0090-1
Removal .............................................................................................................................................0090-1
Testing................................................................................................................................................0090-2
Installation ..........................................................................................................................................0090-3
Maintenance of Fuel System, Low Fuel Level/Auxiliary Fuel Pump Float Switch: Inspection,
Removal, Testing, Installation............................................................................................................... WP 0091
Inspection ...........................................................................................................................................0091-1
Removal .............................................................................................................................................0091-1
Testing................................................................................................................................................0091-2
Installation ..........................................................................................................................................0091-3
Maintenance of Fuel System, Fuel Pickup: Removal, Inspection, Installation ...................................... WP 0092
Removal .............................................................................................................................................0092-1
Inspection ...........................................................................................................................................0092-2
Installation ..........................................................................................................................................0092-2
Maintenance of Fuel System, Fuel Float Module: Inspection, Testing, Removal, Installation .............. WP 0093
Inspection ...........................................................................................................................................0093-1
Testing................................................................................................................................................0093-1
Removal .............................................................................................................................................0093-1
Installation ..........................................................................................................................................0093-2
Maintenance of Fuel System, Fuel Filter/Drain Valve Assembly: Removal, Inspection, Installation .... WP 0094
Removal .............................................................................................................................................0094-1
Inspection ...........................................................................................................................................0094-2
Installation ..........................................................................................................................................0094-2
Maintenance of Fuel System, Ether Cylinder: Removal, Inspection, Installation .................................. WP 0095
Removal .............................................................................................................................................0095-1
Inspection ...........................................................................................................................................0095-2
Installation ..........................................................................................................................................0095-2
Figure 1. Ether Start System ..............................................................................................................0095-3
Maintenance of Fuel System, Ether Solenoid Valve: Removal, Inspection, Installation ....................... WP 0096
xv
TM 9-6115-644-24
TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Removal .............................................................................................................................................0096-1
Inspection ...........................................................................................................................................0096-2
Installation ..........................................................................................................................................0096-2
Maintenance of Fuel System, Fuel Tank: Inspection, Removal, Installation......................................... WP 0097
Inspection ...........................................................................................................................................0097-2
Removal .............................................................................................................................................0097-2
Installation ..........................................................................................................................................0097-2
Figure 1. Fuel Tank ............................................................................................................................0097-3
Maintenance of Output Box Assembly, Output Box Assembly: Removal, Installation .......................... WP 0098
Removal .............................................................................................................................................0098-2
Installation ..........................................................................................................................................0098-3
Figure 1. Output Box Assembly..........................................................................................................0098-4
Maintenance of Output Box Assembly, Voltage Reconnection Terminal Board: Inspection, Removal,
Installation............................................................................................................................................. WP 0099
Inspection ...........................................................................................................................................0099-2
Removal .............................................................................................................................................0099-2
Installation ..........................................................................................................................................0099-3
Maintenance of Output Box Assembly, Output Box Wiring Harness: Inspection, Removal, Testing,
Repair, Installation ................................................................................................................................ WP 0100
Inspection ...........................................................................................................................................0100-2
Figure 1. Output Box Assembly..........................................................................................................0100-3
Removal .............................................................................................................................................0100-4
Testing................................................................................................................................................0100-4
Repair .................................................................................................................................................0100-4
Installation ..........................................................................................................................................0100-5
Maintenance of Output Box Assembly, Current Transformer: Inspection, Removal, Testing,
Installation............................................................................................................................................. WP 0101
Inspection ...........................................................................................................................................0101-2
Removal .............................................................................................................................................0101-2
Testing................................................................................................................................................0101-3
Figure 1. Testing Current Transformer ...............................................................................................0101-3
Installation ..........................................................................................................................................0101-4
Maintenance of Output Box Assembly, Droop Current Transformer: Inspection, Removal, Testing,
Installation............................................................................................................................................. WP 0102
Inspection ...........................................................................................................................................0102-2
Removal .............................................................................................................................................0102-2
Testing................................................................................................................................................0102-3
Figure 1. Testing Droop Current Transformer ....................................................................................0102-3
Installation ..........................................................................................................................................0102-3
Maintenance of Output Box Assembly, Power Potential Transformer: Inspection, Removal, Testing,
Installation............................................................................................................................................. WP 0103
Inspection ...........................................................................................................................................0103-2
Removal .............................................................................................................................................0103-2
xvi
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TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Testing................................................................................................................................................0103-3
Installation ..........................................................................................................................................0103-3
Maintenance of Output Box Assembly, Ac Circuit Interrupter Relay: Inspection, Testing, Removal,
Installation............................................................................................................................................. WP 0104
Inspection ...........................................................................................................................................0104-1
Testing................................................................................................................................................0104-2
Removal .............................................................................................................................................0104-2
Installation ..........................................................................................................................................0104-2
Maintenance of Output Box Assembly, Cranking Relay: Inspection, Testing, Removal, Installation.... WP 0105
Inspection ...........................................................................................................................................0105-1
Testing................................................................................................................................................0105-2
Removal .............................................................................................................................................0105-2
Installation ..........................................................................................................................................0105-2
Maintenance of Output Box Assembly, Load Output Terminal Board: Removal, Inspection, Repair,
Installation............................................................................................................................................. WP 0106
Removal .............................................................................................................................................0106-1
Inspection ...........................................................................................................................................0106-2
Repair .................................................................................................................................................0106-2
Installation ..........................................................................................................................................0106-3
Figure 1. Load Terminal Board Assembly ..........................................................................................0106-4
Maintenance of Output Box Assembly, Load Output Terminals: Removal, Inspection, Installation ..... WP 0107
Removal .............................................................................................................................................0107-1
Inspection ...........................................................................................................................................0107-2
Installation ..........................................................................................................................................0107-2
Maintenance of Output Box Assembly, Varistors: Removal, Test and Inspection, Installation ............. WP 0108
Removal .............................................................................................................................................0108-1
Test and Inspection ............................................................................................................................0108-2
Installation ..........................................................................................................................................0108-2
Maintenance of Output Box Assembly, Output Box Panels: Inspection, Removal, Repair,
Installation............................................................................................................................................. WP 0109
Inspection ...........................................................................................................................................0109-2
Removal .............................................................................................................................................0109-2
Repair .................................................................................................................................................0109-3
Installation ..........................................................................................................................................0109-3
Maintenance of Engine Accessories, Low Oil Pressure Switch: Testing, Removal, Cleaning and
Inspection, Installation .......................................................................................................................... WP 0110
Testing................................................................................................................................................0110-1
Removal .............................................................................................................................................0110-2
Cleaning and Inspection .....................................................................................................................0110-2
Installation ..........................................................................................................................................0110-3
Figure 1. Engine Switches and Senders ............................................................................................0110-4
xvii
TM 9-6115-644-24
TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Maintenance of Engine Accessories, Oil Pressure Sender: Testing, Removal, Cleaning and
Inspection, Installation .......................................................................................................................... WP 0111
Testing................................................................................................................................................0111-1
Removal .............................................................................................................................................0111-2
Cleaning and Inspection .....................................................................................................................0111-2
Installation ..........................................................................................................................................0111-3
Maintenance of Engine Accessories, Coolant Temperature Sender: Testing, Removal, Cleaning and
Inspection, Installation .......................................................................................................................... WP 0112
Testing................................................................................................................................................0112-1
Removal .............................................................................................................................................0112-2
Cleaning and Inspection .....................................................................................................................0112-2
Installation ..........................................................................................................................................0112-3
Maintenance of Engine Accessories, Coolant High Temperature Switch: Testing, Removal,
Cleaning and Inspection, Installation .................................................................................................... WP 0113
Testing................................................................................................................................................0113-1
Removal .............................................................................................................................................0113-2
Cleaning and Inspection .....................................................................................................................0113-2
Installation ..........................................................................................................................................0113-3
Maintenance of Engine Accessories, Magnetic Pickup: Removal, Cleaning and Inspection,
Installation, Adjustment......................................................................................................................... WP 0114
Removal .............................................................................................................................................0114-1
Cleaning and Inspection .....................................................................................................................0114-2
Installation ..........................................................................................................................................0114-2
Adjustment..........................................................................................................................................0114-3
Maintenance of Engine Accessories, Dead Crank Switch: Testing, Removal, Installation ................... WP 0115
Testing................................................................................................................................................0115-1
Removal .............................................................................................................................................0115-2
Installation ..........................................................................................................................................0115-2
Maintenance of Engine Accessories, Diode Assembly: Removal, Testing, Repair, Installation ........... WP 0116
Removal .............................................................................................................................................0116-1
Testing................................................................................................................................................0116-2
Repair .................................................................................................................................................0116-2
Installation ..........................................................................................................................................0116-2
Maintenance of Engine Accessories, Governor Actuator: Testing, Removal, Installation,
Adjustment ............................................................................................................................................ WP 0117
Testing................................................................................................................................................0117-2
Removal .............................................................................................................................................0117-3
Figure 1. Governor Actuator Assembly ..............................................................................................0117-4
Installation ..........................................................................................................................................0117-4
Adjustment..........................................................................................................................................0117-5
Figure 2. Governor Actuator Adjustment ............................................................................................0117-6
Maintenance of Lubrication System, Oil Drain Line: Inspection, Removal, Installation ........................ WP 0118
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TM 9-6115-644-24
TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Inspection ...........................................................................................................................................0118-1
Removal .............................................................................................................................................0118-1
Figure 1. Oil Drain Line.......................................................................................................................0118-2
Installation ..........................................................................................................................................0118-2
Maintenance of Generator Assembly, Generator Assembly: Removal, Installation ............................. WP 0119
Removal .............................................................................................................................................0119-2
Figure 1. Generator Assembly Removal ............................................................................................0119-3
Installation ..........................................................................................................................................0119-3
Maintenance of Generator Assembly, Rotating Rectifier Diodes: Testing, Removal, Installation......... WP 0120
Testing................................................................................................................................................0120-1
Figure 1. Rectifier Assembly...............................................................................................................0120-2
Removal .............................................................................................................................................0120-3
Installation ..........................................................................................................................................0120-3
Maintenance of Generator Assembly, End Bell and Main Bearing: Removal, Installation.................... WP 0121
Removal .............................................................................................................................................0121-1
Figure 1. End Bell Removal................................................................................................................0121-3
Installation ..........................................................................................................................................0121-3
Figure 2. Generator Assembly............................................................................................................0121-4
Maintenance of Generator Assembly, Rotating Rectifier: Removal, Installation................................... WP 0122
Removal .............................................................................................................................................0122-1
Installation ..........................................................................................................................................0122-2
Maintenance of Generator Assembly, Exciter Stator: Testing, Removal, Installation ........................... WP 0123
Testing................................................................................................................................................0123-1
Table 1. Generator Resistance Values at 25 °C (77 °F).....................................................................0123-2
Removal .............................................................................................................................................0123-2
Installation ..........................................................................................................................................0123-3
Maintenance of Generator Assembly, Exciter Rotor: Testing ............................................................... WP 0124
Testing................................................................................................................................................0124-1
Maintenance of Generator Assembly, Main Rotor Assembly: Testing, Removal, Installation .............. WP 0125
Testing................................................................................................................................................0125-1
Removal .............................................................................................................................................0125-2
Figure 1. Rotor Assembly Lifting Device (Typical)..............................................................................0125-3
Installation ..........................................................................................................................................0125-3
Maintenance of Generator Assembly, Main Stator and Housing: Testing, Removal, Installation ......... WP 0126
Testing................................................................................................................................................0126-1
Removal .............................................................................................................................................0126-2
Installation ..........................................................................................................................................0126-3
Maintenance of Skid Base: Removal, Repair, Installation .................................................................... WP 0127
Removal .............................................................................................................................................0127-1
Repair .................................................................................................................................................0127-2
Installation ..........................................................................................................................................0127-2
xix
TM 9-6115-644-24
TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Figure 1. Skid Base ............................................................................................................................0127-3
Preparation for Storage or Shipment .................................................................................................... WP 0128
Preparation for Storage or Shipment..................................................................................................0128-1
Illustrated List of Manufactured Items Introduction ............................................................................... WP 0129
Cable Assembly, AC Power (P/N 88-22126-1 through 88-22126-7) .................................................... WP 0130
Figure 1. Cable Assembly, AC Power (P/N 88-22126-1 through 88-22126-7)...................................0130-1
Cable Assembly, Battery (P/N 88-22178) ............................................................................................. WP 0131
Figure 1. Cable Assembly, Battery (P/N 88-22178) ...........................................................................0131-1
Cable Assembly, Battery (P/N 88-22127) ............................................................................................. WP 0132
Figure 1. Cable Assembly, Battery (P/N 88-22127) ...........................................................................0132-1
Cable Assembly, Battery (P/N 88-22181) ............................................................................................. WP 0133
Figure 1. Cable Assembly, Battery (P/N 88-22181) ...........................................................................0133-1
Cable Assembly, Battery (P/N 88-22179) ............................................................................................. WP 0134
Figure 1. Cable Assembly, Battery (P/N 88-22179) ...........................................................................0134-1
Cable Assembly, Battery (P/N 88-22207) ............................................................................................. WP 0135
Figure 1. Cable Assembly, Battery (P/N 88-22207) ...........................................................................0135-1
Holder, Control Panel (P/N 88-22120) .................................................................................................. WP 0136
Figure 1. Holder, Control Panel (P/N 88-22120) ................................................................................0136-1
Hose Assembly (P/N 88-20191-6) ........................................................................................................ WP 0137
Figure 1. Hose Assembly (P/N 88-20191-6).......................................................................................0137-1
Insulation, Panel, Top (P/N 88-22582).................................................................................................. WP 0138
Figure 1. Insulation, Panel, Top (P/N 88-22582) ................................................................................0138-1
Insulation, Baffle (P/N 88-22592).......................................................................................................... WP 0139
Figure 1. Insulation, Baffle (P/N 88-22592) ........................................................................................0139-2
Insulation, Baffle (P/N 88-22593).......................................................................................................... WP 0140
Figure 1. Insulation, Baffle (P/N 88-22593) ........................................................................................0140-2
Insulation, Top, Center (P/N 88-22584) ................................................................................................ WP 0141
Figure 1. Insulation, Top, Center (P/N 88-22584) ..............................................................................0141-2
Insulation, Top, Rear (P/N 88-22585) ................................................................................................... WP 0142
Figure 1. Insulation, Top, Rear (P/N 88-22585) .................................................................................0142-1
Insulation, Front Housing (P/N 88-22591) ............................................................................................ WP 0143
Figure 1. Insulation, Front Housing (P/N 88-22591)...........................................................................0143-2
Insulation, Top, Front (P/N 88-22586) .................................................................................................. WP 0144
Figure 1. Insulation, Top, Front (P/N 88-22586).................................................................................0144-2
Insulation, Top, Center (P/N 88-22587) ................................................................................................ WP 0145
Figure 1. Insulation, Top, Center (P/N 88-22587) ..............................................................................0145-2
Insulation, Top, Center (P/N 88-22588) ................................................................................................ WP 0146
Figure 1. Insulation, Top, Center (P/N 88-22588) ..............................................................................0146-2
xx
TM 9-6115-644-24
TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Insulation, Top, Front (P/N 88-22583) .................................................................................................. WP 0147
Figure 1. Insulation, Top, Front (P/N 88-22583).................................................................................0147-2
Resistor Assembly (P/N 122-3066-1 and 29879) ................................................................................. WP 0148
Figure 1. Resistor Assembly (P/N 122-3066-1 and 29879)................................................................0148-1
Resistor Assembly, Volt (P/N 88-22631) .............................................................................................. WP 0149
Figure 1. Resistor Assembly, Volt (P/N 88-22631).............................................................................0149-1
Resistor-Diode Assembly (P/N 88-22632) ............................................................................................ WP 0150
Figure 1. Resistor-Diode Assembly (P/N 88-22632) ..........................................................................0150-1
Resistor-Diode Assembly (P/N 88-22106) ............................................................................................ WP 0151
Figure 1. Resistor-Diode Assembly (P/N 88-22106) ..........................................................................0151-1
Solenoid Assembly (P/N 88-22553)...................................................................................................... WP 0152
Figure 1. Solenoid Assembly (P/N 88-22553) ....................................................................................0152-1
Switch Assembly, Fuel Level (P/N 88-22548)....................................................................................... WP 0153
Figure 1. Switch Assembly, Fuel Level (P/N 88-22548) .....................................................................0153-2
Wire, Varistor (P/N 88-20305-1 through 88-20305-3 and 88-20305-5) ................................................ WP 0154
Figure 1. Wire, Varistor (P/N 88-20305-1 through 88-20305-3 and 88-20305-5)...............................0154-1
Torque Limits ........................................................................................................................................ WP 0155
Table 1. Torque Limits........................................................................................................................0155-1
Chapter 4 - Supporting Information
References............................................................................................................................................ WP 0156
Scope .................................................................................................................................................0156-1
Maintenance Allocation Chart (MAC) Introduction................................................................................ WP 0157
Maintenance Allocation Chart (MAC).................................................................................................... WP 0158
Table 1. MAC for MEP-805A and MEP-815A.....................................................................................0158-1
Table 2. Tools and Test Equipment Requirements for MEP-805A and MEP-815A. ..........................0158-7
Table 3. Remarks for MEP-805A and MEP-815A. .............................................................................0158-8
Expendable and Durable Items List ...................................................................................................... WP 0159
Scope .................................................................................................................................................0159-1
Explanation of Columns in the Expendable/Durable Items List..........................................................0159-1
Table 1. Expendable and Durable Items List......................................................................................0159-1
Chapter 5 - Winterization Kit
Winterization Kit, General Information .................................................................................................. WP 0160
Scope .................................................................................................................................................0160-1
Repair Parts; Special Tools; Test, Measurement, and Diagnostic Equipment (tmde); and Special
Support Equipment.............................................................................................................................0160-1
Winterization Kit, Equipment Description and Data .............................................................................. WP 0161
General...............................................................................................................................................0161-1
Equipment Characteristics, Capabilities and Features.......................................................................0161-1
Location and Description of Major Components.................................................................................0161-1
xxi
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TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Table 1. Description of Major Winterization Kit Components. ............................................................0161-1
Figure 1. Location of Major Winterization Kit Components ................................................................0161-2
Tabulated/Illustrated Data ..................................................................................................................0161-3
Table 2. Heater Operating Data. ........................................................................................................0161-3
Winterization Kit, Theory of Operation .................................................................................................. WP 0162
General...............................................................................................................................................0162-1
Winterization Kit, Description and Use of Controls and Indicators........................................................ WP 0163
General...............................................................................................................................................0163-1
Table 1. Data Plates. ..........................................................................................................................0163-1
Winterization Kit, Troubleshooting Index .............................................................................................. WP 0164
General...............................................................................................................................................0164-1
Figure 1. Heater Function Codes Plate ..............................................................................................0164-2
Figure 2. Example Troubleshooting Table..........................................................................................0164-2
Winterization Kit, Troubleshooting Procedures..................................................................................... WP 0165
Winterization Kit, Service Upon Receipt ............................................................................................... WP 0166
Service Upon Receipt of Materiel for Winterization Kit.......................................................................0166-1
Removal Instructions ..........................................................................................................................0166-1
Winterization Kit, PMCS Introduction.................................................................................................... WP 0167
Table 1. Leakage Definitions. .............................................................................................................0167-2
Figure 1. Winterization PMCS Routing Diagram ................................................................................0167-3
Winterization Kit, PMCS, Including Lubrication Instructions ................................................................. WP 0168
Lubrication for Winterization Kit..........................................................................................................0168-1
Table 1. Preventive Maintenance Checks and Services for Winterization Kit. ...................................0168-1
Winterization Kit, Installation Instructions ............................................................................................. WP 0169
General...............................................................................................................................................0169-1
Figure 1. Heater Mounting..................................................................................................................0169-3
Figure 2. Exhaust Hose Assembly .....................................................................................................0169-4
Figure 3. Coolant Inlet Hose Assembly ..............................................................................................0169-5
Figure 4. Coolant Outlet Hose Assembly ...........................................................................................0169-5
Figure 5. Control Unit Assembly.........................................................................................................0169-6
Figure 6. Fuel System Assembly........................................................................................................0169-7
Figure 7. Fuse and Wiring Harness....................................................................................................0169-8
Figure 8. Cover and Instrument Panel............................................................................................
....0169-10
Figure 9. Breather Tube Heater Assembly .....................................................................................
....0169-11
Winterization Kit, Control Unit Maintenance: Testing, Inspection, Removal, Replacement,
Installation............................................................................................................................................. WP 0170
Testing................................................................................................................................................0170-1
Inspection ...........................................................................................................................................0170-1
Removal .............................................................................................................................................0170-1
Replacement ......................................................................................................................................0170-2
Installation ..........................................................................................................................................0170-2
xxii
TM 9-6115-644-24
TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Figure 1. Control Unit Maintenance....................................................................................................0170-2
Winterization Kit, Heater Assembly Maintenance: Inspection, Removal, Repair, Replacement,
Installation............................................................................................................................................. WP 0171
Inspection ...........................................................................................................................................0171-1
Removal .............................................................................................................................................0171-1
Repair .................................................................................................................................................0171-2
Replacement ......................................................................................................................................0171-2
Installation ..........................................................................................................................................0171-2
Figure 1. Heater Assembly Maintenance ...........................................................................................0171-3
Winterization Kit, Fuel Pump Maintenance: Testing, Removal, Replacement, Installation................... WP 0172
Testing................................................................................................................................................0172-1
Removal .............................................................................................................................................0172-1
Figure 1. Fuel Pump Maintenance .....................................................................................................0172-2
Replacement ......................................................................................................................................0172-2
Installation ..........................................................................................................................................0172-2
Winterization Kit, Fuel Line Maintenance: Inspection, Removal, Replacement, Installation................. WP 0173
Inspection ...........................................................................................................................................0173-1
INSPECTION......................................................................................................................................0173-1
Removal .............................................................................................................................................0173-1
Replacement ......................................................................................................................................0173-1
REPLACEMENT.................................................................................................................................0173-1
Installation ..........................................................................................................................................0173-1
Figure 1. Fuel Line Maintenance ........................................................................................................0173-2
Winterization Kit, Heater Switch Plate/Heater Switch/Indicator Light Maintenance: Installation,
Inspection, Testing, Removal, Replacement ........................................................................................ WP 0174
Installation - Heater Switch Plate........................................................................................................0174-1
Inspection - Heater Switch..................................................................................................................0174-1
Testing - Heater Switch ......................................................................................................................0174-1
Removal - Heater Switch....................................................................................................................0174-1
Replacement - Heater Switch.............................................................................................................0174-1
Installation - Heater Switch.................................................................................................................0174-2
Inspection - Indicator Light .................................................................................................................0174-2
Figure 1. Heater Switch/Heater Switch Plate/Indicator Light Maintenance ........................................0174-2
Installation - Indicator Light.................................................................................................................0174-2
Removal - Indicator Light....................................................................................................................0174-3
Replacement - Indicator Light.............................................................................................................0174-3
Winterization Kit, Coolant Hose Maintenance: Inspection, Removal, Replacement, Installation.......... WP 0175
Inspection ...........................................................................................................................................0175-1
Removal .............................................................................................................................................0175-1
Replacement ......................................................................................................................................0175-1
Installation ..........................................................................................................................................0175-1
Figure 1. Coolant Hose Maintenance .................................................................................................0175-2
xxiii
TM 9-6115-644-24
TABLE OF CONTENTS - Continued
Page No.
WP Sequence No.
Winterization Kit, Air Inlet and Exhaust Hose Maintenance: Inspection, Removal, Replacement,
Installation............................................................................................................................................. WP 0176
Inspection ...........................................................................................................................................0176-1
Removal .............................................................................................................................................0176-1
Replacement ......................................................................................................................................0176-1
Installation ..........................................................................................................................................0176-1
Figure 1. Air Inlet and Exhaust Hose Maintenance ............................................................................0176-2
Winterization Kit, Wiring Harness Maintenance: Inspection, Testing, Removal, Repair,
Replacement, Installation...................................................................................................................... WP 0177
Inspection ...........................................................................................................................................0177-1
Testing................................................................................................................................................0177-1
Removal .............................................................................................................................................0177-1
Repair .................................................................................................................................................0177-1
Replacement ......................................................................................................................................0177-1
Installation ..........................................................................................................................................0177-1
Figure 1. Wiring Harness Maintenance ..............................................................................................0177-2
Winterization Kit, Igniter/Glow Plug and Resistor Maintenance: Testing, Replacement ....................... WP 0178
Testing................................................................................................................................................0178-1
Replacement ......................................................................................................................................0178-1
Figure 1. Igniter/Glow Plug and Resistor Maintenance ......................................................................0178-2
Winterization Kit, Function Codes/Operating ID Plate Maintenance: Inspection, Installation,
Removal, Replacement......................................................................................................................... WP 0179
Inspection - Function Codes Plate......................................................................................................0179-1
Installation - Function Codes Plate.....................................................................................................0179-1
Removal - Function Codes Plate........................................................................................................0179-1
Replacement - Function Codes Plate.................................................................................................0179-1
Inspection - Operating Instruction Plate .............................................................................................0179-2
Installation - Operating Instruction Plate.............................................................................................0179-2
Removal - Operating Instruction Plate................................................................................................0179-2
Replacement - Operating Instruction Plate.........................................................................................0179-2
Figure 1. Function Codes Plate/Operating Instruction Plate Maintenance.........................................0179-3
Winterization Kit, Removal Instructions ................................................................................................ WP 0180
Removal Procedures ..........................................................................................................................0180-1
Figure 1. Control Unit Removal ..........................................................................................................0180-2
Figure 2. Fuel Pump and Lines Removal ...........................................................................................0180-3
Figure 3. Coolant Inlet Hose Removal................................................................................................0180-4
Figure 4. Coolant Outlet Hose Removal.............................................................................................0180-4
Figure 5. Wiring Harness Removal.....................................................................................................0180-5
Figure 6. Heater Assembly Removal..................................................................................................0180-6
Figure 7. Breather Tube Heater Assembly Removal..........................................................................0180-7
Figure 8. Exhaust Hose Removal.......................................................................................................0180-7
Index
Foldout Figures
xxiv
TM 9-6115-644-24
TABLE OF CONTENTS - Continued
FO 1.
FO 2.
FO 3.
FO 4.
FO 5.
Page No.
WP Sequence No.
........................................................................................................................................................... FP-1
........................................................................................................................................................... FP-3
........................................................................................................................................................... FP-5
........................................................................................................................................................... FP-7
........................................................................................................................................................... FP-9
xxv
TM 9-6115-644-24
How to Use This Manual
This manual contains field instructions for the MEP-805A and MEP-815A Tactical Quiet Generator (TQG) Sets.
NOTE
Throughout the family of manuals, directional orientation in relation to the equipment is described
from the point of view of the operator facing the operator's controls looking out over the
equipment. From this perspective, the end of the equipment containing the operator's controls will
be referred to as the rear.
This manual provides operating procedures, troubleshooting, maintenance, and supporting information required to
operate and maintain the 30 kW 50/60 Hz and 400 Hz Tactical Quiet (TQ) Generator Sets. Listed below are some
of the features included in this TM to help locate and use the provided information.
WORK PACKAGES
This TM has been organized using the WP concept. Each chapter contains a series of WPs rather than sections
and paragraphs. Each WP is designed to stand alone as a complete information module; if the user keeps the
section(s) of this TM in a loose-leaf binder, the user will be able to remove just the WP needed to complete a
specific task. Here are some WP features of which the user should be aware.
Each WP is numbered using a four-digit number beginning with WP 0001. WPs are numbered sequentially
throughout the TM (ex. WP 0016, WP 0020, etc.). The Table of Contents lists each chapter and WP title as well
as all figures and tables contained within each. Figures and tables are numbered sequentially for each WP.
The WP number is located at the top right of each page. It is also located at the bottom of the page with the WP
page number included (0001-1 would be page 1 of the General Information WP (WP 0001, General Information)).
Each WP starts on a right-hand page. This is done so the user can remove a single WP from the paper TM if
needed for a task. Blank pages are assigned a number, but it appears on the preceding or following page. For
example. if page 0001-10 of a WP is blank. page 0001-9 will have the number 0001-9/10 blank; or if page 0001-1
of a WP is blank, page 0001-2 will have the number 0001-1 blank/2.
Each WP containing step-by-step maintenance or troubleshooting procedures will end with the words END OF
TASK, and each WP ends with the statement END OF WORK PACKAGE. Think of each WP as a small,
standalone TM.
Typographical conventions are as follows:
[Unload] indicates a soft key or a switch.
[Previous] + [Next] indicates two simultaneous key presses. [ + ] [ - ] indicates two sequential key presses.
References to equipment Data and Description Plates are printed as they appear on the equipment whenever
possible.
Warnings, Cautions and Notes Definitions
Warnings, cautions, notes. chapter titles, and paragraph headings are printed in bold type. Icons related to
warnings are shown directly above the warning text.
The following definitions apply to WARNINGS, CAUTIONS and NOTES found throughout this publication.
Warning, cautions and notes provide supplemental information. Personnel must understand and apply these
Warnings, Cautions and Notes during many phases of operation and maintenance to ensure personnel safety and
health and the protection of property. Portions of this information may be repeated in certain chapters of this
publication for emphasis.
WARNING
A warning identifies a clear danger to the person doing that procedure.
CAUTION
A caution identifies risk of damage to the equipment.
xxvi
TM 9-6115-644-24
NOTE
A note highlights essential procedures, conditions, or statements or conveys important
instructional data to the user.
CHAPTER OVERVIEW
Chapter 1 - General Information, Equipment Description and Theory of Operation
Chapter 1 provides an introduction to the 15 kW 50/60 Hz and 400 Hz Tactical Quiet (TQ) Generator Sets. It is
divided into three work packages, as follows:
General Information. This work package provides general information about this manual and the related forms
and records. Instructions are provided for making equipment improvement recommendations. Coverage includes
a reference to the TM that contains instructions on destruction of materiel to prevent enemy use. Also, a
nomenclature cross-reference list is provided as well as a list of abbreviations and acronyms.
Equipment Description and Data. This work package describes capabilities, characteristics, and features. It
provides basic equipment data and shows the locations of major components. Descriptions of the major
components are also provided.
Theory of Operation. This work package provides functional descriptions of the equipment.
Chapter 2 - Field and Sustainment Troubleshooting Procedures
Chapter 2 covers troubleshooting procedures of the 15 kW 50/60 Hz and 400 Hz Tactical Quiet (TQ) Generator
Sets to be performed by the operator. The chapter is divided as follows:
Field and Sustainment Troubleshooting Index. This work package provides a troubleshooting introduction and
malfunction/symptom index to direct you to the appropriate troubleshooting procedure at the field and sustainment
level.
Field and Sustainment Troubleshooting Procedures. This work package provides troubleshooting procedures
and corrective actions that are to be performed by the operator. It also provides references to the applicable
technical manuals.
Chapter 3 - Field and Sustainment Maintenance Instructions
Chapter 3 covers maintenance procedures for the 30 kW 50/60 Hz and 400 Hz Tactical Quiet (TQ) Generator
Sets to be performed by the operator. Its purpose is to provide you with the information that you need to keep the
equipment in good operating condition. The chapter is divided as follows:
Service Upon Receipt. This work package contains instructions for inspecting and servicing the equipment when
it is received. It includes instructions for unpacking the equipment when it is received. The instructions also
include unpacking and stowing the basic issue items that accompany the 15 kW 50/60 Hz and 400 Hz Tactical
Quiet (TQ) Generator Sets. Also included are instructions on positioning the equipment for operation and
connecting an external fuel source.
Field and Sustainment Preventive Maintenance Checks and Services (PMCS) Introduction. This work
package provides a detailed explanation of each table entry in the PMCS table along with applicable warnings,
cautions and notes prior to starting on the PMCS procedures.
Field and Sustainment Preventive Maintenance Checks and Services (PMCS). This work package contains
detailed instructions that the operator must perform before, during, and after preventive maintenance checks and
services. Coverage includes all operator PMCS for the equipment.
Lubrication Instructions. This work package provides references to the applicable lubrication instructions.
Field and Sustainment Maintenance Procedures. These work packages refer the operator to the preventive
maintenance checks and services required by WP 0008.
Preparation for Storage or Shipment. This work package provides information on short-term, intermediate-term,
and long-term storage.
Illustrated List of Manufactured Items. These work packages provide instructions for making the items
authorized to be manufactured or fabricated at the field maintenance level.
xxvii
TM 9-6115-644-24
Torque Limits. This work package lists standard torque values for bolts and screws used in maintaining the
equipment.
Chapter 4 - Supporting Information
The chapter is divided as follows:
References. This work package lists all publications referenced in the various chapters of the technical manual.
The listing includes the title and document number of each publication.
Maintenance Allocation Chart (MAC) Introduction. This work package explains what is covered in the
maintenance allocation chart.
Maintenance Allocation Chart (MAC). This work package has three sections, as follows:
Maintenance Allocation Chart (MAC). Table 1 contains a tabular listing that assigns maintenance functions
to specific maintenance levels. It lists the work time needed to perform each maintenance function at the
assigned level. It also contains a column that has entries keyed to the tools and equipment listed in Table 2.
Another column has entries keyed to the remarks in Table 3.
Tool and Test Equipment Requirements. Table 2 contains complete identification information for the items
referenced in the tools and equipment column of Table 1.
Remarks. Table 3 provides additional information for each entry in the remarks column of Table 2.
Expendable and Durable Items List. This work package lists expendable/durable supplies and materials
needed to operate and maintain your equipment. The work package contains two sections, as follows:
Introduction. This section explains the entries in Table 1.
Expendable and Durable Items List. The list indicates the maintenance level that needs each item and
identifies the items by National Stock Number (NSN), description, and unit of measure.
Chapter 5 - Winterization Kit
Chapter 5 provides Field and Sustainment Level information on the operation, troubleshooting and maintenance
of the winterization kit designed to be mounted in generator sets where extreme cold temperatures are
anticipated. The chapter is divided as follows:
General Information.This work package provides general information concerning the scope of this chapter in the
discussion of the operation, maintenance and troubleshooting procedures for the winterization kit. It also contains
Repair Parts; Special Tools; Test, Measurement, and Diagnostic Equipment (TMDE); and Special Support
Equipment information concerning the RPSTL, support equipment, and maintenance repair parts for the
winterization kit at the field level.
Equipment Description and Data.This work package describes winterization kit capabilities, characteristics, and
features. It provides descriptions of the major components and tabulated data for the heater.
Theory of Operation. This work package provides a functional description of the winterization kit.
Description and Use of Controls and Indicators. This work package describes and illustrates winterization kit
controls and indicators to ensure proper operations.
Service Upon Receipt. This work package provides information concerning the service upon receipt required by
field for the winterization kit already installed on the generator set.
Preventive Maintenance Checks and Services (PMCS) Introduction. This work package provides a detailed
explanation of each table entry in the PMCS table along with applicable warnings, cautions and notes prior to
starting on the PMCS procedures of the winterization kit.
Preventive Maintenance Checks and Services (PMCS). This work package contains detailed instructions that
must be performed before, during, and after preventive maintenance checks and services of the winterization kit.
Lubrication Instructions. This work package provides the information that no lubrication is required on the
winterization kit.
Installation Instructions. This work package provides the procedures for installing the winterization kit on the 30
kW generator set.
Troubleshooting Index. This work package provides a troubleshooting introduction and malfunction/symptom
index to direct you to the appropriate troubleshooting procedure.
xxviii
TM 9-6115-644-24
Troubleshooting Procedures. This work package lists diagnostic and symptom related malfunctions that may
occur during operation of the generator set with the winterization kit installed.
Maintenance Procedures. These work packages provide the maintenance procedures for the winterization kit
components.
Removal Instructions. This work package provides instructions for removing the winterization kit from the 30 kW
generator set.
HOW TO FIX A GENERATOR SET MALFUNCTION
Determining the Cause
Finding the cause of a malfunction, troubleshooting, is the first step in fixing the generator set and returning it to
operation. Follow these simple steps to determine the root of the problem:
1. Turn to the Table of Contents in this manual.
2. Locate "Troubleshooting Procedures" and turn to the page indicated.
3. Follow the instructions in the references.
Preparing for a Task
Be sure that you understand the entire maintenance procedure before beginning any maintenance task. Make
sure that all parts, materials, and tools are handy. Read all steps before beginning. Prepare to do the task as
follows:
1. Carefully read the entire task before starting. It tells you what you will need and what you have to know to
start the task. DO NOT START THE TASK UNTIL:
a. You know what is needed
b. You have everything you need
c. You understand what to do
2. If parts are listed, they can be drawn from technical supply. Before you start the task, check to make sure you
can get the needed parts.
3. If expendable/durable supplies or materials are needed, get them before starting the task. Refer to WP 0160
for the correct nomenclature and NSN.
How to Do the Task
Before starting, read the entire task. Be sure that you understand the entire procedure before you begin the task.
As you read, remember the following:
1. PAY ATTENTION TO WARNINGS, CAUTIONS, AND NOTES.
2. Use the List of Abbreviations/Acronyms if you do not understand the special abbreviations or unusual terms
used in this manual.
3.
The following are standard maintenance practices. Instructions about these practices are usually not included
in task steps. When standard maintenance practices do not apply, the task steps will tell you.
a. Tag electrical wiring before disconnecting it.
b. Discard used preformed packing, retainers, gaskets, cotter pins, lockwashers, and similar items. Install
new parts to replace the discarded items.
c. Coat packing before installation, in accordance with the task instructions.
d. Disassembly procedures describe the disassembly needed for total authorized repair. You may not need
to disassemble an item as far as described in the task. Follow the disassembly steps only as far as
needed to repair/replace worn or damaged parts.
e. Clean the assembly, subassembly, or part before inspecting it.
f. Before installing components having mating surfaces, inspect the mating surfaces to make sure they are
in serviceable condition.
g. Hold the bolt (or screw) head with a wrench (or screwdriver) while tightening or loosening a nut on the
bolt (or screw).
h. Torque to the special torque cited when the task instructions include the words "torque to." Use standard
torques at all other times.
i. When a cotter pin is required, align the cotter pin holes within the allowable torque range.
xxix
TM 9-6115-644-24
j.
Inspect for foreign objects after performing maintenance.
xxx
TM 9-6115-644-24
CHAPTER 1
FIELD GENERAL INFORMATION, EQUIPMENT
DESCRIPTION AND THEORY OF OPERATION
FOR
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL
QUIET GENERATOR SETS
TM 9-6115-644-24
CHAPTER 1
GENERAL INFORMATION, EQUIPMENT DESCRIPTION AND THEORY OF OPERATION
WORK PACKAGE INDEX
Title
WP Sequence No.
General Information.............................................................................................................................................0001
Equipment Description and Data.........................................................................................................................0002
Theory of Operation.............................................................................................................................................0003
TM 9-6115-644-24
0001
FIELD AND SUSTAINMENT MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
GENERAL INFORMATION
SCOPE
Type of Manual
This manual contains Field and Sustainment maintenance instructions for the 30 kW 50/60 Hz and 400 Hz
Tactical Quiet (TQ) Generator Sets (Figure 1), herein referred to as generator sets. Included are descriptions of
major components and their functions in relation to other components.
Model Numbers and Equipment Names
Model Number
Equipment Name
MEP-805A
Generator Set, Skid Mounted, Tactical Quiet 30 kW 50/60 Hz
MEP-815A
Generator Set, Skid Mounted, Tactical Quiet 30 kW 400 Hz
Purpose of Equipment
The generator set provides tactical quiet AC power. The generator set is easily transported, operated, and
maintained.
LIMITED APPLICABILITY
Some portions of this publication are not applicable to all services. These portions are prefixed to indicate the
service(s) to which they pertain: (A) for Army, (F) for Air Force, (N) for Navy, and (MC) for Marine Corps.
MAINTENANCE FORMS, RECORDS, AND REPORTS
1.
2.
3.
4.
(A) Department of the Army forms and procedures used for equipment maintenance will be those prescribed
by (as applicable) DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual; DA
PAM 738-751, Functional Users Manual for the Army Maintenance Management Systems - Aviation
(TAMMS-A); or AR 700-138, Army Logistics Readiness and Sustainability.
(MC) Maintenance forms and records used by Marine Corps personnel are prescribed by TM 4700-15/1.
(N) Navy users should refer to their service peculiar directives to determine applicable maintenance forms
and records to be used.
(F) Maintenance forms and records used by Air Force personnel are prescribed in AFI 21-101 and the
applicable TO 00-20 Series Technical Orders.
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATION (EIR)
If your generator set needs improvement, let us know. Send us an EIR. You, the user, are the only one who can
tell us what you don't like about your equipment. Let us know why you don't like the design or performance. If you
have Internet access, the easiest and fastest way to report problems or suggestions is to go to
https://aeps.ria.army.mil/aepspublic.cfm (scroll down and choose the "Submit Quality Deficiency Report" bar). The
Internet form lets you choose to submit an Equipment Improvement Recommendation (EIR), a Product Quality
Deficiency Report (PQDR or a Warranty Claim Action (WCA). You may also submit your information using an SF
368 (Product Quality Deficiency Report). You can send your SF 368 via e-mail, regular mail, or facsimile using the
addresses/facsimile numbers specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS)
Users Manual. We will send you a reply.
0001-1
TM 9-6115-644-24
Figure 1. Generator Set, 30 kW, Tactical Quiet.
0001-2
0001
TM 9-6115-644-24
0001
CORROSION PREVENTION AND CONTROL (CPC)
Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any
corrosion problems with this item be reported so that the problem can be corrected and improvements can be
made to prevent the problem in future items.
Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals.
It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron.
Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue,
and/or cracking.
Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen),
solvation (solvents), or photolytic (light, typically UV) processes. The most common exposures are excessive heat
or light. Damage from these processes will appear as cracking, softening, swelling, and/or breaking.
SF Form 368, Product Quality Deficiency Report should be submitted to the address specified in DA PAM 750-8,
The Army Maintenance Management System (TAMMS) Users Manual.
LEVELS OF MAINTENANCE
(A) Army users shall refer to the Maintenance Allocation Chart (MAC) for tasks and levels of maintenance to be
performed.
(F) (MC) Refer to the Source Maintenance Recoverability (SMR) Codes for maintenance to be performed.
(N) Navy users shall determine their maintenance levels in accordance with their service directives.
DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE
(A) (MC) Destruction of the generator set to prevent enemy use shall be in accordance with TM 750-244-3.
(F) (N) Air Force and Navy users shall refer to their service directives to obtain procedures for destruction of
material to prevent enemy use.
PREPARATION FOR STORAGE OR SHIPMENT
Information on Preparation for Storage or Shipment refer to WP 0128, Preparation for Storage or Shipment.
LIST OF ABBREVIATIONS/ACRONYMS
Not applicable.
QUALITY OF MATERIEL
Material used for replacement, repair, or modification must meet the requirements of this TM 9-6115-644-24. If
Quality of Material requirements are not state in this TM 9-6115-644-24, the material must meet the requirements
of the drawings, standards, specifications, or approved engineering change proposals applicable to subject
equipment.
SAFETY, CARE, AND HANDLING
Nuclear, Biological, Chemical (NBC) Contamination
The generator set is capable of being operated by personnel wearing nuclear, biological, or chemical (NBC)
protective clothing without special tools or support equipment. Refer to FM 3-5, NBC decontamination, for
information on decontamination procedures. The following are specific procedures for the generator set:
Control panel indicators, sealing gaskets, rubber sleeves, rope draw cords at output terminal access ports, control
panel door gaskets, access door gaskets, rubber tubing and belts within the engine compartment, coverings for
electrical conduits, external water drain tubing, and retaining cords for slave receptacle covers will absorb and
retain chemical agents. Replacement of these items is the recommended method of decontamination.
Lubricants, fuel, coolant, or battery fluid may be present on the external surfaces of the generator set or
0001-3
TM 9-6115-644-24
0001
components due to leaks or normal operation. These fluids will absorb NBC agents. The preferred method of
decontamination is removal of these fluids using conventional decontamination methods in accordance with FM
3-5.
Continued decontamination of external generator set surfaces with super-tropical bleach (STB)/ decontaminating
solution number 2 (DS2) will degrade clear plastic indicator coverings to a point where reading indicators will
become impossible. This problem will become more evident for soldiers wearing protective masks. Therefore, the
use of STB or DS2 decontaminants in these areas should be minimized. Indicators should be decontaminated
with warm soapy water.
External surfaces of the control panel assembly that are marked with painted or stamped lettering will not
withstand repeated decontamination with STB or DS2 without degradation of this lettering. The recommended
method of decontamination for these areas is warm soapy water.
Areas that will entrap contaminants, making efficient decontamination extremely difficult, include the following:
space behind knobs and switches on the control panel, exposed heads of screws, areas adjacent to and behind
exposed wiring conduits, hinged areas of access doors, spaces behind externally mounted equipment
specification data plates, areas around external oil drain valve, retaining chains for external receptacle covers,
areas behind external receptacle covers, access door locking mechanisms, recessed wells for access door
handles, fuel caps, load output terminal board access door, slave receptacles, frequency adjustment controls,
areas around tiedown/lifting rings, crevices around access doors, external screens covering ventilation areas, and
areas adjacent to the external fuel drain valve. Replacement of these items, if available, is the preferred method
of decontamination. Conventional decontamination methods should be used on these areas, while stressing the
importance of thoroughness and the probability of some degree of continuing contact and vapor hazard.
In an NBC contaminated environment, the generator set should be operated with all access doors closed to
reduce the effects of contamination.
The use of overhead shelters or chemical protective covers is recommended as an additional means of protection
against contamination in accordance with FM 3-5. When using covers, care should be taken to provide adequate
space for air flow and exhaust.
For additional NBC information, refer to FM 3-3 and 3-4. Other services use applicable publications for NBC.
SUPPORTING INFORMATION FOR REPAIR PARTS, SPECIAL TOOLS, TMDE AND SUPPORT EQUIPMENT
Tools and Equipment
There are no special tools or support equipment required to perform any level of maintenance on the generator
set. A list of recommended tools and support equipment required to maintain the generator set is contained in WP
0158, Table 2.
Maintenance Repair Parts
Repair parts and equipment are listed and illustrated in the repair parts and special tools list manuals TM
9-6115-644-24P and TM 9-2815-255-24P.
Fabrication of Tools and Equipment
No requirement exists for fabrication of tools and equipment for maintenance of the generator set.
END OF WORK PACKAGE
0001-4
TM 9-6115-644-24
0002
FIELD AND SUSTAINMENT MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
EQUIPMENT DESCRIPTION AND DATA
EQUIPMENT CAPABILITIES AND FEATURES
The generator sets, models MEP-805A and MEP-815A (WP 0001, Figure 1), are fully enclosed, self-contained,
skidmounted, portable units. They are equipped with controls, instruments, and accessories necessary for
operation as single units or in parallel with another unit of the same class and mode. The generator sets consist of
a diesel engine, brushless generator, excitation system, speed-governing system, fuel system, 24 VDC starting
system, control system, and fault system.
TABULATED/ILLUSTRATED DATA
For generator set tabulated data, refer to Table 1.
Table 1. Tabulated Data.
Item
1.
Characteristic
Generator Set:
Model Number:
30 kW 50/60 Hz
MEP-805A
30 kW 400 Hz
MEP-815A
National Stock Number (NSN):
MEP-805A
6115-01-274-7389
MEP-815A
6115-01-274-7394
Overall Length:
MEP-805A
79.7 in. (202.5 cm)
MEP-815A
79.7 in. (202.5 cm)
Overall Width:
MEP-805A
35.7 in. (90.8 cm)
MEP-815A
35.7 in. (90.8 cm)
Overall Height:
MEP-805A
55 in. (139.7 cm)
MEP-815A
55 in. (139.7 cm)
Dry Weight (Less Basic Issue Items):
MEP-805A
2,732 lb. (1239.2 kg.)
MEP-815A
2,732 lb. (1239.2 kg.)
Wet Weight:
2.
MEP-805A
2,931 lb. (1329.5 kg.)
MEP-815A
2,931 lb. (1329.5 kg.)
Engine (MEP-805A/MEP-815A):
Manufacturer
John Deere
Model
4039T
Type
Four cylinder, four cycle, turbocharged diesel
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Table 1. Tabulated Data. - Continued
Item
Characteristic
Displacement
239 cu. in. (3.9 liters)
Altitude Degradation, 4,000 ft (1,220m) to 80,00 ft
(2,440m)
3.5% per 1,000 ft (305m)
Firing Order
1, 3, 4, 2
Cold Weather Starting Aid System Use
40 °F (4 °C) or below
Valve Tappet Clearance Adjustment:
3.
4.
5.
Hot or Cold (Intake)
0.014 in. (0.35 mm)
Hot or Cold (Exhaust)
0.018 in. (0.45 mm)
Cooling System (MEP-805A/MEP-815A):
Type
Pressurized radiator and pump
Capacity
15.5 qts (14.7 liters)
Normal Operating Temperature
170-200 °F (77-93 °C)
Temperature Indicating System Voltage Rating
24 VDC
Lubricating System (MEP-805A/MEP-815A):
Type
Full flow, circulating pressure
Oil Pump Type
Positive displacement gear
Normal Operating Pressure
25-60 psi (172-414 kPa)
Oil Filter Type
Full flow, spin-on, replaceable element
Capacity
6 qts (5.7 liters)
Pressure Indicating System Voltage Rating
24 VDC
Fuel System (MEP-805A/MEP-815A):
Type of Fuel
DF-1, DF-2, DF-A, JP4, JP5, JP8
Fuel Tank Capacity
14 gal. (53 liters)
Fuel Consumption Rate:
MEP-805A
2.60 gal (9.8 liters) per hour
MEP-815A
2.75 gal (10.4 liters) per hour
Auxiliary Fuel Pump:
Voltage Rating
24 VDC
Delivery Pressure
5.0-6.5 psi (34.5-65.5 kPa) (max)
Fuel Level Switch:
6.
Type
Float
Current
0.6 amps (min) at 24 VDC
Engine Starting System
(MEP-805A/MEP-815A):
Batteries
Two 12 volt, connected in series
Starter:
Manufacturer
Nippondenso Co. Ltd.
Model
RE39930A
Voltage Rating
24 VDC
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Table 1. Tabulated Data. - Continued
Item
Drive Type
Characteristic
Gear reduction
Battery Charging Alternator:
7.
Manufacturer
Prestolite
Model
8EM3002GC
Amperage Rating
42 amps at 24 VDC
Protective Fuse
30 amps
AC Generator (MEP-805/MEP-815):
Manufacturer
Marathon Electric
Type
Rotating field, synchronous
Load Capacity
30 kW
Current Ratings:
120/208 (240/416) Volt Connection
8.
50 Hz
86 (43) amps
Power Factor
0.8
Cooling
Fan cooled
Drive Type
Direct coupling
Duty Classification
Continuous
60 Hz
104 (52) amps
400 Hz
104 (52) amps
Governing System (MEP-805A/MEP-815A):
Load Measuring Unit:
Manufacturer
Technology Research
Model
19310
Governor Control Unit:
9.
Manufacturer
Barber-Coleman
Model
DYNA 10502-002-0-2
Protection Devices (MEP-805A/MEP-815A):
Low Oil Pressure Switch:
Trip Pressure
15±3 psi (103.4±20.7 kPa)
Voltage Rating
12/24 VDC
Current Rating
7 amps resistive; 4 amps inductive
Coolant High Temperature Switch:
Trip Temperature
225±5 °F (107±3 °C)
Voltage Rating
20-32 VDC
Current Rating
7 amps resistive; 4 amps inductive
Overspeed Switch:
Element Trip and Reset
2200±40 rpm
Voltage Rating
28 VDC
Current Rating
1 amp
Overvoltage Relay:
Trip Point Conditions
155±1 VAC for no less than 200 milliseconds (120 VAC
coil winding)
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Table 1. Tabulated Data. - Continued
Item
Trip Point
Characteristic
No more than 1.25 seconds after trip conditions exist
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
Figure 1. Generator Set Components.
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NOTE
All locations (Figure 1) of the index numbers referenced herein are given facing the control box
side (rear) of the generator set.
Malfunction Indicator Panel (1). The malfunction indicator panel is located to the left of the control panel
assembly. It indicates malfunctions of the generator set components.
Control Panel Assembly (2). The generator set control panel assembly is located at the rear of the generator set
and contains controls and instruments for operating the engine and the generator.
Muffler (3). The muffler and exhaust tubing are connected to the turbocharger on the engine. The exhaust exits
from the top of the generator set housing. Gases are exhausted upward.
NATO Slave Receptacle (4). The NATO slave receptacle is located on the right side (front) of the generator set.
It is a NATO receptacle used for remote battery connection.
Fan Belt (5). The fan belt is located in the engine compartment on the front of the engine. The belt drives the fan,
water pump, and battery charging alternator.
Battery Charging Alternator (6). The battery charging alternator is located on the right side of the engine. It is
capable of maintaining the batteries in a state of full charge in addition to providing the required 24 VDC control
power.
Oil Filter (7). The oil filter is located in the engine compartment on the right side. The filter removes impurities
from the engine lube oil.
Dipstick (8). The dipstick is located in the engine compartment on the right side. The dipstick shows the lube oil
level in the engine crankcase.
Starter (9). The starter is located on the right side of the engine. The electric cranking motor mechanically
engages the engine flywheel in order to start the diesel engine.
Fuel Filter/Water Separator (10). The fuel filter/water separator is located in the engine compartment on the right
side. The element removes impurities and water from the diesel fuel.
AC Voltage Reconnection Terminal Board (11). The AC voltage reconnection terminal board is located on the
right side (rear) of the generator set. The board allows reconfiguration from 120/208 to 240/416 VAC output.
Load Output Terminal Board (12). The load output terminal board is located on the right side (rear) of the
generator set. Four AC output terminals are located on the board. They are marked L1, L2, L3, and L0. A fifth
terminal, marked GND, is located next to the output terminals and serves as equipment ground for the generator
set. A removable, solid copper bar is connected between the L0 and GND terminals.
Skid Base (13). The skid base supports the generator set. It has fork lift access openings and cross members for
short distance movement. The skid base has provisions in the bottom for installation of the generator set on a
trailer.
CONVENIENCE RECEPTACLE (14). The CONVENIENCE RECEPTACLE is a 120 VAC receptacle used to
operate small plug-in type equipment.
PARALLELING RECEPTACLE (15). The PARALLELING RECEPTACLE is used to connect the paralleling cable
between two generator sets of the same size and mode to operate in parallel.
Diagnostic Connector (16). The diagnostic connector is a multi-pin plug that is wired to specific points in the
generator set electrical system to enable monitoring and troubleshooting of the generator set operation at a single
location.
Air Cleaner Assembly (17). The air cleaner assembly is located on the left side behind the air cleaner access
door. It consists of a dry-type, disposable paper filter and canister. The air cleaner assembly features a dust
collector which traps large dust particles. The air cleaner assembly has a restriction indicator which will pop up
during operation when the air cleaner requires servicing.
AC Generator (18). The AC generator is a single bearing, drip-proof, synchronous, brushless, three phase,
air-cooled generator. The generator is coupled directly to the rear of the diesel engine.
Fuel Tank (19). The 23 gallon (87.1 liters) fuel tank is located in the front of the generator set below the engine
and between the skid base side members. The fuel tank is a fuel reservoir and has sufficient capacity to enable
the generator set to operate for at least 8 hours without refueling.
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Engine (20). The generator is powered by a four cylinder, four cycle, fuel injected, turbocharged, liquidcooled
diesel engine which occupies the front half of the generator set. The engine is also equipped with a fuel
filter/water separator, oil filter, and an air cleaner assembly. Protection devices automatically stop the engine
during conditions of high coolant temperature, low oil pressure, no fuel, overspeed, or overvoltage.
DEAD CRANK Switch (21). The DEAD CRANK switch is located in the engine compartment on the left side. The
switch allows the engine to be turned over without starting for maintenance purposes.
Water Pump (22). The water pump is located in the engine compartment on the front of the engine. The pump
circulates the engine coolant through the engine block and the radiator.
Radiator (23). The radiator is located at the front of the generator set. It acts as a heat exchanger for the engine
coolant.
Batteries (24). Two batteries are located at the front of the generator set. The batteries are electrolyte
serviceable, lead acid, 12 VDC type. After starting, the generator set is capable of operating with batteries
removed. A diode, located behind the control panel, protects the generator set if the batteries are incorrectly
connected.
DIFFERENCES BETWEEN MODELS
The differences between models of the generator sets covered in this manual are as follows:
a. Model MEP-805A is equipped with a 50/60 Hz generator, 50/60 Hz frequency meter, and 50/60 Hz frequency
selector switch.
b. Model MEP-815A is equipped with a 400 Hz generator and a 400 Hz frequency meter.
EQUIPMENT DATA
For generator set performance characteristics, refer to Table 2.
Table 2. Performance Characteristics.
Item
1.
MEP-805A
MEP-815A
Voltage:
Voltage Waveform Deviation
Factor
5% (max)
5% (max)
Single Voltage Harmonics
2% (max)
2% (max)
b.
Voltage Unbalance
5% of rated voltage (max)
5% of rated voltage (max)
c.
Phase Balance Voltage
1% of rated voltage (max)
1% of rated voltage (max)
d.
Voltage Modulation
1% (max)
1% (max)
e.
Voltage Regulation
1% (max)
1% (max)
f.
Short-term Stability (30 seconds)
1% of rated voltage
1% of rated voltage
g.
Long-term Stability (4 hours)
2% of rated voltage
2% of rated voltage
h.
Voltage Drift (60 °F (16 °C)) in 8
hour period)
±1% (max)
±1% (max)
i.
Dip and Rise for Rated Load
15% of rated voltage (max)
12% of rated voltage (max)
Recovery Time
0.5 second
0.5 second
Dip for Low Power Factor Load
30% of no-load voltage (max)
25% of no-load voltage (max)
Recovery Time
0.7 second
0.7 second
85% of no-load voltage (max)
85% of no-load voltage (max)
a.
j.
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Table 2. Performance Characteristics. - Continued
Item
k.
MEP-805A
MEP-815A
Adjustment Range VAC
50 Hz
400 Hz
120/208 V Connection
190-213 V
197-229 V
240/416 V Connection
380-426 V
395-458 V
60 Hz
2.
120/208 V Connection
197-240 V
240/416 V Connection
395-480 V
Frequency:
a.
Regulation
0.25% of rated frequency
0.25% of rated frequency
b.
Short-term Steady-state Stability
(30 seconds)
0.5% of rated frequency
0.5% of rated frequency
c.
Long-term Steady-state Stability
(4 hours)
1% of rated frequency
1% of rated frequency
d.
Frequency Drift (60 °F (16 °C) in 8 0.5% (max)
hour period)
e.
Undershoot with Application of
Load
4% of rated frequency (max)
4% of rated frequency (max)
Recovery Time
2 seconds
1 second
Overshoot with Application of
Load
4% of rated frequency (max)
1.5% of rated frequency (max)
Recovery Time
2 seconds
1 second
Adjustment Range
48-52 Hz, not below 45 Hz for
50 Hz operation
390-420 Hz, not below 370 Hz
or above 430 Hz
f.
g.
0.5% (max)
58-62 Hz, not above 65 Hz for
60 Hz operation
NOTE
Maintenance procedures for the 50/60 Hz (MEP-805A) and 400 Hz (MEP-815A) generators are
identical except where noted.
GENERATOR ASSEMBLY TECHNICAL DESCRIPTION
General
Revolving field type generators have a DC field revolving within a stationary AC winding called the stator. AC
power is distribution from the generator through leads connected to the stator windings. There are no sliding
contacts between the AC winding and the load, therefore, great amounts of power may be drawn from this
generator.
NOTE
Refer to Figure 2 as needed.
To energize the field, DC excitation must be applied to the generator field coils. The excitation current is supplied
from a brushless exciter mounted on the generator shaft.
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The brushless exciter is actually an AC generator with its output rectified through a full wave bridge circuit. This
type of brushless exciter will provide the necessary excitation current. The generator set field flash circuit,
activated during each engine start, applies voltage to the exciter stator to begin the voltage buildup process to
energize the generator field.
The generator output voltage is controlled by controlling the alternating field current. This is accomplished by
regulating the exciter field coil voltage. The exciter field coil voltage is regulated with a solidstate-type AC Voltage
Regulator.
Figure 2. Brushless Generator Schematic.
Damper Bars
Damper bars are inserted through the field laminations and welded at the end to a solid copper plate. The damper
windings provide stable parallel operation, reduce damping current losses, and limit the increase of third harmonic
voltage with increase in load.
Brushless Exciter
The brushless exciter consists of an armature with a three-phase AC winding and rotating rectifier assembly
within a stationary field. The stationary exciter field assembly is mounted in the main generator frame. The exciter
armature is press-fit and keyed onto the shaft assembly. The rotating rectifier assembly slides over the bearing
end of the generator rotor shaft and is secured with bolts and washers to an adapter hub which is shrunk onto the
generator shaft.
Rotating Rectifier Bridge
The rotating rectifier bridge consists of rectifying diodes mounted on a brass heat sink which is in turn mounted on
an insulating ring. The entire assembly bolts to the adapter on the generator shaft. Therefore, the rotating rectifier
assembly will rotate with the exciter armature eliminating the need for any sliding contacts between the exciter
output and the alternator field.
Exciter Field
The exciter field on the high frequency exciter consists of laminated segments of high carbon steel which are
fitted together to make up the field poles. The field coils are placed into the slots of the field poles.
Exciter Field Coil Voltage Source
Field coil DC voltage is obtained by rectifying the voltage from a phase to neutral line of the generator output or
other appropriate terminal to provide the needed voltage reference. The rectifier bridge is an integral part of the
static regulator. The static regulator senses a change in the generator output and automatically regulates current
flow in the exciter field coil circuit to increase or decrease the exciter field strength. An external adjust rheostat
sized to be compatible with the regulator is used to provide adjustment to the regulator sensing circuit.
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Balance
The rotor assembly is precision balanced to a high degree of static and dynamic balance. Balance is achieved
with the balance lugs on the field pole tips. The balance will remain dynamically stable at speeds in excess of the
design frequencies.
Bearing
The generator rotor assembly is suspended on shielded, factory-lubricated ball bearings. They are greased for life
and do not require lubrication.
Stator Assembly
The stator assembly consists of laminations of steel mounted in a rolled steel frame. Random wound stator coils
are fitted into the insulated slots.
END OF WORK PACKAGE
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FIELD AND SUSTAINMENT MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
THEORY OF OPERATION
INTRODUCTION
This work package contains functional descriptions of the generator set, explains how the controls and indicators
interact with the systems, and provides the location and description of major components.
PRINCIPLES OF OPERATION
Fault System
The fault system (Figure 1) protects the generator set and any connected load against the potential faults
described below and provides an indication of any incurred fault. The following summary of the fault system will
assist in understanding the operation of the other generator set systems. Additional details relating to specific
protection devices are also provided in the descriptions of the respective systems.
The fault system consists of the malfunction indicator, low fuel level float switch, fuel float switch module, fuel
level relay, low oil pressure switch, coolant high temperature switch, overvoltage relay, overload/short circuit
relay, overspeed switch, overspeed relay, OVERSPEED RESET switch, undervoltage relay, reverse power relay,
engine fault relay, electrical fault relay, and BATTLE SHORT switch. In addition to the fault indicator lamps, the
malfunction indicator includes the PUSH TEST & RESET LAMPS switch which, when depressed, illuminates all
the lamps and resets any fault indication.
Activation of any one of the following protection devices will cause three events to occur. The AC circuit
interrupter relay will open; the generator set engine will be shut down; and a fault indicator lamp will be illuminated
to show which malfunction occurred.
Coolant High Temperature Switch. This device will activate when the engine coolant leaving the engine
exceeds 225±5 °F (107±3 °C).
Low Oil Pressure Switch. This device activates when the engine lubrication oil pressure falls below 15±3 psi
(103.4±20.7 kPa).
Low Fuel Level Float Switch. This device will activate when the fuel level falls to a point at which the operating
time of the set at rated load is four minutes.
Overvoltage Relay. This device will activate when the 120-volt generator coil winding has risen to and remained
at any value greater than 155±1 volts.
Overspeed Relay. This device will activate when the engine speed exceeds 2200±40 rpm.
Fuel Float Switch Module. The fuel float switch module is a device that prevents inadvertent engine shutdown
by providing a one second delay after actuation of the low fuel level float switch.
Electrical Protection. Electrical protection devices will cause two events to occur. The AC circuit interrupter relay
will open, and a fault indicator lamp will illuminate to indicate which fault occurred.
Short Circuit Relay. This device will activate when the set output current in any phase exceeds 425 percent of
rated value.
Overload Relay. This device will operate when the load current in any phase exceeds 110 percent of rated value.
Undervoltage Relay. This device will activate instantaneously when the 120 volt generator coil winding has
dropped to 48 volts and will trip after time delay when the coil voltage drops below 99 volts.
Reverse Power Relay. This device will operate if power flow into the generator set exceeds 20 percent of rated
value.
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Although it is possible for more than one fault to occur at one time during operation, only the first fault to occur will
be displayed by the malfunction indicator. The activated indicator lamp circuit remains illuminated until the
malfunction indicator is reset. The lamp will be off with the MASTER SWITCH in the OFF position and will be
reilluminated when the MASTER SWITCH is turned to one of the RUN positions. Resetting a fault indication is
done in two steps. First, push the PUSH TEST & RESET LAMPS switch located on the malfunction indicator.
Second, move the MASTER SWITCH to the OFF position. After a shutdown due to engine overspeed, the
OVERSPEED RESET switch must be actuated to reset the engine electrical control circuit before the engine can
be restarted.
After the generator set engine has been started, the BATTLE SHORT switch can be used to override all of the
potential faults except engine overspeed and short circuit.
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Figure 1. Fault System.
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Fuel System
The fuel system (Figure 2) includes a primary subsystem and an auxiliary subsystem.
The primary subsystem consists of fuel lines, fittings, fuel tank, low fuel level float switch, fuel float switch module,
fuel level sender, FUEL LEVEL indicator, transfer pump, fuel filter/water separator, injection pump, and injectors.
The injection pump includes a 24 VDC fuel shutoff valve.
The injection pump output is controlled by the electronic governor control and governor actuator. When the
electronic governor control is deenergized, electrical power is removed from the governor actuator which is
spring-loaded to the fuel shutoff position. The electronic governor control is energized by turning the MASTER
SWITCH to the START position or either of the two RUN positions. With the engine cranking or running, fuel is
drawn from the fuel tank by the transfer pump. After reaching the transfer pump, fuel passes through a fuel
filter/water separator where water and small impurities are removed. The fuel then goes to the injection pump.
With the governor system energized, the fuel is metered, pressurized, and pushed through the injectors by the
injection pump. Fuel is sprayed by the injectors into the diesel engine combustion chambers where it is mixed with
air and ignited. The fuel that is not used by the injectors is returned to the fuel tank by an excess fuel return line.
Power is removed from the electronic governor control, and the fuel is shut off whenever the MASTER SWITCH is
turned to the OFF position. The electronic governor control is also deenergized by the fault system (Fault
System). The FUEL LEVEL indicator displays the fuel level of the fuel tank from E (empty) to F (full) in quarter
tank increments.
The auxiliary subsystem consists of an auxiliary fuel supply, fuel lines, fittings, auxiliary fuel filter, auxiliary fuel
pump, an auxiliary fuel pump float switch located in the fuel tank, and a fuel float switch module.
When the MASTER switch is set on PRIME & RUN AUX FUEL, it actuates the auxiliary fuel pump and transfers
fuel from the auxiliary fuel supply to the fuel tank. The auxiliary fuel pump float switch shuts off the auxiliary fuel
pump when the fuel tank is full and reactivates the pump as the level drops. The fuel float switch module allows
the current used by the auxiliary fuel pump to bypass the float switch.
The 24 VDC control circuits provide control and power for indicators, float switches, fault system, governor control
system, and auxiliary fuel pump.
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Figure 2. Generator Set Fuel System.
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Generator Set Cooling System
The generator set cooling system (Figure 3) includes air intake and exhaust grilles, baffles and ducting within the
generator set housing, and the engine-driven radiator cooling fan. The air intake grilles are located in panels on
both sides of the generator set housing. The air exhaust grille is located in the housing top panel.
Air is drawn in through the air intake grilles and forced through the engine coolant radiator and out of the
generator set through the exhaust grille by the radiator cooling fan. Most of the cooling air flows externally past
the generator assembly and engine. Some cooling air is circulated internally through the generator assembly by a
generator fan which is an integral part of the AC generator assembly. Baffles, ducting, and sound-absorbing
material are used to control the airflow through the generator set and to reduce sound transmission through the
grilles.
Figure 3. Generator Set Cooling System.
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Engine Cooling System
The engine cooling system (Figure 4) consists of a radiator, hoses, thermostat, temperature sender, coolant high
temperature switch, COOLANT TEMP indicator, water pump, oil cooler, belt-driven fan, and cooling jackets (part
of engine).
The water pump forces coolant through passages (cooling jackets) in the engine block and cylinder head where
the coolant absorbs heat from the engine. When the engine reaches normal operating temperature, the
thermostat opens and the heated coolant flows through the upper radiator hose assembly into the radiator. The
cooling fan circulates air through the radiator where the coolant temperature is reduced.
A coolant high temperature switch in conjunction with the fault system provides automatic shutdown in the event
that coolant temperature exceeds 225±5 °F (107±3 °C). The COOLANT TEMP indicator displays the engine
coolant temperature from 120 to 240 °F (48 to 115 °C).
The water pump also circulates coolant through the engine oil cooler to cool the engine oil.
Figure 4. Engine Cooling System.
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Engine Lubrication System
The engine lubrication system (Figure 5) consists of an oil pan, dipstick, pump, oil cooler, oil sample valve, oil
pressure sender, OIL PRESSURE indicator, low oil pressure switch, and filter.
The oil pan is a reservoir for engine lubricating oil. The dipstick indicates oil level in the pan. The oil level can be
checked during engine operation. One side of the dipstick is used for checking oil level while the engine is running
and the other side is used while the engine is shut down. The pump draws oil from the oil pan through a screen
that removes large impurities. The oil then passes through tubes in the oil cooler. Engine coolant from the engine
cooling system is circulated around the tubes to cool the oil. From the cooler, oil passes through a spin-on type
filter where small impurities are removed. From the filter, oil is distributed to the engine and turbocharger moving
parts and then returns to the oil pan. The oil pressure sender located in the engine block senses oil pressure. The
oil pressure is displayed on the OIL PRESSURE indicator. An Army Oil Analysis Program (AOAP) sample valve
located in the block allows oil samples to be taken while the engine is operating. The low oil pressure switch, also
located in the engine block, functions with the generator set fault system. The engine is automatically shut off if
the oil pressure drops below 15±3 psi (103.4±20.7 kPa).
Figure 5. Engine Lubrication System.
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Engine Air Intake and Exhaust System
The engine air intake and exhaust system (Figure 6) consists of an air cleaner assembly, intake manifold, ether
supply tank, ether solenoid valve, ETHER switch, exhaust manifold, turbocharger, crankcase breather filter, and
muffler. The air cleaner assembly includes a dust collector, filter element, restriction indicator, and dust evacuator
valve.
Air is drawn into the dust collector and passes through the filter element. Airborne dirt is removed and trapped in
the dust collector and filter element. Some dust can be removed from the dust collector by pinching the evacuator
valve. The restriction indicator indicates when the filter should be serviced. Filtered air is drawn out of the filter
through air intake tubes into the turbocharger where it is compressed and forced into the engine.
The engine exhaust gases are expelled into the exhaust manifold and ported to the turbine of the turbocharger.
The turbine drives the turbocharger compressor which compresses the intake air. Exhaust gases discharged by
the turbocharger are channeled into the muffler to deaden the sound of the exhaust gases. The gases pass from
the muffler through the muffler outlet and are vented upward from the generator set housing. A cover, which is
held open by the pressure of the exhaust gases during operation, closes over the exhaust port to prevent rain,
water, or other foreign matter from entering the exhaust port when the set is not in use. The cover is easily
removed for connection of an exhaust pipe for indoor operation.
Combustion gases which enter the crankcase are filtered through the crankcase breather filter to remove oil
droplets and are then recycled through the intake manifold.
An ether supply system is provided to improve engine starting when outside ambient air temperature is below 40
°F (4 °C). The ether system includes an ether supply tank, ether solenoid valve, ETHER switch, and piping from
the solenoid valve to the intake manifold. The ether system is activated by turning the MASTER SWITCH to
START and holding the ETHER switch in the ON position.
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Figure 6. Engine Air Intake and Exhaust System.
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Output Supply System
The output supply system (Figure 7) consists of the AC generator, GROUND FAULT CIRCUIT INTERRUPTER
(GFCI), CONVENIENCE RECEPTACLE, current transformer, AC voltage reconnection terminal board, AC circuit
interrupter relay, load output terminals, AC CIRCUIT INTERRUPTER switch, kilowatt transducer, kilowattmeter
(PERCENT POWER), VM-AM transfer switch, AC voltmeter (VOLTS AC), and ammeter (PERCENT RATED
POWER).
Power created by the generator is supplied through the current transformer, AC voltage reconnection terminal
board, and AC circuit interrupter relay to the output terminals. The AC voltage reconnection terminal board allows
configuration of the generator set for 120/208 volt connections or 240/416 volt connections. The AC CIRCUIT
INTERRUPTER switch closes and opens the AC circuit interrupter relay. This enables or interrupts the power flow
between the AC voltage reconnection terminal board and the load output terminals. The voltage regulation system
(Voltage Regulation System) senses generator output voltage and provides a control signal to the generator
exciter to maintain the desired generator output voltage. Generator output frequency is controlled by the governor
control system (Governor Control System) and is read on the FREQUENCY meter (HERTZ). The current
transformer provides a reduced current signal to the kilowatt transducer and ammeter (PERCENT RATED
CURRENT). The kilowatt transducer and kilowattmeter (PERCENT POWER) provide an indication of the power
being used by the load. The ammeter (PERCENT RATED CURRENT) indicates the percent of rated current
being supplied to the load. The position of the VM-AM transfer switch selects the output load terminals from which
current and voltage is measured. The AC circuit interrupter relay will open and disconnect the load whenever any
of the following faults occur: reverse power, undervoltage, overload, or short circuit.
The AC generator also provides 120 VAC power to the CONVENIENCE RECEPTACLE through the GROUND
FAULT CIRCUIT INTERUPTER.
0003-11
TM 9-6115-644-24
Figure 7. Output Supply System.
0003-12
0003
TM 9-6115-644-24
0003
Generator Set Controls
Engine Starting System. Engine starting is accomplished primarily with two 12-volt batteries, connected in series
to provide 24 VDC power, and a starter (Figure 8). The starter includes a cranking motor and a solenoid. To
permit engine starting, the DC CONTROL POWER circuit breaker must be pushed in, the DEAD CRANK switch
must be in the NORMAL position, and the BATTLE SHORT switch must be in the OFF position. In addition, any
ENGINE SHUTDOWN fault previously registered on the malfunction indicator panel must have been corrected
and the malfunction indicator panel must have been reset. When the MASTER SWITCH is then placed in the
START position, the starting circuits supply 24 VDC power to the starter. As the engine accelerates to
approximately 900 rpm, the starting circuits disconnect power from the starter.
When the MASTER SWITCH is first moved to the START position, the various instrument and control circuits are
energized. The engine starting system includes two control circuits. One starting control circuit energizes the start
relay through closed switch contacts of the engine fault relay and the BATTLE SHORT switch. The other starting
control circuit energizes the cranking relay coil through closed contacts of the crank disconnect switch and the
start relay. (The crank disconnect switch is an integral part of the electronic governor control.) With the cranking
relay energized, power passes from the batteries through closed contacts of the cranking relay to energize the
starter solenoid. With the starter solenoid energized, power passes from the starter solenoid to the cranking
motor. The cranking motor then cranks the engine. Engine speed is sensed by the magnetic pickup which sends
a signal to the electronic governor control. As the engine accelerates to approximately 900 rpm, the signal from
the magnetic pickup causes the crank disconnect switch to open one set of contacts and close another set of
contacts. The open contacts break the circuit to the cranking relay and stop engine cranking. The closed contacts
cause the field flash relay to be energized. When the MASTER SWITCH is moved to one of the two RUN
positions, both starting control circuits are deenergized. The other generator set control and instrument circuits
remain energized.
The engine may be cranked without starting by use of the DEAD CRANK switch. With the DEAD CRANK switch
in the CRANK position, the cranking relay coil is energized to initiate engine cranking without energizing any other
starting or control functions.
The generator set can be started without batteries by connecting an external 24 VDC power source to the NATO
slave receptacle. The generator set can also supply starting power to another generator set through the NATO
slave receptacle.
The batteries are charged by the battery charging alternator that is belt-driven by the engine. The BATTERY
CHARGE ammeter indicates the charge/discharge rate of the batteries from -10 amps to +20 amps. A shunt
provides a DC voltage signal, which is directly proportional to the actual battery current flow, to the BATTERY
CHARGE ammeter. Normal operating indication on the BATTERY CHARGE ammeter depends on the state of the
charge in the batteries. A low charge, which may exist immediately after engine starting, will cause a high reading
(needle moves toward CHARGE area). When the charge in the batteries has been restored, the indicator moves
near zero (0). The battery charging system is protected from reverse polarity in the battery connections by a fuse
and diode.
Field Flash. When the engine reaches sufficient speed (900 rpm), the magnetic pickup causes a set of contacts
in the crank disconnect switch to close and energize the field flash relay. This circuit provides current to the
exciter field windings which sets up an electromagnetic field. The field current is necessary for the set to generate
sufficient voltage for the voltage regulator (Figure 10) to begin controlling the output voltage of the generator set.
The field flash circuit is maintained until the MASTER SWITCH is released from the START position.
Operation. Placing the MASTER SWITCH in the PRIME & RUN or PRIME & RUN AUX FUEL position keeps the
electronic governor control (Figure 9) energized, and fuel will be supplied to the fuel injection pump as long as no
fault condition exists. During operation, the operator should periodically check generator set instruments to ensure
they are reading in the normal operating ranges. The VOLTAGE and FREQUENCY potentiometers are adjusted
as required to maintain desired frequency and voltage output.
0003-13
TM 9-6115-644-24
Figure 8. Engine Starting System.
0003-14
0003
TM 9-6115-644-24
0003
Applying the Load. The load is applied by placing the AC CIRCUIT INTERRUPTER switch in the CLOSED
position. This is a momentary contact switch that returns to the neutral or center position. The AC circuit
interrupter relay is energized by this momentary contact and a holding circuit keeps it closed, bringing the load on
line.
Shutdown. The AC circuit interrupter relay is disengaged by placing the AC CIRCUIT INTERRUPTER switch in
the OPEN position. This is a momentary contact switch which will break the AC circuit interrupter relay holding
circuit and then return to the neutral or center position disconnecting the load from the line.
The generator set should remain running for five minutes after disconnecting the load. During this five minute
interval, oil circulates through the turbocharger, cooling it enough to be shut down.
When the MASTER SWITCH is placed in the OFF position, all power is removed from the control circuit and the
engine will stop.
The EMERGENCY STOP switch assembly will remove power from the control circuit by energizing the engine
fault relay. This will cause the engine to shut down. The EMERGENCY STOP switch assembly is not to be used
as an alternative for routine shutdown procedures. When the generator set is stopped using the EMERGENCY
STOP switch assembly, some circuits remain energized causing a drain on the batteries until the MASTER
SWITCH is placed in the OFF position.
Paralleling. The generator set is capable of being operated in parallel with one other set of the same model
number. This capability is provided by the PARALLELING RECEPTACLE, paralleling cable, LOAD SHARING
ADJUST and REACTIVE CURRENT ADJUST rheostats, two SYNCHRONIZATION LIGHTS, UNIT-PARALLEL
switch, reverse power relay, voltage sensing relay, droop current transformer, and permissive paralleling relay.
The paralleling cable is used to interconnect the governor and AC voltage regulator paralleling circuits of two
generator sets. The UNIT-PARALLEL switch is used to select parallel operation. Voltage and frequency of the two
generator sets are synchronized by adjusting each set's VOLTAGE and FREQUENCY controls. Phase
synchronization is indicated by the SYNCHRONIZATION LIGHTS. The reverse power relay serves as a safety
device that opens the AC circuit interrupter relay when one of the sets fails to produce power and begins to
receive power from the other set. The reverse power relay operates when the power received exceeds 20% of set
rating. The load sharing adjust and reactive current adjust rheostats, and the droop current transformer are used
to adjust power and current for load sharing at the factory or by maintenance. No adjustment of the rheostats is
required for normal operation. The permissive paralleling relay monitors the voltage phase relationship and
prevents the AC circuit interrupter relay from closing when the units are not properly synchronized. The voltage
sensing relay senses the operating voltage range, 120/208 volts or 240/416 volts, and switches an additional
resistor to each of the SYNCHRONIZATION LIGHT circuits during 240/416 volts operation to protect the lights.
Governor Control System
The governor control system (Figure 9) includes the electronic governor control, governor actuator, magnetic
pickup, load measuring unit, frequency transducer, FREQUENCY meter (HERTZ), kilowatt transducer, fuel
injection pump, FREQUENCY SELECT switch, and FREQUENCY adjust potentiometer.
The governor actuator is a linear electromechanical actuator which controls the output of the fuel injection pump
in response to the electrical input from the electronic governor control. The FREQUENCY adjust potentiometer,
located on the control panel and adjusted by the operator, provides a signal representing the desired engine
speed/ generator frequency to the electronic governor control. A signal representative of the actual engine
speed/generator frequency is sent to the electronic governor control by the magnetic pickup. Any change in
engine speed from that selected by the operator, as sensed by the magnetic pickup, causes the electronic
governor control to increase or decrease the fuel injection pump output to maintain the desired speed. The load
measuring unit senses changes in external load demand and provides a change signal to the electronic governor
control allowing the control to start its response prior to any actual change in engine speed. The generator set
frequency and power output are indicated by the FREQUENCY meter (HERTZ) and the kilowattmeter (PERCENT
POWER) on the control panel. The FREQUENCY SELECT switch is used to set the generator for 50 or 60 Hz
operating frequencies (MEP-805A).
The electronic governor control also contains the engine overspeed switch (fault system) and the crank
disconnect switch (engine starting system). These switches function as a result of input from the magnetic pickup.
The 24 VDC power is supplied to the electronic governor control through the governor control power relay. The
governor control relay is controlled by the fault system. The electronic governor controls of two generator sets
operating in parallel are interconnected by the paralleling cable.
0003-15
TM 9-6115-644-24
Figure 9. Governor Control System.
0003-16
0003
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0003
Voltage Regulation System
The voltage regulation system (Figure 10) consists of the AC voltage regulator, VOLTAGE adjust potentiometer,
and power transformer. The AC voltage regulator senses and controls the generator output voltage which is
operator adjustable within the design limits by use of the VOLTAGE adjust potentiometer. The power transformer
provides operating power to the AC voltage regulator. The output voltage is indicated by the AC voltmeter
(VOLTS AC) on the control panel.
Figure 10. Voltage Regulation System.
RADIO INTERFERENCE SUPPRESSION
General Methods Used To Attain Proper Suppression
Suppression is attained by providing a low resistance path to ground for stray currents. The methods used include
shielding the ignition and high-frequency wires, grounding the frame with bonding straps, and using filtering
systems.
Interference Suppression Components
Primary Suppression Components. Primary suppression components are those whose primary function is to
suppress electromagnetic interference.
The primary suppression components on this generator set are the output box access door EMI seal (outer seal)
(WP 0018); the load output terminal board EMI filters (WP 0107); and the voltage reconnection terminal board
capacitors (WP 0099).
0003-17
TM 9-6115-644-24
0003
Secondary Suppression Components. Secondary suppression components have electromagnetic interference
suppression functions which are incidental or secondary to their primary function. The only secondary
suppression component for the generator set is the housing; refer to WP 0014 through WP 0017, for removal and
installation procedures.
END OF WORK PACKAGE
0003-18
TM 9-6115-644-24
CHAPTER 2
FIELD TROUBLESHOOTING PROCEDURES
FOR
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL
QUIET GENERATOR SETS
TM 9-6115-644-24
CHAPTER 2
TROUBLESHOOTING PROCEDURES
WORK PACKAGE INDEX
Title
WP Sequence No.
Troubleshooting Index .........................................................................................................................................0004
Troubleshooting Procedures ...............................................................................................................................0005
TM 9-6115-644-24
0004
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
TROUBLESHOOTING INDEX
INITIAL SETUP:
References
FO-1 Electrical Schematic
FO-3 Wiring Diagram
WP 0008, PMCS Including Lubrication Instructions
WP 0063, Maintenance of Control Box Assembly,
Diagnostic Connector
PURPOSE OF TROUBLESHOOTING TABLE
This work package contains troubleshooting information for locating and correcting operating troubles which may
develop in the generator set. Each malfunction for an individual component, unit, or system is followed by a list of
tests or inspections which will help you to determine probable causes and corrective actions to take. You should
perform the tests/inspections and corrective actions in the order listed.
This table cannot list all malfunctions that can occur, nor all tests or inspections and corrective actions. If a
malfunction is not listed or cannot be corrected by listed corrective actions, notify your supervisor.
NOTE
Before you use this table, be sure you have performed your Preventive Maintenance Checks
and Services (PMCS).
Before using this table, ensure that operator level troubleshooting steps have been
performed.
Refer to the Diagnostic Connector Connection Points WP 0063, Table 1, Electrical Schematic FO-1, and Wiring Diagram FO-3 as troubleshooting aids.
Malfunction/Symptom
Troubleshooting
Procedure
COOLING SYSTEM
Engine coolant temperature too low
Engine overheating
14
13
ELECTRICAL SYSTEM
AC voltmeter (VOLTS AC); Does not indicate voltage
AC voltmeter (VOLTS AC); Indicates voltage but FREQUENCY meter (HERTZ) is off scale
AC voltmeter (VOLTS AC); Voltage fluctuates
BATTERY CHARGE ammeter; Shows no charge when batteries are low or discharged
BATTERY CHARGE ammeter; Shows excessive charging after prolonged operation
FREQUENCY meter (HERTZ); frequency fluctuates
No voltage at CONVENIENCE RECEPTACLE
ENGINE
0004-1
21
22
23
19
20
24
25
TM 9-6115-644-24
0004
TROUBLESHOOTING INDEX - Continued
Malfunction/Symptom
Troubleshooting
Procedure
Abnormal engine noise
Coolant in crankcase or oil in coolant
Cranks but fails to start
Does not develop full power
Excessive fuel consumption
Fails to crank
Fails to start in cold weather
Misfiring
Runs erratically or stalls frequently
Stops suddenly
Vibrating
7
16
2
6
15
1
18
5
4
3
17
EXHAUST SYSTEM
Black or grey smoke in exhaust
Blue or white exhaust smoke
8
9
GENERATOR SET
Fails to generate power
Fails to generate sufficient voltage
Noisy when running
Output fluctuates
Overheats
26
27
30
28
29
LUBRICATION SYSTEM
High oil consumption
High oil pressure
Low oil pressure
10
12
11
END OF WORK PACKAGE
0004-2
TM 9-6115-644-24
0005
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
TROUBLESHOOTING PROCEDURES
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
One
References
References
WP 0006, Service Upon Receipt, Table 2 & Table 3
WP 0071, Maintenance of Air Intake & Exhaust
WP 0010, Removal & Installation of Majory
System, Muffler & Exhaust Pipe
Components, Engine Assembly
WP 0072, Maintenance of Air Intake & Exhaust
WP 0012, Maintenance of DC Electrical Systems,
System, Air Cleaner Assembly
Batteries
WP 0086, Maintenance of Fuel System, Low
WP 0025, Maintenance of Control Box Assembly, Oil
Pressure Fuel Lines/Filters
Pressure Indicator
WP 0087, Maintenance of Fuel System, Auxiliary
WP 0032, Maintenance of Control Box Assembly,
Fuel Pump
Master Switch
WP 0105, Maintenance of Outbox Assembly,
WP 0041, Maintenance of Control Box Assembly,
Cranking Relay
Emergency Stop Switch Assembly
WP 0111, Maintenance of Engine Accessories, Oil
WP 0050, Maintenance of Control Box Assembly,
Pressure Sender
DC Control Power Circuit Breaker
WP 0115, Maintenance of Engine Accessories,
WP 0054, Maintenance of Control Box Assembly,
Dead Crank Switch
Shunt
WP 0117, Maintenance of Engine Accessories,
WP 0060, Maintenance of Control Box Assembly,
Governor Actuator
Relays
WP 0118, Maintenance of Lubrication System, Oil
WP 0061, Maintenance of Control Box Assembly,
Drain Line
Governor Control Unit (GCO)
WP 0066, Maintenance of Control Box Assembly,
Resistor-Diode Assembly
Equipment Condition
Grounded, Off & Operational
SYMPTOM
1.
ENGINE FAILS TO CRANK.
TEST OR INSPECTION
Step 1. Test for defective DEAD CRANK switch (WP 0115, Testing).
CORRECTIVE ACTION
a.
If DEAD CRANK switch is not defective, do Step 2.
b.
If defective, replace DEAD CRANK switch (WP 0115).
TEST OR INSPECTION
Step 2. Check for loose or corroded battery cable terminals or battery posts.
CORRECTIVE ACTION
a.
If terminals are tight and posts are clean, do Step 3.
b.
If not clean and tight, clean and tighten battery cable terminals and posts (WP 0012, Cleaning).
TEST OR INSPECTION
0005-1
TM 9-6115-644-24
0005
Step 3. Check that batteries are installed correctly (WP 0012, Installation).
CORRECTIVE ACTION
a.
If batteries are installed correctly, do Step 4.
b.
If not incorrectly installed, install batteries correctly (WP 0012, Installation).
TEST OR INSPECTION
Step 4. Test for low or no battery charge (WP 0012, Testing).
CORRECTIVE ACTION
a.
If fully charged, do Step 5.
b.
If not fully charged, replace batteries (WP 0012).
TEST OR INSPECTION
Step 5. Test for defective DC CONTROL POWER circuit breaker (WP 0050, Testing).
CORRECTIVE ACTION
a.
If DC CONTROL POWER circuit breaker is not defective, do Step 6.
b.
If defective, replace DC CONTROL POWER circuit breaker (WP 0050).
TEST OR INSPECTION
Step 6. Test for battery voltage at input of MASTER SWITCH.
CORRECTIVE ACTION
a.
If battery voltage is present, do Step 7.
b.
If battery voltage is not present, do Step 8.
TEST OR INSPECTION
Step 7. Test MASTER SWITCH output voltage in START position.
CORRECTIVE ACTION
a.
If battery voltage is present at MASTER SWITCH output terminal (7) and GND, do Step 11.
b.
If battery voltage is not present at output terminal, test MASTER SWITCH (WP 0032, Testing).
TEST OR INSPECTION
Step 8. Test for defective battery charging ammeter shunt (WP 0054, Testing).
CORRECTIVE ACTION
a.
If battery charging ammeter shunt is not defective, do Step 9.
b.
If defective, replace battery charging ammeter shunt (WP 0054).
TEST OR INSPECTION
Step 9. Test for defective reverse battery diode (CR1) (WP 0066, Testing).
CORRECTIVE ACTION
a.
If reverse battery diode is not defective, do Step 10.
b.
If defective, replace reverse battery diode (WP 0066).
TEST OR INSPECTION
Step 10. Test for defective EMERGENCY STOP switch assembly (WP 0041, Testing).
CORRECTIVE ACTION
a.
If EMERGENCY STOP switch assembly is not defective, do Step 11.
0005-2
TM 9-6115-644-24
b.
If defective, replace EMERGENCY STOP switch assembly (WP 0041).
TEST OR INSPECTION
Step 11. Test for defective start relay (K15) (WP 0060, Testing).
CORRECTIVE ACTION
a.
If start relay is not defective, do Step 12.
b.
If defective, replace start relay (WP 0060).
TEST OR INSPECTION
Step 12. Test for defective cranking relay (K2) (WP 0105, Testing).
CORRECTIVE ACTION
a.
If cranking relay is not defective, do Step 13.
b.
If defective, replace cranking relay (WP 0105).
TEST OR INSPECTION
Step 13. Test for defective crank disconnect relay (K16) (WP 0060, Testing).
CORRECTIVE ACTION
a.
If crank disconnect relay is not defective, do Step 14.
b.
If defective, replace crank disconnect relay (WP 0060).
TEST OR INSPECTION
Step 14. Check starting circuit for breaks or loose connections; refer to Electrical Schematic FO-1.
CORRECTIVE ACTION
a.
If starting circuit has no breaks and connections are tight, do Step 15.
b.
If defective, repair or replace defective wires or connections.
TEST OR INSPECTION
Step 15. Test for defective starter solenoid (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If starter solenoid is not defective, do Step 16.
b.
If defective, replace starter solenoid (TM 9-2815-255-24).
TEST OR INSPECTION
Step 16. Test for defective starting motor (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If defective, replace starting motor (TM 9-2815-255-24).
b.
If starting motor is not defective, notify next higher level of maintenance.
SYMPTOM
2.
ENGINE CRANKS BUT FAILS TO START.
TEST OR INSPECTION
Step 1. Test for low battery output (WP 0012, Testing).
CORRECTIVE ACTION
a.
If batteries are fully charged, do Step 2.
b.
If not fully charged, replace batteries (WP 0012).
0005-3
0005
TM 9-6115-644-24
0005
TEST OR INSPECTION
Step 2. Check for clogged or defective fuel filter/water separator.
CORRECTIVE ACTION
a.
If fuel filter/water separator is not clogged or defective, do Step 3.
b.
If clogged or defective, service fuel filter/water separator (TM 9-2815-255-24).
TEST OR INSPECTION
Step 3. Check for blocked fuel line(s) and/or components starting at injector pump inlet line.
CORRECTIVE ACTION
a.
If fuel lines are not blocked, do Step 4.
b.
If blocked, unblock or replace fuel line(s) and/or components (WP 0086 and/or WP 0087).
TEST OR INSPECTION
Step 4. Check for air in fuel lines.
CORRECTIVE ACTION
a.
If air in fuel lines, bleed fuel lines (TM 9-2815-255-24).
b.
If no air in fuel lines, do Step 5.
TEST OR INSPECTION
Step 5. Check for contaminated or incorrect grade of fuel.
CORRECTIVE ACTION
a.
If fuel is not contaminated and is correct grade, do Step 6.
b.
If contaminated or incorrect grade, drain engine fuel system and service fuel filter/water
separator (TM 9-2815-255-24). Drain generator set tank. Service generator set fuel tank with a
proper grade of clean fuel (WP 0006, Table 2). Prime engine fuel system (TM 9-2815-255-24).
TEST OR INSPECTION
Step 6. Check for defective fuel supply pump (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If defective, replace fuel supply pump (TM 9-2815-255-24).
b.
If fuel supply pump is not defective, do Step 7.
TEST OR INSPECTION
Step 7. Test fuel injection pump timing (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If injection pump timing is correct, do Step 8.
b.
If not correctly timed, time fuel injection pump (TM 9-2815-255-24).
TEST OR INSPECTION
Step 8. Test for defective governor actuator (WP 0117).
CORRECTIVE ACTION
a.
If governor actuator is not defective, do Step 9.
b.
If defective, replace governor actuator (WP 0117, Removal).
TEST OR INSPECTION
0005-4
TM 9-6115-644-24
Step 9. Test for defective fuel injection pump (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If fuel injection pump is not defective, do Step 10.
b.
If defective, repair or replace fuel injection pump (TM 9-2815-255-24).
TEST OR INSPECTION
Step 10. Test for defective governor control unit (WP 0061, Testing).
CORRECTIVE ACTION
If defective, replace governor control unit (WP 0061, Replacement).
SYMPTOM
3.
ENGINE STOPS SUDDENLY.
TEST OR INSPECTION
Step 1. Check for tripped protective devices.
CORRECTIVE ACTION
a.
If no malfunction indicator lights are illuminated, do Step 2.
b.
If illuminated, correct fault indicated.
TEST OR INSPECTION
Step 2. Check for air lock in fuel supply line.
CORRECTIVE ACTION
a.
If no air lock in fuel line, do Step 3.
b.
If air in line, bleed fuel lines (TM 9-2815-255-24).
TEST OR INSPECTION
Step 3. Check for blocked fuel line(s) and/or components, starting at injection pump inlet line.
CORRECTIVE ACTION
a.
If fuel lines are not blocked, do Step 4.
b.
If blocked, unblock or replace fuel line(s) and/or components (WP 0086 and/or WP 0087).
TEST OR INSPECTION
Step 4. Check for defective fuel supply pump (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If defective, replace fuel supply pump (TM 9-2815-255-24).
b.
If fuel supply pump is not defective, notify next higher level of maintenance.
SYMPTOM
4.
ENGINE RUNS ERRATICALLY OR STALLS FREQUENTLY.
TEST OR INSPECTION
Step 1. Check for obstruction in fuel line(s).
CORRECTIVE ACTION
a.
If fuel line(s) are not obstructed, do Step 2.
b.
If obstructed, unblock or replace fuel line(s) (WP 0086).
0005-5
0005
TM 9-6115-644-24
0005
TEST OR INSPECTION
Step 2. Check for blocked exhaust pipe or muffler.
CORRECTIVE ACTION
a.
If exhaust pipe and muffler are not blocked, do Step 3.
b.
If blocked, unblock exhaust pipe/muffler or replace exhaust pipe/muffler (WP 0071).
TEST OR INSPECTION
Step 3. Check for contaminated or incorrect grade of fuel.
CORRECTIVE ACTION
a.
If contaminated or incorrect grade, drain engine fuel system and service fuel filter/water
separator (TM 9-2815-255-24). Drain generator set tank. Service generator set fuel tank with
proper grade of clean fuel (WP 0006, Table 2). Prime engine fuel system (TM 9-2815-255-24).
b.
If fuel is not contaminated or incorrect grade, do Step 4.
TEST OR INSPECTION
Step 4. Test fuel injection pump timing (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If fuel injection pump timing is correct, do Step 5.
b.
If not correctly timed, time fuel injection pump (TM 9-2815-255-24).
TEST OR INSPECTION
Step 5. Test for defective fuel injection pump (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If fuel injection pump is not defective, do Step 6.
b.
If defective, repair or replace fuel injector pump (TM 9-2815-255-24).
TEST OR INSPECTION
Step 6. Check cylinder head gasket for leaks (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If cylinder head gasket is not leaking, do Step 7.
b.
If leaking, replace cylinder head gasket (TM 9-2815-255-24).
TEST OR INSPECTION
Step 7. Check valve adjustment (TM 9-2815-255-24)).
CORRECTIVE ACTION
a.
If valves are properly adjusted, do Step 8.
b.
If improperly adjusted, adjust valves (TM 9-2815-255-24).
TEST OR INSPECTION
Step 8. Check for stuck or burnt valves (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If valves are not stuck or burnt, do Step 9.
b.
If stuck or burnt, replace valves (TM 9-2815-255-24).
TEST OR INSPECTION
0005-6
TM 9-6115-644-24
0005
Step 9. Test for defective governor control unit (WP 0061, Testing).
CORRECTIVE ACTION
a.
If governor control unit is not defective, do Step 10.
b.
Adjust governor control unit (WP 0061, Adjustment) or replace governor control unit (WP 0061,
Replacement).
TEST OR INSPECTION
Step 10. Check for low engine compression (TM 9-2815-255-24).
CORRECTIVE ACTION
If compression is low, repair or replace engine (TM 9-2815-255-24).
SYMPTOM
5.
ENGINE MISFIRING.
TEST OR INSPECTION
Step 1. Check for contaminated or incorrect grade of fuel.
CORRECTIVE ACTION
a.
If fuel is not contaminated and is correct grade, do Step 2.
b.
If contaminated or incorrect grade, drain engine fuel system and service fuel filter/water
separator (TM 9-2815-255-24). Drain generator set tank. Service generator set tank with proper
grade of clean fuel (WP 0006, Table 2). Prime engine fuel system (TM 9-2815-255-24).
TEST OR INSPECTION
Step 2. Check for air in fuel lines.
CORRECTIVE ACTION
a.
If air in lines, bleed fuel lines (TM 9-2815-255-24).
b.
If no air in fuel lines, and trouble persists, do Step 3.
TEST OR INSPECTION
Step 3. Check for defective fuel injection nozzles (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If fuel injectors are not defective, do Step 4.
b.
If defective, replace fuel injection nozzles (TM 9-2815-255-24).
TEST OR INSPECTION
Step 4. Test for defective governor actuator (WP 0117, Testing).
CORRECTIVE ACTION
a.
If governor actuator is not defective, do Step 5.
b.
If defective, replace governor actuator (TM 9-2815-255-24).
TEST OR INSPECTION
Step 5. Test fuel injection pump timing (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If fuel injection pump timing is correct, do Step 6.
b.
If defective, repair or replace fuel injection pump (TM 9-2815-255-24).
TEST OR INSPECTION
0005-7
TM 9-6115-644-24
0005
Step 6. Test for defective fuel injection pump (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If fuel injection pump is not defective, do Step 7.
b.
If defective, repair or replace fuel injector pump (TM 9-2815-255-24).
TEST OR INSPECTION
Step 7. Check valve adjustment (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If valves are properly adjusted, do Step 8.
b.
If improperly adjusted, adjust valves (TM 9-2815-255-24).
TEST OR INSPECTION
Step 8. Check for weak valve springs (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If valve springs are not weak, do Step 9.
b.
If weak, replace valve springs (TM 9-2815-255-24).
TEST OR INSPECTION
Step 9. Check for stuck or burnt valves (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If valves are not stuck or burnt, do Step 10.
b.
If stuck or burnt, replace valves (TM 9-2815-255-24).
TEST OR INSPECTION
Step 10. Test for low engine compression (TM 9-2815-255-24).
CORRECTIVE ACTION
If compression is low, repair or replace engine (TM 9-2815-255-24).
SYMPTOM
6.
ENGINE DOES NOT DEVELOP FULL POWER.
TEST OR INSPECTION
Step 1. Test for restricted fuel filter/water separator.
CORRECTIVE ACTION
a.
If fuel filter/water separator is not restricted, do Step 2.
b.
If restricted, service fuel filter/water separator (TM 9-2815-255-24).
TEST OR INSPECTION
Step 2. Check for contaminated or incorrect grade of fuel.
CORRECTIVE ACTION
a.
If fuel is not contaminated and is correct grade, do Step 3.
b.
If contaminated or incorrect grade, drain engine fuel system and service fuel filter/water
separator (TM 9-2815-255-24). Drain generator set tank. Service generator set tank with proper
grade of clean fuel (WP 0006, Table 2). Prime engine fuel system (TM 9-2815-255-24).
TEST OR INSPECTION
0005-8
TM 9-6115-644-24
0005
Step 3. Check for blocked air intake system.
CORRECTIVE ACTION
a.
If air intake system is not blocked, do Step 4.
b.
If blocked, unblock or replace air intake system components as required (WP 0072 and/or WP
0073).
TEST OR INSPECTION
Step 4. Check blocked exhaust pipe or muffler.
CORRECTIVE ACTION
a.
If blocked, unblock or replace exhaust pipe/muffler (WP 0071).
b.
If exhaust pipe and muffler are not blocked, and trouble persists, do Step 5.
TEST OR INSPECTION
Step 5. Check for defective fuel injection nozzles (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If fuel injectors are not defective, do Step 6.
b.
If defective, replace fuel injection nozzles (TM 9-2815-255-24).
TEST OR INSPECTION
Step 6. Test for defective governor actuator (WP 0117, Testing).
CORRECTIVE ACTION
a.
If governor actuatoris not defective, do Step 7.
b.
If defective, replace governor actuator (WP 0117).
TEST OR INSPECTION
Step 7. Test for defective governor control unit (WP 0061, Testing).
CORRECTIVE ACTION
a.
If governor control unit is not defective, do Step 8.
b.
Adjust governor control unit (WP 0061, Adjustment) or replace governor control unit (WP 0061,
Replacement).
TEST OR INSPECTION
Step 8. Test fuel injection pump timing (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If fuel injection pump timing is correct, do Step 9.
b.
If timing is not correct, time fuel injection pump (TM 9-2815-255-24).
TEST OR INSPECTION
Step 9. Check valve adjustment (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If valves are properly adjusted, do Step 10.
b.
If improperly adjusted, adjust valves (TM 9-2815-255-24).
TEST OR INSPECTION
Step 10. Check cylinder head gasket for leaks (TM 9-2815-255-24).
0005-9
TM 9-6115-644-24
0005
CORRECTIVE ACTION
a.
If cylinder head gasket is not leaking, do Step 11.
b.
If leaking, replace cylinder head gasket (TM 9-2815-255-24).
TEST OR INSPECTION
Step 11. Check for weak valve springs (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If valve springs are not weak, do Step 12.
b.
If weak, replace valve springs (TM 9-2815-255-24).
TEST OR INSPECTION
Step 12. Check for stuck or burnt valves (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If valves are not stuck or burnt, do Step 13.
b.
If stuck or burnt, replace valves (TM 9-2815-255-24).
TEST OR INSPECTION
Step 13. Test for low engine compression (TM 9-2815-255-24).
CORRECTIVE ACTION
If compression is low, repair (TM 9-2815-255-24) or replace (WP 0010, Replacement) engine.
SYMPTOM
7.
ABNORMAL ENGINE NOISE.
TEST OR INSPECTION
Step 1. Check for contaminated or incorrect grade of fuel.
CORRECTIVE ACTION
a.
If contaminated or incorrect grade, drain engine fuel system and service fuel filter/water
separator (TM 9-2815-255-24). Drain generator set tank. Service generator set fuel tank with
proper grade of clean fuel (WP 0006, Table 2). Prime engine fuel system (TM 9-2815-255-24).
b.
If fuel is not contaminated and is correct grade, and trouble persists, do Step 2.
TEST OR INSPECTION
Step 2. Check for defective engine mounts.
CORRECTIVE ACTION
a.
If engine mounts are not defective, do Step 3.
b.
If engine mounts are defective, replace mounts (WP 0010).
TEST OR INSPECTION
Step 3. Check valve adjustment (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If valves are properly adjusted, do Step 4.
b.
If improperly adjusted, adjust valves (TM 9-2815-255-24).
TEST OR INSPECTION
Step 4. Check for worn rocker arm shafts (TM 9-2815-255-24).
0005-10
TM 9-6115-644-24
0005
CORRECTIVE ACTION
a.
If rocker arm shafts are not worn, do Step 5.
b.
If worn, replace shafts and/or rocker arms (TM 9-2815-255-24).
TEST OR INSPECTION
Step 5. Check for bent push rods (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If push rods are not bent, do Step 6.
b.
If bent, replace push rods (TM 9-2815-255-24) or replace engine (WP 0010, Replacement).
TEST OR INSPECTION
Step 6. Check for worn idler gears (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If idler gears are not worn, do Step 7.
b.
If worn, replace idler gears (TM 9-2815-255-24) or replace engine (WP 0010, Replacement).
TEST OR INSPECTION
Step 7. Check for foreign material in combustion chamber(s) (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If foreign material is found, clean combustion chamber(s) (TM 9-2815-255-24).
b.
If no foreign matter is found and problem persists, replace engine (WP 0010, Replacement).
SYMPTOM
8.
BLACK OR GREY SMOKE IN EXHAUST.
TEST OR INSPECTION
Step 1. Check for improper grade of fuel.
CORRECTIVE ACTION
a.
If improper grade of fuel, drain engine fuel system. Drain generator set tank. Service generator
set fuel tank with clean fuel of a proper grade (WP 0006, Table 2). Prime engine fuel system
(TM 9-2815-255-24).
b.
If proper grade of fuel, and trouble persists, do Step 2.
TEST OR INSPECTION
Step 2. Check for defective fuel injection nozzles (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If fuel injection nozzles are not defective, do Step 3.
b.
If defective, replace fuel injectors (TM 9-2815-255-24).
TEST OR INSPECTION
Step 3. Test fuel injection pump timing (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If timing is not correct, time fuel injection pump (TM 9-2815-255-24).
SYMPTOM
9.
BLUE OR WHITE EXHAUST SMOKE.
0005-11
TM 9-6115-644-24
0005
TEST OR INSPECTION
Step 1. Check for excessive engine oil level.
CORRECTIVE ACTION
a.
If proper oil level, do Step 2.
b.
If excessive oil level, drain to proper level (WP 0006, Lubricating Oil).
TEST OR INSPECTION
Step 2. Check for improper grade of fuel.
CORRECTIVE ACTION
a.
If proper grade of fuel, do Step 3.
b.
If improper grade, drain engine fuel system and generator set tank. Service generator set fuel
tank with clean fuel of a proper grade (WP 0006, Table 2). Prime engine fuel system (TM
9-2815-255-24).
TEST OR INSPECTION
Step 3. Check for defective thermostat (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If defective, replace thermostat (TM 9-2815-255-24).
b.
If thermostat is not defective, and trouble persists, do Step 4.
TEST OR INSPECTION
Step 4. Test fuel injection pump timing (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If timing is not correct, time fuel injection pump (TM 9-2815-255-24).
SYMPTOM
10. HIGH OIL CONSUMPTION.
TEST OR INSPECTION
Step 1. Check for blocked air intake system.
CORRECTIVE ACTION
a.
If air intake system is not blocked, do Step 2.
b.
If blocked, unblock or replace air intake system components as required (WP 0072 and/or WP
0073).
TEST OR INSPECTION
Step 2. Check for improper lube oil type.
CORRECTIVE ACTION
a.
If improper, drain oil and refill with proper lube oil type (WP 0006, Table 3 and WP 0118,
Removal). Replace oil filter (TM 9-2815-255-24).
b.
If proper lube oil type, and trouble persists, notify next higher level of maintenance.
SYMPTOM
11. LOW OIL PRESSURE.
TEST OR INSPECTION
0005-12
TM 9-6115-644-24
Step 1. Check for improper lube oil type.
CORRECTIVE ACTION
a.
If proper lube oil type, do Step 2.
b.
If improper, drain oil and refill with proper lube oil type (WP 0006, Table 3 and WP 0118,
Removal). Replace oil filter (TM 9-2815-255-24).
TEST OR INSPECTION
Step 2. Test for defective OIL PRESSURE indicator (WP 0025, Testing).
CORRECTIVE ACTION
a.
If OIL PRESSURE indicator is not defective, do Step 3.
b.
If defective, replace OIL PRESSURE indicator (WP 0025).
TEST OR INSPECTION
Step 3. Test for defective oil pressure sender (WP 0111, Testing).
CORRECTIVE ACTION
a.
If defective, replace oil pressure sender (WP 0111).
b.
If oil pressure sender is not defective, and trouble persists, do Step 4.
TEST OR INSPECTION
Step 4. Check oil regulating valve for proper operation (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If oil regulating valve is operating properly, do Step 5.
b.
If not operating properly, replace oil regulating valve (TM 9-2815-255-24).
TEST OR INSPECTION
Step 5. Check for defective oil pump (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If oil pump is not defective, repair or replace engine (TM 9-2815-255-24).
b.
If oil pump is defective, replace oil pump (TM 9-2815-255-24).
SYMPTOM
12. HIGH OIL PRESSURE.
TEST OR INSPECTION
Step 1. Check for improper lube oil type.
CORRECTIVE ACTION
a.
If proper lube oil type, do Step 2.
b.
If improper, drain oil and refill with proper lube oil type (WP 0006, Table 3 and WP 0118,
Removal). Replace oil filter (TM 9-2815-255-24).
TEST OR INSPECTION
Step 2. Test for defective OIL PRESSURE indicator (WP 0025, Testing).
CORRECTIVE ACTION
a.
If OIL PRESSURE indicator is not defective, do Step 3.
b.
If defective, replace OIL PRESSURE indicator (WP 0025).
0005-13
0005
TM 9-6115-644-24
0005
TEST OR INSPECTION
Step 3. Test for defective oil pressure sender (WP 0111, Testing).
CORRECTIVE ACTION
a.
If defective, replace oil pressure sender (WP 0111).
b.
If oil pressure sender is not defective, and trouble persists, do Step 4.
TEST OR INSPECTION
Step 4. Test for defective oil relief valve (TM 9-2815-255-24).
CORRECTIVE ACTION
If defective, replace oil relief valve (TM 9-2815-255-24).
SYMPTOM
13. ENGINE OVERHEATING.
TEST OR INSPECTION
Step 1. Check for broken or loose fan belt (WP 0084).
CORRECTIVE ACTION
a.
If fan belt is not broken and tension is correct, do Step 2.
b.
If worn or broken, replace fan belt (WP 0084). If loose, adjust fan belt (WP 0084, Testing and
Adjustment).
TEST OR INSPECTION
Step 2. Check for defective radiator cap (WP 0077, Inspection and Cleaning).
CORRECTIVE ACTION
a.
If radiator cap is not defective, do Step 3.
b.
If defective, replace radiator cap (WP 0077).
TEST OR INSPECTION
Step 3. Check for defective coolant hose(s).
CORRECTIVE ACTION
a.
If coolant hoses are not leaking or collapsed, do Step 4.
b.
If defective, replace coolant hose(s) (WP 0077, WP 0079, WP 0080, and WP 0081).
TEST OR INSPECTION
Step 4. Test for defective thermostat (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If thermostat is not defective, do Step 5.
b.
If defective, replace thermostat (TM 9-2815-255-24).
TEST OR INSPECTION
Step 5. Check for clogged radiator (WP 0082, Inspection and Cleaning).
CORRECTIVE ACTION
a.
If radiator is not clogged, do Step 6.
b.
If clogged, remove obstruction or replace radiator (WP 0082).
0005-14
TM 9-6115-644-24
0005
TEST OR INSPECTION
Step 6. Check for defective water pump (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If defective, replace water pump (TM 9-2815-255-24).
b.
If water pump is not defective, and trouble persists, notify next higher level of maintenance.
SYMPTOM
14. ENGINE COOLANT TEMPERATURE TOO LOW.
TEST OR INSPECTION
Step 1. Check for defective thermostat (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If thermostat is operating correctly, do Step 2.
b.
If defective, replace thermostat (TM 9-2815-255-24).
TEST OR INSPECTION
Step 2. Test for defective temperature sender (WP 0112, Testing).
CORRECTIVE ACTION
a.
If temperature sender is not defective, do Step 3.
b.
If defective, replace temperature sender (WP 0112).
TEST OR INSPECTION
Step 3. Test for defective TEMPERATURE indicator (WP 0023, Testing).
CORRECTIVE ACTION
a.
If defective, replace TEMPERATURE indicator (WP 0024).
b.
If TEMPERATURE indicator is not defective, and trouble persists, notify next higher level of
maintenance.
SYMPTOM
15. EXCESSIVE FUEL CONSUMPTION.
TEST OR INSPECTION
Step 1. Check for blocked air intake system.
CORRECTIVE ACTION
a.
If air intake system is not blocked, do Step 2.
b.
If blocked, unblock or replace air intake system components as required (WP 0072 and/or WP
0073).
TEST OR INSPECTION
Step 2. Check for leaks in fuel system.
CORRECTIVE ACTION
a.
If no leaks in fuel system, do Step 3.
b.
If leaks are found, repair fuel system as required.
TEST OR INSPECTION
Step 3. Check for contaminated oil.
0005-15
TM 9-6115-644-24
CORRECTIVE ACTION
a.
If oil is contaminated, change oil (WP 0118, Removal).
b.
If oil is not contaminated, and trouble persists, notify next higher level of maintenance.
SYMPTOM
16. COOLANT IN CRANKCASE OR OIL IN COOLANT.
TEST OR INSPECTION
Step 1. Check for defective oil cooler.
CORRECTIVE ACTION
a.
If defective, replace oil cooler (TM 9-2815-255-24).
b.
If cooler is not defective, and trouble persists, do Step 2.
TEST OR INSPECTION
Step 2. Check for cracked cylinder head or block (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If cylinder head or block is not cracked, do Step 3.
b.
If cracked, replace cylinder head or block (TM 9-2815-255-24).
TEST OR INSPECTION
Step 3. Check for defective cylinder head gasket (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If defective, replace cylinder head gasket (TM 9-2815-254-24).
b.
If not defective and problem persists, repair (TM 9-2815-254-24) or replace (WP 0010,
Replacement) engine.
SYMPTOM
17. ENGINE VIBRATING.
TEST OR INSPECTION
Step 1. Check for bent or broken cooling fan blades.
CORRECTIVE ACTION
a.
If fan blades are not damaged, do Step 2.
b.
If damaged, replace cooling fan (WP 0083).
TEST OR INSPECTION
Step 2. Check for loose or defective engine mounts.
CORRECTIVE ACTION
a.
Tighten loose mounting bolts.
b.
If bolts are tight, and trouble persists, notify next higher level of maintenance.
SYMPTOM
18. ENGINE FAILS TO START IN COLD WEATHER.
TEST OR INSPECTION
Step 1. Test for low or no battery charge (WP 0012, Testing).
0005-16
0005
TM 9-6115-644-24
0005
CORRECTIVE ACTION
a.
If batteries are fully charged, do Step 2.
b.
If not fully charged, replace batteries (WP 0012).
TEST OR INSPECTION
Step 2. Check for improper lube oil type.
CORRECTIVE ACTION
a.
If proper lube oil type, do Step 3.
b.
If improper, drain oil and refill with proper lube oil type (WP 0006, Table 3 and WP 0118,
Removal). Replace oil filter (TM 9-2815-255-24).
TEST OR INSPECTION
Step 3. Check for improper grade of fuel.
CORRECTIVE ACTION
a.
If proper grade of fuel, do Step 4.
b.
If improper grade of fuel, drain engine fuel system. Drain generator set tank. Service generator
set fuel tank with clean fuel of a proper grade (WP 0006, Table 2). Prime engine fuel system
(TM 9-2815-255-24).
TEST OR INSPECTION
Step 4. Check for defective ether start system (WP 0095 and WP 0096).
CORRECTIVE ACTION
a.
If ether start system is operating properly, do Step 5.
b.
If ether start system is not operating properly, replace defective parts (WP 0095 and WP 0096).
TEST OR INSPECTION
Step 5. Test for defective ETHER SWITCH (WP 0033, Testing).
CORRECTIVE ACTION
a.
If defective, replace ETHER SWITCH (WP 0033).
b.
If ETHER SWITCH is not defective, and trouble persists, notify next higher level of
maintenance.
SYMPTOM
19. BATTERY CHARGE AMMETER SHOWS NO CHARGE WHEN BATTERIES ARE LOW OR
DISCHARGED.
TEST OR INSPECTION
Step 1. Check for broken or loose fan belt (WP 0084).
CORRECTIVE ACTION
a.
If fan belt is not broken and tension is correct, do Step 2.
b.
If worn or broken, replace fan belt (WP 0084). If loose, adjust fan belt (WP 0084, Testing and
Adjustment).
TEST OR INSPECTION
Step 2. Check for defective BATTERY CHARGER FUSE (WP 0049, Inspection).
CORRECTIVE ACTION
0005-17
TM 9-6115-644-24
a.
If BATTERY CHARGER FUSE is not blown, do Step 3.
b.
If defective, replace BATTERY CHARGER FUSE (WP 0049).
0005
TEST OR INSPECTION
Step 3. Test for defective battery charging ammeter shunt (MT4) (WP 0054, Testing).
CORRECTIVE ACTION
a.
If battery charging ammeter shunt is not defective, do Step 4.
b.
If defective, replace battery charging ammeter shunt (WP 0054).
TEST OR INSPECTION
Step 4. Test for defective battery charging alternator (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If battery charging alternator is not defective, do Step 5.
b.
If defective, replace battery charging alternator (TM 9-2815-255-24).
TEST OR INSPECTION
Step 5. Test for defective BATTERY CHARGE AMMETER (WP 0027, Testing).
CORRECTIVE ACTION
a.
If BATTERY CHARGE AMMETER is not defective, do Step 6.
b.
If defective, replace BATTERY CHARGE AMMETER (WP 0027.
TEST OR INSPECTION
Step 6. Check for breaks or loose connections in charging circuit.
CORRECTIVE ACTION
If breaks or loose connections are found, repair charging circuit. Refer to Electrical Schematic FO-1.
SYMPTOM
20. BATTERY CHARGE AMMETER SHOWS EXCESSIVE CHARGING AFTER PROLONGED OPERATION.
TEST OR INSPECTION
Step 1. Test for defective batteries (WP 0012, Testing).
CORRECTIVE ACTION
a.
If batteries are not defective, do Step 2.
b.
If defective, replace batteries (WP 0012).
TEST OR INSPECTION
Step 2. Test for defective BATTERY CHARGE AMMETER (WP 0027, Testing).
CORRECTIVE ACTION
a.
If BATTERY CHARGE AMMETER is not defective, do Step 3.
b.
If defective, replace BATTERY CHARGE AMMETER (WP 0027).
TEST OR INSPECTION
Step 3. Test for defective battery charging alternator (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If battery charging alternator is not defective, do Step 4.
b.
If defective, replace battery charging alternator (TM 9-2815-255-24).
0005-18
TM 9-6115-644-24
0005
TEST OR INSPECTION
Step 4. Check for short in charging circuit. If shorted, repair charging circuit. Refer to Electrical Schematic
FO-1.
SYMPTOM
21. AC VOLTMETER (VOLTS AC) DOES NOT INDICATE VOLTAGE.
TEST OR INSPECTION
Step 1. Test for defective AC voltmeter (VOLTS AC) (WP 0031, Testing).
CORRECTIVE ACTION
a.
If AC voltmeter (VOLTS AC) is not defective, do Step 2.
b.
If defective, replace AC voltmeter (VOLTS AC) (WP 0031).
TEST OR INSPECTION
Step 2. Test for defective VOLTAGE adjust potentiometer (WP 0034, Testing).
CORRECTIVE ACTION
a.
If VOLTAGE adjust potentiometer is not defective, do Step 3.
b.
If defective, replace VOLTAGE adjust potentiometer (WP 0034).
TEST OR INSPECTION
Step 3. Test for defective VM-AM transfer switch (WP 0039, Testing).
CORRECTIVE ACTION
a.
If defective, replace VM-AM transfer switch (WP 0039).
b.
If VM-AM transfer switch is not defective, and trouble persists, notify next higher level of
maintenance.
SYMPTOM
22. AC VOLTMETER (VOLTS AC) INDICATES VOLTAGE, BUT FREQUENCY METER (HERTZ) IS OFF
SCALE.
TEST OR INSPECTION
Step 1. Test for defective frequency transducer (WP 0052, Testing (MEP-805A)/WP 0052, Testing
(MEP-815A)) .
CORRECTIVE ACTION
a.
If frequency transducer is not defective, do Step 2.
b.
If defective, replace frequency transducer (WP 0052).
TEST OR INSPECTION
Step 2. Test for defective FREQUENCY meter (HERTZ) (WP 0028, Testing (50/60 Hz) and WP 0028,
Testing (400 Hz)).
CORRECTIVE ACTION
a.
If defective, replace FREQUENCY meter (HERTZ) (WP 0028).
b.
If FREQUENCY meter (HERTZ) is not defective, and trouble persists, notify next higher level of
maintenance.
SYMPTOM
23. AC VOLTMETER (VOLTS AC) VOLTAGE FLUCTUATES.
0005-19
TM 9-6115-644-24
0005
TEST OR INSPECTION
Step 1. Check for loose electrical connections. Refer to Electrical Schematic FO-1.
CORRECTIVE ACTION
a.
If no loose connections, do Step 2.
b.
If loose, tighten electrical connections.
TEST OR INSPECTION
Step 2. Test for defective AC voltmeter (VOLTS AC) (WP 0031, Testing).
CORRECTIVE ACTION
a.
If AC voltmeter (VOLTS AC) is not defective, do Step 3.
b.
If defective, replace AC voltmeter (VOLTS AC) (WP 0031).
TEST OR INSPECTION
Step 3. Test for defective VOLTAGE adjust potentiometer (WP 0034, Testing).
CORRECTIVE ACTION
a.
If VOLTAGE adjust potentiometer is not defective, do Step 4.
b.
If defective, replace VOLTAGE adjust potentiometer (WP 0034).
TEST OR INSPECTION
Step 4. Test for defective VM-AM transfer switch (WP 0039, Testing).
CORRECTIVE ACTION
a.
If VM-AM transfer switch is not defective, do Step 5.
b.
If defective, replace VM-AM transfer switch (WP 0039).
TEST OR INSPECTION
Step 5. Check for defective load measuring unit (WP 0065, Inspection).
CORRECTIVE ACTION
a.
If defective, replace load measuring unit (WP 0065).
b.
If load measuring unit is not defective, and trouble persists, notify next higher level of
maintenance.
SYMPTOM
24. FREQUENCY METER (HERTZ) FREQUENCY FLUCTUATES.
TEST OR INSPECTION
Step 1. Check for erratic engine operation. Refer to Malfunction 4, ENGINE RUNS ERRATICALLY OR
STALLS FREQUENTLY. If engine is operating properly, do Step 2.
TEST OR INSPECTION
Step 2. Test for defective frequency transducer (WP 0052, Testing (MEP-805A) and WP 0052, Testing
(MEP-815A)).
CORRECTIVE ACTION
a.
If frequency transducer is not defective, do Step 3.
b.
If defective, replace frequency transducer (WP 0052).
TEST OR INSPECTION
0005-20
TM 9-6115-644-24
0005
Step 3. Test for defective FREQUENCY meter (HERTZ) (WP 0028, Testing (50/60 Hz) and WP 0028,
Testing (400 Hz)).
CORRECTIVE ACTION
a.
If defective, replace FREQUENCY meter (HERTZ) (WP 0028).
b.
If FREQUENCY meter (HERTZ) is not defective, and trouble persists, notify next higher level of
maintenance.
SYMPTOM
25. NO VOLTAGE AT CONVENIENCE RECEPTACLE.
TEST OR INSPECTION
Step 1. Open control panel and inspect circuit interrupter on side of GROUND FAULT CIRCUIT
INTERRUPTER.
CORRECTIVE ACTION
a.
If device is tripped, reset device for generator sets, contract number DAAK01-94-D-0036 and
contract number DAAK02-92-D-0034.
b.
For generator sets contract number DAAK01-88-D-0082, check in-line fuse on black lead of
GROUND FAULT CIRCUIT INTERRUPTER.
c.
If device is not tripped, do Step 2.
TEST OR INSPECTION
Step 2. Check GROUND FAULT CIRCUIT INTERRUPTER.
CORRECTIVE ACTION
a.
If indicator is tripped, reset by pressing RESET button.
b.
If Indicator is not tripped, do Step 3.
TEST OR INSPECTION
Step 3. Check voltage across CONVENIENCE RECEPTACLE.
CORRECTIVE ACTION
a.
If voltage is present, replace CONVENIENCE RECEPTACLE.
b.
If voltage is not present, do Step 4.
TEST OR INSPECTION
Step 4. Check voltage across terminals 4 and 6 on TB-5.
CORRECTIVE ACTION
a.
If voltage is present, replace GROUND FAULT CIRCUIT INTERRUPTER.
b.
If voltage is not present, search for loose or broken wires or loose pin in connectors.
SYMPTOM
26. GENERATOR SET FAILS TO GENERATE POWER.
TEST OR INSPECTION
Step 1. Test for defective governor control unit (WP 0061, Testing).
CORRECTIVE ACTION
a.
If a governor control unit is not defective, do Step 2.
b.
If necessary, adjust governor control unit (WP 0061, Adjustment) or replace governor control
unit (WP 0061, Replacement).
0005-21
TM 9-6115-644-24
0005
TEST OR INSPECTION
Step 2. Test for defective AC voltage regulator (WP 0051, Testing, (AC Voltage Regulator P/N 112-3055,
for MEP-805A, AC Voltage Regulator P/N 19880-001, for MEP-805A, or AC Voltage Regulator P/N
19890-002, for MEP-815A)).
CORRECTIVE ACTION
a.
If AC voltage regulator is not defective, do Step 3.
b.
If defective, replace AC voltage regulator (WP 0051).
TEST OR INSPECTION
Step 3. Test for defective generator exciter stator (WP 0123, Testing).
CORRECTIVE ACTION
a.
If exciter stator is not defective, do Step 4.
b.
If defective, replace exciter stator (WP 0123).
TEST OR INSPECTION
Step 4. Test for defective generator stator (WP 0126, Testing).
CORRECTIVE ACTION
a.
If generator stator is not defective, do Step 5.
b.
If defective, replace generator stator and housing assembly (WP 0126).
TEST OR INSPECTION
Step 5. Test for defective diode(s) in generator rotating rectifier (WP 0120, Testing).
CORRECTIVE ACTION
a.
If diodes are not defective, do Step 6.
b.
If defective, replace diode(s) (WP 0120).
TEST OR INSPECTION
Step 6. Test for defective generator rotor (WP 0125, Testing).
CORRECTIVE ACTION
a.
If generator rotor is not defective, do Step 7.
b.
If defective, replace generator rotor assembly (WP 0125).
TEST OR INSPECTION
Step 7. Test for defective generator exciter rotor (WP 0124, Testing).
CORRECTIVE ACTION
If defective, replace generator exciter rotor (WP 0124).
SYMPTOM
28. GENERATOR SET FAILS TO GENERATE SUFFICIENT VOLTAGE.
TEST OR INSPECTION
Step 1. Check for low engine speed (TM 9-2815-254-24).
CORRECTIVE ACTION
a.
If engine is operating correctly, do Step 2.
b.
If engine is not operating correctly, repair engine (TM 9-2815-254-24).
0005-22
TM 9-6115-644-24
0005
TEST OR INSPECTION
Step 2. Test for defective power potential transformer (WP 0103).
CORRECTIVE ACTION
a.
If power potential transformer is not defective, do Step 3.
b.
If defective, replace power potential transformer (WP 0103, Removal).
TEST OR INSPECTION
Step 3. Test for defective AC voltage regulator (WP 0051, Testing, (AC Voltage Regulator P/N 112-3055,
for MEP-805A, AC Voltage Regulator P/N 19880-001, for MEP-805A, or AC Voltage Regulator P/N
19890-002, for MEP-815A)).
CORRECTIVE ACTION
a.
If AC voltage regulator is not defective, do Step 4.
b.
If defective, replace AC voltage regulator (WP 0051).
TEST OR INSPECTION
Step 4. Test for defective generator stator (WP 0126, Testing).
CORRECTIVE ACTION
If defective, replace generator stator and housing assembly (WP 0126).
SYMPTOM
29. GENERATOR SET OUTPUT FLUCTUATES.
TEST OR INSPECTION
Step 1. Check for irregular engine speed (frequency fluctuation) (TM 9-2815-255-24).
CORRECTIVE ACTION
a.
If engine is operating correctly, do Step 2.
b.
If engine is not operating correctly, repair engine (TM 9-2815-255-24).
TEST OR INSPECTION
Step 2. Check for loose terminations. Refer to Electrical Schematic FO-1.
CORRECTIVE ACTION
a.
If terminations are tight, do Step 3.
b.
If loose, tighten terminals.
TEST OR INSPECTION
Step 3. Check AC voltage regulator for incorrect output.
CORRECTIVE ACTION
a.
If AC voltage regulator is operating properly, do Step 4.
b.
If AC voltage regulator is inoperative, replace AC voltage regulator (WP 0051).
TEST OR INSPECTION
Step 4. Test for intermediate short in generator exciter field (WP 0123, Testing).
CORRECTIVE ACTION
If shorted, replace exciter stator (WP 0123).
SYMPTOM
0005-23
TM 9-6115-644-24
30. GENERATOR OVERHEATS.
TEST OR INSPECTION
Step 1. Check for clogged air intake screens.
CORRECTIVE ACTION
a.
If air intake screens are not clogged, do Step 2.
b.
If clogged, clean air intake screens.
TEST OR INSPECTION
Step 2. Check for defective generator fan (WP 0125, Testing).
CORRECTIVE ACTION
a.
If fan is not defective, do Step 3.
b.
If defective, replace fan (WP 0125).
TEST OR INSPECTION
Step 3. Check for dry generator main bearing (WP 0121).
CORRECTIVE ACTION
If dry, replace main bearing (WP 0121).
SYMPTOM
31. GENERATOR NOISY WHEN RUNNING.
TEST OR INSPECTION
Step 1. Check for defective generator main bearing (WP 0121).
CORRECTIVE ACTION
a.
If generator main bearing is not defective, do Step 2.
b.
If defective, replace main bearing (WP 0121).
TEST OR INSPECTION
Step 2. Check for loose engine/generator coupling (WP 0010, Installation).
CORRECTIVE ACTION
a.
If engine/generator coupling is not loose, do Step 3.
b.
If loose, tighten engine/generator coupling bolts (WP 0010, Installation).
TEST OR INSPECTION
Step 3. Test for defective generator.
CORRECTIVE ACTION
If defective, replace generator (WP 0119).
END OF WORK PACKAGE
0005-24
0005
TM 9-6115-644-24
CHAPTER 3
FIELD MAINTENANCE INSTRUCTIONS
FOR
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL
QUIET GENERATOR SETS
TM 9-6115-644-24
CHAPTER 3
MAINTENANCE INSTRUCTIONS
WORK PACKAGE INDEX
Title
WP Sequence No.
Service Upon Receipt..........................................................................................................................................0006
PMCS Introduction ..............................................................................................................................................0007
PMCS, Including Lubrication Instructions............................................................................................................0008
Removal and Installation of Major Components, Engine and Generator Assembly............................................0009
Removal and Installation of Major Components, Engine Assembly ....................................................................0010
Maintenance of DC Electrical System, Battery and Slave Receptacle Cables....................................................0011
Maintenance of DC Electrical System, Batteries .................................................................................................0012
Maintenance of DC Electrical System, Nato Slave Receptacle...........................................................................0013
Maintenance of Housing, Access Doors..............................................................................................................0014
Maintenance of Housing, Control Box Top Panel................................................................................................0015
Maintenance of Housing, Top Housing Section ..................................................................................................0016
Maintenance of Housing, Front Housing Section ................................................................................................0017
Maintenance of Control Box Assembly, Rear Housing Section...........................................................................0018
Maintenance of Control Box Assembly, Control Box Assembly ..........................................................................0019
Maintenance of Control Box Assembly, Panel Lights..........................................................................................0020
Maintenance of Control Box Assembly, Press-to-Test Lights .............................................................................0021
Maintenance of Control Box Assembly, Synchronizing Lights ............................................................................0022
Maintenance of Control Box Assembly, Fuel Level Indicator ..............................................................................0023
Maintenance of Control Box Assembly, Temperature Indicator ..........................................................................0024
Maintenance of Control Box Assembly, Oil Pressure Indicator ...........................................................................0025
Maintenance of Control Box Assembly, Time Meter (Total Hours) .....................................................................0026
Maintenance of Control Box Assembly, Battery Charge Ammeter......................................................................0027
Maintenance of Control Box Assembly, Frequency Meter (Hertz) ......................................................................0028
Maintenance of Control Box Assembly, Ammeter (Percent Rated Current)........................................................0029
Maintenance of Control Box Assembly, Kilowattmeter (Percent Power).............................................................0030
Maintenance of Control Box Assembly, AC Voltmeter (Volts AC).......................................................................0031
Maintenance of Control Box Assembly, Master Switch .......................................................................................0032
Maintenance of Control Box Assembly, Ether Switch .........................................................................................0033
Maintenance of Control Box Assembly, Voltage Adjust Potentiometer ...............................................................0034
Maintenance of Control Box Assembly, Frequency Adjust Potentiometer ..........................................................0035
Maintenance of Control Box Assembly, Battle Short Switch ...............................................................................0036
Maintenance of Control Box Assembly, AC Circuit Interrupter Switch ................................................................0037
Maintenance of Control Box Assembly, Parallel-Unit Switch ..............................................................................0038
TM 9-6115-644-24
Title
WP Sequence No.
Maintenance of Control Box Assembly, VM-AM Transfer Switch........................................................................0039
Maintenance of Control Box Assembly, Panel Lights Switch ..............................................................................0040
Maintenance of Control Box Assembly, Emergency Stop Switch Assembly.......................................................0041
Maintenance of Control Box Assembly, Reactive Current Adjust Rheostat ........................................................0042
Maintenance of Control Box Assembly, Load Sharing Adjust Rheostat..............................................................0043
Maintenance of Control Box Assembly, Overspeed Reset Switch ......................................................................0044
Maintenance of Control Box Assembly, Frequency Select Switch (MEP-805A) .................................................0045
Maintenance of Control Box Assembly, Convenience Receptacle......................................................................0046
Maintenance of Control Box Assembly, Ground Fault Circuit Interrupter............................................................0047
Maintenance of Control Box Assembly, Malfunction Indicator Panel ..................................................................0048
Maintenance of Control Box Assembly, Battery Charger Fuse ...........................................................................0049
Maintenance of Control Box Assembly, DC Control Power Circuit Breaker........................................................0050
Maintenance of Control Box Assembly, AC Voltage Regulator...........................................................................0051
Maintenance of Control Box Assembly, Frequency Transducer .........................................................................0052
Maintenance of Control Box Assembly, Kilowatt Transducer..............................................................................0053
Maintenance of Control Box Assembly, Shunt ....................................................................................................0054
Maintenance of Control Box Assembly, Overvoltage/Undervoltage Relay..........................................................0055
Maintenance of Control Box Assembly, Short Circuit/Overload Relay ................................................................0056
Maintenance of Control Box Assembly, Permissive Paralleling Relay ................................................................0057
Maintenance of Control Box Assembly, Reverse Power Relay...........................................................................0058
Maintenance of Control Box Assembly, Voltage Sensing Relay .........................................................................0059
Maintenance of Control Box Assembly, Relays...................................................................................................0060
Maintenance of Control Box Assembly, Governor Control Unit (GCU) ...............................................................0061
Maintenance of Control Box Assembly, Control Box Wiring Harness .................................................................0062
Maintenance of Control Box Assembly, Diagnostic Connector ...........................................................................0063
Maintenance of Control Box Assembly, Parallel Connector ................................................................................0064
Maintenance of Control Box Assembly, Load Measuring Unit ............................................................................0065
Maintenance of Control Box Assembly, Resistor-Diode Assembly .....................................................................0066
Maintenance of Control Box Assembly, Control Panel........................................................................................0067
Maintenance of Control Box Assembly, Control Panel Frame ............................................................................0068
Maintenance of Control Box Assembly, Control Box Side Panels.......................................................................0069
Maintenance of Control Box Assembly, Control Box Tray (Bottom)....................................................................0070
Maintenance of Air Intake and Exhaust System, Muffler and Exhaust Pipe........................................................0071
Maintenance of Air Intake and Exhaust System, Air Restriction Indicator...........................................................0072
Maintenance of Air Intake and Exhaust System, Air Cleaner Assembly .............................................................0073
Maintenance of Air Intake and Exhaust System, Air Cleaner Element................................................................0074
Maintenance of Air Intake and Exhaust System, Air Cleaner Tubing and Breather ............................................0075
TM 9-6115-644-24
Title
WP Sequence No.
Maintenance of Coolant System, Coolant System ..............................................................................................0076
Maintenance of Coolant System, Radiator Filler Hose and Panel Assembly ......................................................0077
Maintenance of Coolant System, Fan Guards.....................................................................................................0078
Maintenance of Coolant System, Upper Coolant Hose .......................................................................................0079
Maintenance of Coolant System, Lower Coolant Hose .......................................................................................0080
Maintenance of Coolant System, Coolant Overflow and Drain Hoses ................................................................0081
Maintenance of Coolant System, Radiator ..........................................................................................................0082
Maintenance of Coolant System, Generator Set Cooling Fan.............................................................................0083
Maintenance of Coolant System, Fan Belt ..........................................................................................................0084
Maintenance of Coolant System, Coolant Recovery System ..............................................................................0085
Maintenance of Fuel System, Low Pressure Fuel Lines and Fittings..................................................................0086
Maintenance of Fuel System, Auxiliary Fuel Pump .............................................................................................0087
Maintenance of Fuel System, Fuel Tank Filler Neck ...........................................................................................0088
Maintenance of Fuel System, Fuel Drain Valve ..................................................................................................0089
Maintenance of Fuel System, Fuel Level Sender................................................................................................0090
Maintenance of Fuel System, Low Fuel Level/Auxiliary Fuel Pump Float Switch ...............................................0091
Maintenance of Fuel System, Fuel Pickup ..........................................................................................................0092
Maintenance of Fuel System, Fuel Float Module ................................................................................................0093
Maintenance of Fuel System, Fuel Filter/Drain Valve Assembly.........................................................................0094
Maintenance of Fuel System, Ether Cylinder ......................................................................................................0095
Maintenance of Fuel System, Ether Solenoid Valve ...........................................................................................0096
Maintenance of Fuel System, Fuel Tank .............................................................................................................0097
Maintenance of Output Box Assembly, Output Box Assembly............................................................................0098
Maintenance of Output Box Assembly, Voltage Reconnection Terminal Board..................................................0099
Maintenance of Output Box Assembly, Output Box Wiring Harness...................................................................0100
Maintenance of Output Box Assembly, Current Transformer..............................................................................0101
Maintenance of Output Box Assembly, Droop Current Transformer ...................................................................0102
Maintenance of Output Box Assembly, Power Potential Transformer.................................................................0103
Maintenance of Output Box Assembly, Ac Circuit Interrupter Relay ...................................................................0104
Maintenance of Output Box Assembly, Cranking Relay......................................................................................0105
Maintenance of Output Box Assembly, Load Output Terminal Board .................................................................0106
Maintenance of Output Box Assembly, Load Output Terminals..........................................................................0107
Maintenance of Output Box Assembly, Varistors ................................................................................................0108
Maintenance of Output Box Assembly, Output Box Panels ................................................................................0109
Maintenance of Engine Accessories, Low Oil Pressure Switch ..........................................................................0110
Maintenance of Engine Accessories, Oil Pressure Sender .................................................................................0111
Maintenance of Engine Accessories, Coolant Temperature Sender...................................................................0112
TM 9-6115-644-24
Title
WP Sequence No.
Maintenance of Engine Accessories, Coolant High Temperature Switch ...........................................................0113
Maintenance of Engine Accessories, Magnetic Pickup .......................................................................................0114
Maintenance of Engine Accessories, Dead Crank Switch...................................................................................0115
Maintenance of Engine Accessories, Diode Assembly .......................................................................................0116
Maintenance of Engine Accessories, Governor Actuator ....................................................................................0117
Maintenance of Lubrication System, Oil Drain Line.............................................................................................0118
Maintenance of Generator Assembly, Generator Assembly ...............................................................................0119
Maintenance of Generator Assembly, Rotating Rectifier Diodes ........................................................................0120
Maintenance of Generator Assembly, End Bell and Main Bearing......................................................................0121
Maintenance of Generator Assembly, Rotating Rectifier.....................................................................................0122
Maintenance of Generator Assembly, Exciter Stator...........................................................................................0123
Maintenance of Generator Assembly, Exciter Rotor ...........................................................................................0124
Maintenance of Generator Assembly, Main Rotor Assembly ..............................................................................0125
Maintenance of Generator Assembly, Main Stator and Housing.........................................................................0126
Maintenance of Skid Base...................................................................................................................................0127
Preparation for Storage or Shipment...................................................................................................................0128
Illustrated List of Manufactured Items Introduction..............................................................................................0129
Cable Assembly, AC Power (P/N 88-22126-1 through 88-22126-7) ...................................................................0130
Cable Assembly, Battery (P/N 88-22178)............................................................................................................0131
Cable Assembly, Battery (P/N 88-22127)............................................................................................................0132
Cable Assembly, Battery (P/N 88-22181)............................................................................................................0133
Cable Assembly, Battery (P/N 88-22179)............................................................................................................0134
Cable Assembly, Battery (P/N 88-22207)............................................................................................................0135
Holder, Control Panel (P/N 88-22120).................................................................................................................0136
Hose Assembly (P/N 88-20191-6).......................................................................................................................0137
Insulation, Panel, Top (P/N 88-22582) ................................................................................................................0138
Insulation, Baffle (P/N 88-22592) ........................................................................................................................0139
Insulation, Baffle (P/N 88-22593) ........................................................................................................................0140
Insulation, Top, Center (P/N 88-22584)...............................................................................................................0141
Insulation, Top, Rear (P/N 88-22585)..................................................................................................................0142
Insulation, Front Housing (P/N 88-22591) ...........................................................................................................0143
Insulation, Top, Front (P/N 88-22586) .................................................................................................................0144
Insulation, Top, Center (P/N 88-22587)...............................................................................................................0145
Insulation, Top, Center (P/N 88-22588)...............................................................................................................0146
Insulation, Top, Front (P/N 88-22583) .................................................................................................................0147
Resistor Assembly (P/N 122-3066-1 and 29879) ................................................................................................0148
Resistor Assembly, Volt (P/N 88-22631) .............................................................................................................0149
TM 9-6115-644-24
Title
WP Sequence No.
Resistor-Diode Assembly (P/N 88-22632)...........................................................................................................0150
Resistor-Diode Assembly (P/N 88-22106)...........................................................................................................0151
Solenoid Assembly (P/N 88-22553) ....................................................................................................................0152
Switch Assembly, Fuel Level (P/N 88-22548) .....................................................................................................0153
Wire, Varistor (P/N 88-20305-1 through 88-20305-3 and 88-20305-5) ...............................................................0154
Torque Limits.......................................................................................................................................................0155
TM 9-6115-644-24
0006
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
SERVICE UPON RECEIPT
SERVICE ON RECEIPT OF MATERIEL
This work package provides information and guidance for inspecting, servicing, and installing the generator set
under normal conditions.
Inspection
1.
Unpack and inventory all end item components for serviceability.
2.
Check that all packing materials have been removed.
3.
Check generator set identification plate for proper identification.
4.
Inspect generator set exterior for shipping damage.
5.
Open battery compartment access door and inspect batteries for damage.
6.
Check battery cables for proper polarity connection, damage, and loose connections.
7.
Open control panel access door and check panel for damage. Lower control panel and check electrical
components for damage/loose connections. Raise control panel and secure fasteners.
8.
Check air cleaner assembly for external damage and exhaust opening for obstruction.
9.
Check fan belt for looseness and ensure it is not frayed or cracked.
10. Inspect generator set for loose or missing mounting hardware or damaged or missing parts.
NOTE
Dipstick is marked indicating that oil level can be checked and oil added when engine is running
or stopped. Make sure the correct side of dipstick is checked.
11. Check oil level. As required, drain preservative from engine and fill with proper lubricating oil; refer to
Lubricating Oil.
12. Unpack grounding rod from inside left engine access door, parallel cable, and auxiliary fuel hose from
storage box. Inspect each item for damage and accountability.
END OF TASK
Service
Batteries. When servicing batteries, refer to TM 9-6140-200-14.
WARNING
Each battery weighs more than 70 pounds (32 kg) and requires a two-person lift. Lifting batteries
can cause back strain. Ensure proper lifting techniques are used when lifting batteries. Failure to
comply with this warning can cause injury to personnel.
WARNING
Batteries give off a flammable gas. Do not smoke or use open flame when performing
maintenance. Failure to comply with this warning can cause injury or death to personnel, and
damage to the generator set.
WARNING
Battery acid can cause burns to unprotected skin. Wear safety goggles and chemical gloves and
avoid acid splash while working on batteries. Failure to comply with this warning can cause injury
to personnel.
0006-1
TM 9-6115-644-24
0006
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
Many components require a two-person lift. Lifting heavy components can cause back strain.
Ensure proper lifting techniques are used when lifting heavy components. Failure to comply with
this warning can cause injury to personnel.
Radiator.
WARNING
Do not operate generator set while servicing radiator. Failure to comply with this warning can
cause injury to personnel and damage to the equipment.
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool
before performing checks, services and maintenance, or wear gloves and additional protective
clothing and goggles as required. Failure to comply with this warning can cause injury or death to
personnel.
1.
Remove radiator cap.
2.
Check that radiator drain valve is closed (WP 0002, Figure 1).
3.
Fill radiator with proper coolant/antifreeze (Table 1). Fill radiator to a level two inches below fill opening.
4.
Remove overflow bottle cap.
5.
Fill overflow bottle to COLD level.
Table 1. Coolant.
Ambient Temperature
6.
Radiator Coolant
Ratio
+40 to +120 °F
(+4 to +49 °C)
Water: MIL-A-53009A(1)
Inhibitor, Corrosion
35:1
-25 to +120 °F
(-32 to +49 °C)
Water: A-A-52624A
Antifreeze
1:1
-25 to +120 °F
(-32 to +49 °C)
A-A-52624A Antifreeze
N/A
Install overflow bottle and radiator caps.
0006-2
TM 9-6115-644-24
0006
WARNING
Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool
before performing checks, services and maintenance, or wear gloves and additional protective
clothing and goggles as required. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Fan has sharp blades. Use caution and wear gloves when removing or installing belts. Failure to
comply with this warning can cause injury to personnel.
7.
After 30 minutes of operation check coolant/antifreeze level at overflow bottle. Add coolant/antifreeze to
overflow bottle, as required.
END OF TASK
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
Fuel Tank.
WARNING
Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Operators are to wash exposed skin and change chemical soaked clothing
promptly if exposed to fuel. Failure to comply with this warning can cause injury or death to
personnel.
1.
Check that fuel drain valve is closed (WP 0002, Figure 1).
2.
Remove fuel tank filler cap.
3.
Fill fuel tank with fuel type (Table 2). Fuel tank capacity is 23 gallons (87.1 liters).
WARNING
Fuels used in the generator set are flammable. When filling the fuel tank, maintain metal-to-metal
contact between filler nozzle and fuel tank opening to eliminate static electrical discharge. Failure
to comply with this warning can cause injury or death to personnel, and damage to the generator
set.
WARNING
Fuels used in the generator set are flammable. Do not smoke or use open flames when
performing maintenance. Failure to comply with this warning can cause injury or death to
personnel, and damage to the generator set.
4.
Install fuel tank filler cap.
Table 2. Fuel.
Ambient Temperature
+20 to +120 °F
(-7 to +49 °C)
Diesel Fuel
A-A-52557A, Grade 2-D
MIL-DTL-83133E, JP-8
0006-3
TM 9-6115-644-24
0006
Table 2. Fuel. - Continued
Ambient Temperature
-25 to +20 °F
(-32 to -7 °C)
Diesel Fuel
A-A-52557A, Grade 1-D
MIL-DTL-5624T, JP-5
END OF TASK
Lubricating Oil.
1.
Place suitable container under oil drain plug and remove plug.
WARNING
Oil filter base and housing springs are under tension and can act as projectiles when being
removed. Use eye protection when removing springs. Failure to comply with this warning can
cause injury to personnel.
2.
Open battery access door, open oil drain valve (WP 0002, Figure 1), and drain oil.
3.
Close oil drain valve and remove oil fill cap.
NOTE
Dipstick is marked indicating that oil level can be checked and oil added when engine is running
or stopped. Make sure the correct side of dipstick is checked.
4.
Fill engine with proper engine lubricating oil (Table 3) to FULL mark on dipstick. Lubrication system capacity
is 15 quarts (14.2 Liters).
WARNING
The high pressure oil system operates at high temperature and pressure. Contact with hot oil can
result in burns and scalding. Shut down generator set, and allow system to cool before
performing checks, services, and maintenance. Wear heat resistant gloves and avoid contacting
hot surfaces. Do not allow hot oil or components to contact skin or hands. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
components have been heated. Wear additional protective clothing as required. Failure to comply
with this warning can cause injury to personnel.
5.
Install oil fill cap. Close battery access door.
6.
Close battery access door.
Table 3. Lubricating Oil.
Ambient Temperature
Lubricating Oil
+20 to +120 °F
(-7 to +49 °C)
MIL-PRF-2104H
OE HDO-30 or OE HDO-15/40
0 to +20 °F
(-17 to +6 °C)
MIL-PRF-2104H
OE HDO-10
-25 to 0 °F (-32 to -17 °C)
MIL-PRF-46167C
END OF TASK
0006-4
TM 9-6115-644-24
INSTALLATION INSTRUCTIONS
General
WARNING
Exhaust discharge contains deadly gases including carbon monoxide. DO NOT operate
generator set in enclosed areas unless exhaust discharge is properly vented outside. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Hot exhaust gases can ignite flammable materials. Allow room for safe discharge of hot gases
and sparks. Failure to comply with this warning can cause injury or death to personnel.
1.
Ensure that installation site is as level as possible.
2.
Provide adequate ventilation to prevent recirculation of hot air exhausted from generator set.
3.
Refer to Figure 1 for base mounting measurements.
Figure 1. Base Mounting Measurements.
END OF TASK
0006-5
0006
TM 9-6115-644-24
Outdoor Installation
1.
Make use of natural protective barriers.
2.
Allow space on all sides for service and maintenance. Refer to Figure 2 for minimum clearance
measurements.
3.
Ensure that site soil is firm and well drained.
4.
Use planks or other material for support in areas where soil will not support generator set.
END OF TASK
Indoor Installation
WARNING
Hot exhaust gases can ignite flammable materials. Allow room for safe discharge of hot gases
and sparks. Failure to comply with this warning can cause injury or death to personnel.
WARNING
Exhaust discharge contains deadly gases including carbon monoxide. DO NOT operate
generator set in enclosed areas unless exhaust discharge is properly vented outside. Failure to
comply with this warning can cause injury or death to personnel.
CAUTION
Never position generator set with the air inlets near a wall or other object that interferes with
cooling air circulation. Damage to equipment could occur.
1.
Provide ducts and vents to outside of building if good supply of cooling air is not available.
2.
Make air intake and outlet openings in building same size or larger as those on the generator set.
3.
Install a gas-tight metal pipe from exhaust pipe of generator set to outside of building.
NOTE
Make exhaust pipe extension as short and straight as possible with only one 90 degree bend, if
needed.
4.
Ensure that inside diameter of exhaust pipe extension is as large as or larger than generator set exhaust
pipe.
WARNING
Hot exhaust gases can ignite flammable materials. Allow room for safe discharge of hot gases
and sparks. Failure to comply with this warning can cause injury or death to personnel.
5.
Provide for harmless discharge of hot gases and sparks. Do not direct exhaust into area containing
flammable materials.
WARNING
If not shielded, hot exhaust pipe can ignite flammable wall materials. Failure to comply with this
warning can cause injury or death to personnel.
6.
Shield exhaust pipe with fireproof material at point where it passes through a flammable wall.
WARNING
An unwrapped exhaust pipe can cause injury if touched. Failure to comply with this warning can
cause injury to personnel.
7.
Wrap exhaust pipe in protective material.
0006-6
0006
TM 9-6115-644-24
8.
Allow space on all sides for service and maintenance. Refer to Figure 2 for minimum clearance
measurements.
WARNING
Exhaust discharge contains deadly gases including carbon monoxide. DO NOT operate
generator set in enclosed areas unless exhaust discharge is properly vented outside. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Engine exhaust fumes contain deadly poisonous gases.
Severe exposure can cause death or permanent brain damage.
Exhaust gases are most dangerous in places with poor airflow. Best defense against exhaust
gas poisoning is very good airflow.
To protect yourself and your partners, always obey the following rules:
•
DO NOT run engine indoors unless you have VERY GOOD AIRFLOW.
•
DO NOT idle engine for a long time unless there is VERY GOOD AIRFLOW.
•
Be alert at all times. Check for smell of exhaust fumes.
•
REMEMBER: Best defense against exhaust gas poisoning is VERY GOOD AIRFLOW.
•
Exhaust gas poisoning causes dizziness, headache, loss of muscle control, sleepiness,
coma, and death. If anyone shows signs of exhaust gas poisoning, get ALL
PERSONNEL clear of exhaust area. Make sure they have lots of fresh air. KEEP THEM
WARM, CALM, AND INACTIVE. GET MEDICAL HELP. If anyone stops breathing, give
artificial respiration. See FM 4-25.11 for first aid.
0006-7
0006
TM 9-6115-644-24
0006
Figure 2. Minimum Enclosure Clearance Measurements.
END OF TASK
FABRICATION/ASSEMBLY OF PARTS
Table 4 provides a list of generator set parts that require fabrication or assembly when replacing. Refer to WP
0129 for an index to fabrication and assembly instructions.
Table 4. Fabricated/Assembled Parts.
NAME
PART NUMBER
Cable Assembly, AC Power
88-22126-1
Cable Assembly, AC Power
88-22126-2
Cable Assembly, AC Power
88-22126-3
Cable Assembly, AC Power
88-22126-4
Cable Assembly, AC Power
88-22126-5
Cable Assembly, AC Power
88-22126-6
Cable Assembly, AC Power
88-22126-7
Cable Assembly, Battery
88-22178
0006-8
TM 9-6115-644-24
0006
Table 4. Fabricated/Assembled Parts. - Continued
NAME
PART NUMBER
Cable Assembly, Battery
88-22127
Cable Assembly, Battery
88-22181
Cable Assembly, Battery
88-22179
Cable Assembly, Battery
88-22207
Holder, Control Panel
88-22120
Hose Assembly
88-20191-6
Insulation, Panel, Top
88-22582
Insulation, Baffle
88-22592
Insulation, Baffle
88-22593
Insulation, Top, Center
88-22584
Insulation, Top, Rear
88-22585
Insulation, Front Housing
88-22591
Insulation, Top, Front
88-22586
Insulation, Top, Center
88-22587
Insulation, Top, Center
88-22588
Insulation, Top, Front
88-22583
Resistor Assembly
122-3066-1
Resistor Assembly
29879
Resistor Assembly, Volt
88-22631
Resistor-Diode Assembly
88-22632
Resistor-Diode Assembly
88-22106
Solenoid Assembly
88-22553
Switch Assembly, Fuel Level
88-22548
Varistor Wire L1
88-20305-1
Varistor Wire L2
88-20305-2
Varistor Wire L3
88-20305-3
Varistor Wire L0
88-20305-5
END OF WORK PACKAGE
0006-9/(10 blank)
TM 9-6115-644-24
0007
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
PMCS INTRODUCTION
INTRODUCTION TO FIELD PMCS TABLE
WP 0008, Table 1 (PMCS table) has been provided so you can keep your equipment in good operating condition
and ready for its primary mission.
Warnings and Cautions
Always observe the WARNINGS, CAUTIONS, and NOTES appearing in your PMCS table. Warnings and
cautions appear before applicable procedures. You must observe these WARNINGS to prevent serious injury to
yourself and others. You must observe CAUTIONS to prevent your equipment from being damaged. You must
observe NOTES to ensure procedures are performed properly.
Explanation of Table Entries
Item No. Column. Numbers in this column are for reference. When completing DA Form 2404 (Equipment
Inspection and Maintenance Worksheet), include the item number for the check/service indicating a fault. Item
numbers also appear in the order that you must do checks and services for the intervals listed.
Interval Column. This column tells you when you must do the procedure in the procedure column. Perform
procedures such as "Monthly" or "Quarterly" at the listed calendar interval. Perform procedures designated by
number of hours when the equipment has been operated for that many hours.
Item to be Checked or Serviced Column. This column lists the item to be checked or serviced.
Procedure Column. This column gives the procedures for checking or servicing the item listed in the item to be
checked or serviced column. You must perform the procedure to know if the generator set is ready or available for
its intended mission or operation. You must do the procedure at the time stated in the interval column.
Equipment Not Ready/Available if: Column. Information in this column tells you what faults will keep the
generator set from being capable of performing its primary mission. If checks or services show faults listed in this
column, do not return the generator set to service until the faults have been corrected.
NOTE
The terms ready/available and mission capable refer to the same status: generator set is on hand
and is able to perform its combat missions (see DA Pam 750-8).
Other Table Entries
Be sure to observe all special information and notes that appear in your table.
Reporting and Correcting Deficiencies
If your generator set does not perform as required, refer to Troubleshooting for possible problems. Report any
malfunctions or failures on DA Form 2404, or refer to DA Pam 750-8.
Special Instructions
Preventive maintenance is not limited to performing the checks and services listed in the PMCS table. Covering
unused receptacles, stowing unused accessories, and performing other routine procedures such as equipment
inventory, cleaning components, and touch-up painting are not listed in the table. These are things you should do
any time you see that they need to be done. If a routine check is listed in the PMCS table, it is because
experience has shown that problems may occur with this item. Take along tools and cleaning cloths needed to
perform the required checks and services. Use the information in the following paragraphs to help you identify
problems at any time and to help identify potential problems before and during checks and services.
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
0007-1
TM 9-6115-644-24
0007
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
1.
2.
3.
4.
5.
6.
Keep the generator set clean. Dirt, grease, and oil get in the way and may cover up a serious problem. Use
cleaning solvent to clean metal surfaces.
Use soap and water to clean rubber or plastic parts and material.
Check all bolts, nuts, and screws to make sure they are not loose, missing, bent, or broken. Do not try to
check them with a tool, but look for chipped paint, bare metal, or rust around bolt heads. If you find one loose,
report it to the next-higher level of maintenance.
Inspect welds for loose or chipped paint, rust, or gaps where parts are welded together. If a broken weld is
found, report it to the next-higher level of maintenance.
Inspect electrical wires, connectors, terminals, and receptacles for cracked or broken insulation, bare wires,
and loose or broken connectors. Tighten loose connectors. Examine terminals and receptacles for
serviceability. If deficiencies are found, report them to the next-higher level of maintenance.
Inspect hoses and fluid lines. Look for wear, damage, and leaks. Make sure that clamps and fittings are tight.
Wet spots and stains around a fitting or connector can mean a leak. If a leak comes from a loose connector,
or if something is broken or worn out, report it to the next-higher level of maintenance.
Leakage Definitions
You must know how fluid leakage affects the status of your equipment. The following are definitions of the
types/classes of leakage you need to know to be able to determine the status of your equipment. Learn and be
familiar with them. When in doubt, notify your supervisor.
Leakage Class
Leakage Definition
Class I
Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops.
Class II
Leakage of fluid great enough to form drops, but not enough to cause drops to drip from the
item being checked/inspected.
Class III
Leakage of fluid (other than fuel) greater than three drops per minute that fall from the item
being inspected.
Operation of Power Unit/Power Plant with Minor Leaks
1.
2.
Consider the equipment's capacity for the fluid that is leaking. If the capacity is small, the fluid level may soon
become too low for continued operation. If in doubt, notify your supervisor
Check the fluid level more often than required in the PMCS table. Add fluid as needed.
Corrosion Prevention and Control (CPC)
CPC of Army materiel is of continuing concern. It is important that any corrosion problems with the equipment be
reported so that the problem can be corrected and improvements can be made to prevent the problem in future
items. Although corrosion is typically associated with rusting of metals, it can also include deterioration of other
materials, such as rubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may
be a corrosion problem. If a corrosion problem is identified, it can be reported using SF 368, Product Quality
Deficiency Report. Use of key words such as "corrosion," "rust," "deterioration," or "cracking" will ensure that the
information is identified as a CPC problem. The form should be submitted to the address specified in DA Pam
750-8.
END OF WORK PACKAGE
0007-2
TM 9-6115-644-24
0008
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
PMCS, INCLUDING LUBRICATION INSTRUCTIONS
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Fuel Filter/Auxiliary Fuel Filter
Engine Lubrication Oil
Cleaning Cloth
Coolant
Fan Belt
Personnel Required
One
References
LO 9-6115-644-12
TM 9-6115-2815-255-24
WP 0012, Maintenance Of DC Electrical System,
Batteries
WP 0075, Maintenance Of Air Take & Exhaust
System, Air Cleaner Tubing & Breather
WP 0076, Maintenance Of Cooling System, Coolant
System
WP 0082, Maintenance Of Cooling System, Radiator
WP 0084, Maintenance of Coolant System, Fan Belt
Maintenance of Engine Accessories, Magnetic
Pickup
Equipment Condition
Grounded, Off & Operational
SPECIAL LUBRICATION INSTRUCTIONS
NOTE
There are no special lubrication instructions. Refer to LO 9-6115-644-12 for generator set
lubrication requirements.
Table 1. Preventive Maintenance Checks and Services for MEP-805A and MEP-815A.
ITEM
NO.
1
INTERVAL
SemiAnnually,
300 hours
ITEM TO BE
CHECKED OR
SERVICED
Engine Lube Oil
PROCEDURE
NOTE
Oil filter should be
changed with lube oil
change (TM
9-2815-255-24).
Drain engine lube oil. Add proper lube oil
(LO 9-6115-644-12).
2
Annually,
300 hours
Fuel Filter/Water
Separator
Change fuel filter/water separator (TM
9-2815-255-24).
0008-1
EQUIPMENT NOT
READY/AVAILABLE IF:
TM 9-6115-644-24
0008
Table 1. Preventive Maintenance Checks and Services for MEP-805A and MEP-815A. - Continued
ITEM
NO.
INTERVAL
ITEM TO BE
CHECKED OR
SERVICED
PROCEDURE
EQUIPMENT NOT
READY/AVAILABLE IF:
3
Bi-Annually, Cooling System
1500 hours
Drain coolant and flush cooling system or
add proper coolant (WP 0076, Servicing).
4
Annually
Radiator Cap
Inspect radiator cap for corrosion, torn or Radiator cap or seal is
deteriorated seal, and obvious damage. damaged.
5
Annually,
300 hours
Batteries
Remove batteries (WP 0012, Removal).
Clean batteries, cable terminals, and
battery posts; test batteries for state of
charge (WP 0012, Testing).
6
Annually,
300 hours
Air Cleaner
Assembly
Inspect air cleaner assembly and
mounting bracket for cracks, dents, and
other damage. Inspect element for clogs
and damage. Clean or replace, as necessary. Clean housing with cleaning cloth.
7
Annually,
750 hours
Air Cleaner Tubing
and Breather
Remove, clean, and inspect tubing and
breather (WP 0075).
8
Annually,
300 hours
Hardware and
Sound Insulation
Inspect for loose, damaged, or missing
hardware and sound insulation. Tighten
loose hardware. Repair or replace
damaged or missing hardware and insulation.
9
Annually,
1500 hours
Radiator and
Interior of Generator Set
Clean radiator exterior surfaces (WP
0082, Inspection and Cleaning). Clean
engine compartment.
10
Annually,
1500 hours
Magnetic Pickup
Remove, inspect, and clean magnetic
pickup (WP 0114).
Magnetic pickup is
damaged.
11
Annually
Wiring Harnesses
Inspect wiring harnesses for breaks and
loose connections. Repair and tighten
wiring harnesses, as necessary.
Wiring harnesses are
damaged or connections
are loose.
12
Annually,
3000 hours
Muffler
Check muffler for leaks, restriction, and
accumulation of carbon. Replace or
clean, as required.
Muffler leaks, is restricted,
or has excessive carbon
accumulation.
13
Annually,
300 hours
Governor Linkage
Clean and lubricate governor actuator
linkage rod.
14
Annually,
500 hours
Auxiliary Fuel Filter
NOTE
If the auxiliary fuel
system is used as the
primary fuel source, then
the auxiliary fuel filter
must be replaced semiannually.
Check for proper operation using auxiliary fuel system as primary source.
Check for proper operation using auxiliary fuel system as primary source.
15
Annually,
1500 hours
Fan Belt
Replace fan belt (WP 0084).
0008-2
Batteries will not hold
charge.
Hardware or insulation
loose, missing, or
damaged.
TM 9-6115-644-24
0008
Table 1. Preventive Maintenance Checks and Services for MEP-805A and MEP-815A. - Continued
ITEM
NO.
16
INTERVAL
ITEM TO BE
CHECKED OR
SERVICED
Every Oil
Wetstacking
Change, 300
hours
PROCEDURE
NOTE
Perform if the generator
set has been operated
for long periods of times
at low loads and shows
signes of wetstacking.
Place an 80 % load on the generator set
and operate generator for 1-2 hours
until the wetstacking residues burn off.
Place an 80 % load on the generator set
and operate generator for 1-2 hours until
the wetstacking residues burn off.
Mandatory Replacement Parts List
There are no replacement parts required for these PMCS procedures.
END OF WORK PACKAGE
0008-3/(4 blank)
EQUIPMENT NOT
READY/AVAILABLE IF:
TM 9-6115-644-24
0009
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
REMOVAL AND INSTALLATION OF MAJOR COMPONENTS, ENGINE AND GENERATOR ASSEMBLY:
REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Coolant
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0006, Lubricating Oil & Coolant
WP 0017, Maintenance Of Housing, Front Housing
Section
WP 0018, Maintenance Of Control Box Assembly,
Rear Housing Section
WP 0081, Maintenance Of Coolant System, Coolant
Overflow & Drain Hoses
WP 0082, Maintenance Of Coolant System, Radiator
WP 0086, Maintenance Of Fuel System, Auxiliary
Fuel Pump
WP 0098, Maintenance Of Outbox Assembly,
Outbox Assembly
WP 0118, Maintenance Of Lube System, Oil Drain
Line
WP 0127, Maintenance Of Skid Base
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
GENERAL
The engine and generator are bolted together at the engine flywheel and flywheel housing adapter. The engine
and generator may be removed as an assembly or individually. The engine and generator assembly is mounted
on the skid base at four points, two at the engine and two at the generator. There are also brackets installed on
both sides of the engine which can be adjusted to support the rear of the engine when removing the generator
separately. There are bolts and nuts which can be adjusted to support the front of the generator when removing
the engine.
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
0009-1
TM 9-6115-644-24
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Slave receptacle (NATO connector) is electrically live at all times and is unfused. The Battery
Disconnect Switch does not remove power from the slave receptacle. NATO slave receptacle has
24 VDC even when Battery Disconnect Switch is set to OFF. This circuit is only dead when the
batteries are fully disconnected. Disconnect the batteries before performing maintenance on the
slave receptacle. Failure to comply with this warning can cause injury or death to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
When disconnecting or removing batteries, disconnect the negative lead that connects directly to
the grounding stud first; disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply with this warning can
cause injury to personnel.
WARNING
Many components require a two-person lift. Lifting heavy components can cause back strain.
Ensure proper lifting techniques are used when lifting heavy components. Failure to comply with
this warning can cause injury to personnel.
WARNING
Each battery weighs more than 70 pounds (32 kg) and requires a two-person lift. Lifting batteries
can cause back strain. Ensure proper lifting techniques are used when lifting batteries. Failure to
comply with this warning can cause injury to personnel.
WARNING
Support components when removing attaching hardware or component may fall. Failure to
comply with this warning can cause injury to personnel, and damage to equipment.
WARNING
The generator set, engine, and generator are extremely heavy and require an assistant and a
lifting device (forklift, overhead lifting device) with sufficient capacity. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
0009-2
0009
TM 9-6115-644-24
0009
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove output box assembly and generator set housing (WP 0098, Removal; WP 0017, Removal; and WP
0018, Removal).
4.
Remove radiator (WP 0082, Removal).
5.
Drain engine oil and disconnect oil drain line at engine fitting (WP 0118, Removal).
6.
Disconnect fuel line at engine fuel pump from fuel pickup (WP 0086, Removal).
7.
Disconnect engine excess fuel return line at tank fitting (WP 0086, Removal).
8.
Disconnect coolant overflow hose from overflow bottle (WP 0081, Removal).
9.
Remove nuts (Figure 1, Item 1), washers (2), snubbing washers (3), washers (37), and bolts (4) from engine
mounts (5).
10. Remove rear forklift guide from generator set (WP 0127, Removal).
11. Remove nuts (6), washers (7), bolts (8), snubbing washers (9), and Belleville washers (10) from generator
mounts.
12. Tie wrap generator power leads and secure out of the way.
CAUTION
Rated capacity of overhead hoist should be at least 2,000 pounds (907 Kg). Arrange lifting device
so that it supports both engine and generator to avoid undue stress on the engine and generator
coupling.
13. Attach lifting harness to engine and generator lifting points. Raise engine and generator assembly from skid
base.
14. Move engine and generator assembly to maintenance work area. Support assembly on maintenance stand or
fixture.
15. Remove engine shock mounts (14) from skid base by removing nuts (11), washers (12), and bolts (13).
16. Remove shock mounts (15) from generator mounting points on skid base.
17. Remove engine mounting brackets (5) by removing bolts (16), lockwashers (17), and washers (18). Discard
lockwashers (17).
18. Remove engine support brackets (22) by removing bolts (19), lockwashers (20), and washers (21). Discard
lockwashers (20).
19. Remove generator mount angles (29), plates (28), nuts (23 and 27), washers (24 and 26), and bolts (25) from
generator.
END OF TASK
INSTALLATION
1.
Install engine shock mount (Figure 1, Item 14) on skid base with bolts (13), washers (12), and nuts (11).
2.
Position generator shock mounts (15) in skid base.
3.
Install engine mounting brackets (5) on engine with bolts (16), new lockwashers (17), and washers (18).
Torque bolts to 120 ft•lbs (163 N•m).
4.
Install engine support brackets (22) on engine with bolts (19), new lockwashers (20), and washers (21).
5.
Install generator mount angles (29) and plates (28) on generator with bolts (25), washers (24 and 26), and
nuts (23 and 27).
CAUTION
Rated capacity of overhead hoist should be at least 2,000 pounds (907 Kg). Arrange lifting device
so that it supports both engine and generator to avoid undue stress on the engine and generator
coupling.
0009-3
TM 9-6115-644-24
0009
6.
Attach lifting harness to engine and generator lifting points. Raise engine and generator assembly from
maintenance stand or fixture.
7.
Position engine and generator assembly on skid base, aligning mounting holes and brackets.
8.
Install bolts (8), Belleville washers (10), snubbing washers (9), washers (7), and nuts (6) to secure generator
to skid base. Torque bolts (8) to 210 ft•lbs (285 N•m).
9.
Adjust nuts (23 and 27) to obtain 0.5 inch (12.7 mm) minimum clearance between ends of bolts (25) and skid
base.
10. Install bolts (4), washers (37), snubbing washers (3), washers (2), and nuts (1) to secure engine to skid base.
Torque bolts (4) to 75 ft•lbs (102 N•m).
11. Install rear forklift guide in skid base (WP 0127, Installation).
12. Connect oil drain line to engine fitting (WP 0118, Installation).
13. Connect coolant overflow hose to overflow bottle (WP 0081, Installation).
14. Install radiator (WP 0082, Installation).
15. Connect fuel line to engine fuel pump from fuel pickup (WP 0086, Installation).
16. Connect engine excess fuel return line at tank fitting (WP 0086, Installation).
17. Install output box assembly and generator set housing (WP 0098, Installation; WP 0017, Installation; WP
0018, Installation).
18. Service engine lubrication system (WP 0006, Lubricating Oil).
0009-4
TM 9-6115-644-24
Figure 1. Engine and Generator Assembly.
19. Service coolant system (WP 0006, Coolant).
20. Connect negative battery cable. Close battery access door.
21. Start generator set. Perform operational checks and check for leaks.
END OF TASK
END OF WORK PACKAGE
0009-5/(6 blank)
0009
TM 9-6115-644-24
0010
MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
REMOVAL AND INSTALLATION OF MAJOR COMPONENTS, ENGINE ASSEMBLY: REMOVAL,
INSTALLATION, REPLACEMENT
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Suitable Container for Oil/Coolant Drainage
New Lockwashers
Coolant
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0006, Coolant & Lubrication Oil
WP 0009, Figure 1, Item 22
WP 0019, Maintenance of Control Box Assembly,
Control Box Assembly
WP 0078, Maintenance of Coolant System, Fan
Guards
WP 0084, Figure 1, Item 6
WP 0095, Figure 1, Item 9
WP 0110, Figure 1, Items: 2, 3, 4, 5, 6 & 13
WP 0114, Maintenance of Engine Accessories,
Magnetic Pickup
WP 0117, Figure 1, Item 11
WP 0118, Figure 1, Item 4
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE ASSEMBLY
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
0010-1
TM 9-6115-644-24
WARNING
Slave receptacle (NATO connector) is electrically live at all times and is unfused. The Battery
Disconnect Switch does not remove power from the slave receptacle. NATO slave receptacle has
24 VDC even when Battery Disconnect Switch is set to OFF. This circuit is only dead when the
batteries are fully disconnected. Disconnect the batteries before performing maintenance on the
slave receptacle. Failure to comply with this warning can cause injury or death to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
When disconnecting or removing batteries, disconnect the negative lead that connects directly to
the grounding stud first; disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply with this warning can
cause injury to personnel.
WARNING
Many components require a two-person lift. Lifting heavy components can cause back strain.
Ensure proper lifting techniques are used when lifting heavy components. Failure to comply with
this warning can cause injury to personnel.
WARNING
Each battery weighs more than 70 pounds (32 kg) and requires a two-person lift. Lifting batteries
can cause back strain. Ensure proper lifting techniques are used when lifting batteries. Failure to
comply with this warning can cause injury to personnel.
WARNING
Support components when removing attaching hardware or component may fall. Failure to
comply with this warning can cause injury to personnel, and damage to equipment.
WARNING
The generator set, engine, and generator are extremely heavy and require an assistant and a
lifting device (forklift, overhead lifting device) with sufficient capacity. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
0010-2
0010
TM 9-6115-644-24
0010
WARNING
Always remove radiator cap slowly to permit any pressure to escape. Failure to comply with this
warning can cause injury to personnel.
3.
Using a suitable container, drain engine oil and engine coolant.
4.
Remove control box assembly (WP 0019, Removal).
5.
Remove bolts (Figure 1, Items 1 and 4), lockwasher (2 and 5), washers (3 and 6), and top housing panel (7)
from generator set. Discard lockwashers (2 and 5).
6.
Loosen clamp (Figure 2, Item 1) at radiator (2).
7.
Loosen clamp (3) and disconnect overflow hose (4) from filler hose and panel assembly (5).
Figure 1. Top Housing Panel.
0010-3
TM 9-6115-644-24
Figure 2. Filler Hose and Panel Assembly.
8.
Remove filler hose and panel assembly (5) from generator set.
9.
Cut wire ties (6) securing overflow hose (4) to upper radiator supports (7).
10. Remove clamp (Figure 3, Item 1) and disconnect hose (2) from overflow bottle assembly (5).
11. Remove bolts (3), lockwashers (4), and overflow bottle assembly (5) from right side of engine. Discard
lockwashers (4).
0010-4
0010
TM 9-6115-644-24
0010
Figure 3. Overflow Bottle Assembly.
12. Remove exhaust pipe clamp (Figure 4, Item 1) at turbocharger outlet.
13. Remove nuts (2), lockwashers (3), flat washers (5), and bolts (4) securing top housing section (10) to front
housing. Discard lockwashers (3).
14. Remove assembled nuts (6) and bolts (7) securing top housing section (10) to rear side panels.
15. Remove assembled nut (8) and bolt (9) securing top housing section (10) to output box angle.
16. Using a lifting device, remove top housing section assembly (10) from generator set.
17. Remove fan guards (WP 0078, Removal).
18. Remove bolts (Figure 5, Item 1), washers (3), lockwashers (2), and shroud (4) from radiator assembly (23).
Allow shroud (4) to lay on fan (7). Discard lockwashers (2).
19. Remove bolts (5), lockwashers (6), fan (7), spacer (6), and shroud (4). Discard lockwashers (6).
20. Remove nuts (9), lockwashers (10), bolts (11), and washers (12) securing support rods (13) to engine lifting
bracket. Discard lockwashers (10).
0010-5
TM 9-6115-644-24
Figure 4. Top Housing Section Assembly.
Figure 5. Radiator Assembly.
0010-6
0010
TM 9-6115-644-24
0010
21. Loosen clamp (14) at thermostat housing and disconnect hose (15).
22. Loosen clamp (16) at water pump and disconnect hose (17).
23. Loosen clamp (18) and disconnect hose (19) from radiator drain valve (20).
24. Remove nuts (21) and lockwashers (22) securing radiator assembly (23). With the aid of an assistant,
remove radiator assembly (23). Discard lockwashers (22).
25. Remove bolts (Figure 6, Items 1 and 4), washers (3 and 5), lockwashers (2 and 6), nuts (7), and rear housing
panel (8) from generator set. Discard lockwashers (2 and 6).
Figure 6. Rear Housing Panel.
26. Loosen clamp (Figure 7, Item 1) securing hose (2) to fuel tank. Cap openings.
27. Loosen clamp (3) and disconnect hose (4) from fuel filler panel assembly (5). Cap openings.
28. Disconnect fuel line (6) from hose (7). Cap openings.
29. Tag and disconnect auxiliary fuel pump (8) and fuel float switch module (9) electrical connectors.
30. Remove bolts (Figure 8, Item 1), lockwashers (2), and washers (3) securing left side panel (4) to skid base.
Discard lockwashers (2).
31. Remove nuts (8), lockwashers (6 and 9), washers (7 and 11), and bolts (5 and 10) securing lower left side
panel (12) to front housing and skid base. With aid of an assistant, remove left rear side panel (4) and lower
left side panel (12) as an assembly. Discard lockwashers (6 and 9).
32. Loosen clamps (Figure 9, Item 1) securing tube (2) to hose (3) and hump hose (4) to turbocharger.
0010-7
TM 9-6115-644-24
Figure 7. Fuel Filler Hoses and Panel Assembly.
Figure 8. Left Side Housing Panels.
0010-8
0010
TM 9-6115-644-24
0010
Figure 9. Air Cleaner Hose and Tube Assembly.
33. Loosen clamp (5) and connect hose (6) from tube (2). Remove tube (2) and hump hose (4) as an assembly.
34. Loosen clamp (Figure 10, Item 1) and disconnect oil drain hose (2) from adapter (3).
Figure 10. Oil Drain Hose.
35. On left side of engine, tag and disconnect electrical leads from coolant high temperature switch (Figure 11,
Item 1), low oil pressure switch (2), oil pressure sender (3), coolant temperature sender (4), magnetic pickup
(5), DEAD CRANK switch (6), and fuel injection pump (7).
36. Remove nut (8) from rod end (9). Loosen nuts (10) and remove governor actuator assembly (11) with wiring
harness attached. Place out of the way.
0010-9
TM 9-6115-644-24
0010
Figure 11. Left Side Engine.
37. Loosen clamp (12) and disconnect coolant drain hose (13) from engine block coolant drain valve (14).
38. Remove bolt (15) and lockwasher (16) securing fuel return line (17) to engine block. Discard lockwasher (16).
39. Disconnect fuel line (17) at injectors excess fuel line, and fuel hose (18) at fuel tank. Remove line (17) and
hose (18) as an assembly. Cap openings.
40. Open right side engine access doors, tag and disconnect electrical leads from battery charging alternator
(Figure 12, Item 1), starter solenoid (2), and starter motor (3).
41. Disconnect fuel line (4) at fuel pump (5). Cap openings.
42. Disconnect tube (6) from ether start spray nozzle (7) at intake manifold.
43. Remove nut (Figure 13, Item 1) lockwashers (2), and bolt (3) securing ground strap (4) to skid base. Discard
lockwashers (2).
44. Remove bolts (5), washers (7), and lockwashers (6) securing load output terminal board assembly (8) to
supports (9 and 10). Pull load output terminal board assembly (8) out through access door. Discard
lockwashers (6).
45. Remove assembled nuts (11), bolts (12), and support (10) from right side panel.
46. Loosen nuts (Figure 1, Items 23 and 27), turn bolts (25) to contact skid base and tighten nuts (23 and 27).
0010-10
TM 9-6115-644-24
0010
Figure 12. Right Side Engine.
Figure 13. Load Output Terminal Board.
47. Remove nuts (30), lockwashers (31), screws (32), washers (33), and screen/cover (34) from generator case.
Discard lockwashers (31).
0010-11
TM 9-6115-644-24
0010
48. Scribe mark on generator drive disc and engine flywheel for alignment of bolts during installation.
49. Remove bolts (35) and lockwashers (36) securing generator disc drive to engine flywheel. Discard
lockwashers (36).
WARNING
Rated capacity of overhead hoist should be at least 1,500 pounds (680 kg). Do not use a hoist
with less capacity. Failure to comply with this warning can cause injury or death to personnel, and
damage to equipment.
50. Attach lifting harness to engine and overhead hoist. Take up slack.
51. Remove bolts (38) and lockwashers (39) securing generator to flywheel housing. Discard lockwashers (39).
52. Remove nuts (1), washers (2), snubbing washers (3), and bolts (4) securing engine mount brackets (5) to
skid base.
53. Remove nuts (Figure 14, Item 1) lockwashers (2), bolts (3), and radiator mounting bracket (4) from engine
mount brackets (5). Discard lockwashers (2).
Figure 14. Radiator Mounting Bracket.
54. With aid of an assistant, slowly lift engine assembly from skid base, ensuring that engine flywheel housing
separates smoothly from generator without binding. Remove engine from generator set housing and place on
engine stand.
55. Remove nuts (WP 0009, Figure 1, Item 11), lockwashers (12), bolts (13), and shock mounts (14) from skid
base. Discard lockwashers (12).
56. Remove bolts (16), lockwashers (17), washers (18), and mount brackets (5) from engine block. Discard
lockwashers (17).
57. Remove bolts (41), lockwashers (42), and front engine lifting bracket (43) from engine assembly. Discard
lockwashers (42).
58. Remove bolt (44), lockwasher (45), and rear engine lifting bracket (40) from engine assembly. Discard
lockwasher (45).
59. Remove bolts (19) lockwashers (20) washers (21) and rear engine support brackets (22) from engine
assembly. Discard lockwashers (20).
END OF TASK
0010-12
TM 9-6115-644-24
0010
INSTALLATION
1.
Install rear engine support brackets (WP 0009, Figure 1, Item 22) on engine assembly with bolts (19), new
lockwashers (20), and washers (21).
2.
Install rear engine lifting bracket (40) on engine assembly with bolt (44) and new lockwasher (45).
3.
Install front engine lifting bracket (43) on engine assembly with bolts (41) and new lockwashers (42).
4.
Install engine mount brackets (5) on engine block with bolts (16), new lockwashers (17), and washers (18).
5.
Install shock mounts (14) on skid base with bolts (13), new lockwashers (12) and nuts (11).
WARNING
Rated capacity of overhead hoist should be at least 1,500 pounds (680 kg). Do not use a hoist
with less capacity. Failure to comply with this warning can cause injury or death to personnel, and
damage to equipment.
6.
Attach lifting harness to engine and overhead hoist. Take up slack.
NOTE
While lowering engine make sure oil drain line hose is fed through panel holes located in battery
and engine compartment.
7.
With aid of an assistant, lift engine from engine stand and position engine on skid base, aligning mounting
holes, brackets and generator to flywheel housing.
8.
Install bolts (38) and new lockwashers (39), tightening bolts (38) slowly to ensure even and proper seating of
generator housing lip to flywheel housing.
9.
Secure engine mount brackets (5) to skid base with bolts (4), snubbing washers (3), washers (2), and nuts
(1). Torque bolts (4) to 75 ft•lbs (102 N•m).
10. Align scribe mark on generator drive disc and engine flywheel, and install bolts (35) and new lockwashers
(36) securing generator drive disc to engine flywheel.
11. Install screen/cover (34) on generator case with screws (32), washers (33), new lockwashers (31), and nuts
(30).
12. Loosen nuts (23 and 27) and adjust bolts (25) to obtain 0.5 inch (12.7 mm) minimum clearance with skid
base. Torque nuts (23) to 150 ft•lbs (204 N•m).
13. Install radiator mounting bracket (Figure 14, Item 4) with bolts (3), new lockwashers (2), and nuts (1) to
engine mount brackets (5).
14. Install support (Figure 13, Item 10) on right side panel with bolts (12) and assembled nuts (11).
15. Install load output terminal board assembly (8) on supports (9 and 10) with bolts (5), new lockwashers (6),
and washers (7).
16. Secure ground strap (4) to skid base with bolt (3), new lockwashers (2), and nut (1).
17. Connect tube (Figure 12, Item 6) to ether start spray nozzle (7) at intake manifold.
18. Connect electrical leads to battery charging alternator (1), starter solenoid (2) and starter motor (3) on right
side of engine, and remove tags.
19. Remove caps and connect fuel line (4) to engine fuel pump (5).
20. Remove caps and position fuel line (Figure 11, Item 17) and hose (18) in generator set. Connect line (17) to
injectors excess fuel line, and hose (18) to fuel tank.
21. Secure fuel line (17) to engine block with bolt (15) and new lockwasher (16).
22. Connect coolant drain hose (13) to engine block coolant drain valve (14) and tighten clamp (12).
23. Install governor actuator assembly (11) to engine assembly with nuts (10), and connect rod end (9) with nut
(8).
0010-13
TM 9-6115-644-24
0010
24. On left side of engine, connect electrical leads to fuel injection pump (7), DEAD CRANK switch (6), magnetic
pickup (5), coolant temperature sender (4), oil pressure sender (3), low oil pressure switch (2), and coolant
high temperature switch (1). Remove tags.
25. Connect oil drain hose (Figure 10, Item 2) to adapter (3) and tighten clamp (1).
26. Connect tube (Figure 9, Item 2) to hose (3), connect hump hose (4) to turbocharger, and tighten clamps (1).
27. Connect hose (6) to tube (2) and tighten clamp (5).
28. With aid of an assistant, position left rear side housing panel (Figure 8, Item 4) and lower left side panel (12)
on generator set.
29. Secure left rear side panel (4) to skid base with bolts (1), new lockwashers (2), and washers (3).
30. Secure lower left side panel (12) to front housing and skid base with bolts (5 and 10), washers (7 and 11),
new lockwashers (6 and 9), and nuts (8).
31. Connect auxiliary fuel pump (Figure 7, Item 8) and fuel float switch module (9) electrical connectors and
remove tags.
32. Remove caps and connect fuel hose (7) to fuel line (6).
33. Remove caps and connect hose (4) to fuel filler panel assembly (5) and tighten clamp (3).
34. Remove caps and connect hose (2) to fuel tank and tighten clamps (1).
35. Install rear housing panel (Figure 6, Item 8) on generator set with bolts (1 and 4), washers (3 and 5), new
lockwashers (2 and 6), and nuts (7).
36. With aid of an assistant, position radiator assembly (Figure 5, Item 23) in generator set with nuts (21) and
new lockwashers (22).
37. Connect hose (17) to water pump and tighten clamp (16).
38. Connect hose (15) at thermostat housing and tighten clamp (14).
39. Connect hose (19) at radiator drain valve (20) and tighten clamp (18).
40. Secure support rods (13) to front engine lifting bracket with bolts (11), washers (12), new lockwashers (10),
and nuts (9).
41. Position spacer (8), fan (7), and shroud (4) in generator set.
42. Secure spacer (8) and fan (7) on water pump with bolts (5) and new lockwashers (6). Torque bolts (5) to 24
ft•lbs (33 N•m).
43. Install shroud (4) on radiator assembly (23) with bolts (1), washers (3), and new lockwashers (2).
44. Install fan guards (WP 0078, Installation).
45. Using lifting device, position top housing section (Figure 4, Item 10) on generator set.
46. Secure top housing section (10) to output box angle with bolt (9) and assembled nut (8).
47. Secure top housing section (10) to rear side panels with bolts (7) and assembled nuts (6).
48. Secure top housing section (10) to front housing with bolts (4), flat washers (5), new lockwashers (3), and
nuts (2).
49. Connect exhaust pipe to turbocharger outlet and install clamp (1).
50. Install overflow bottle assembly (Figure 3, Item 5) on right side of engine with bolts (3) and new lockwashers
(4).
51. Connect hose (2) on overflow bottle assembly (5) with clamp (1).
52. Position filler hose and panel assembly (Figure 2, Item 5) in generator set. Connect filler hose and panel
assembly (5) to radiator (2) and tighten clamp (1).
53. Connect overflow hose (4) to filler hose and panel assembly (5) and tighten clamp (3).
54. Install new ties (6) on radiator supports (7) to secure overflow hose (4).
55. Install top housing panel (Figure 1, Item 7) with bolts (1 and 4), new lockwashers (2 and 5), and washers (3
and 6).
56. Service coolant system (WP 0006, Coolant).
0010-14
TM 9-6115-644-24
0010
57. Service lubrication system (WP 0006, Lubricating Oil).
58. Install control box assembly (WP 0019, Installation).
59. Connect negative battery cable and close battery access door.
60. Close all access doors.
61. Start generator set, check for leaks and proper operation.
62. Shut down generator set and service fluid levels as necessary.
END OF TASK
REPLACEMENT
1.
Remove old engine assembly from generator set (Engine Assembly, Removal).
2.
Remove the following from new engine and return with old engine:
a.
Cooling fan.
b.
Fan spacer.
c.
Fan belt.
3.
Disconnect throttle lever cable (Figure 15, Item 1) from fuel injection pump of old engine.
4.
Remove throttle lever cable bracket (2), with cable (1) attached, from old engine and install on new engine.
5.
Connect throttle lever cable (1) to fuel injection pump lever of new engine.
6.
Remove the following from old engine and install on new engine:
a.
Oil sample valve and low oil pressure switch assembly (Figure 15, Item 3).
b.
Alternator guard (Figure 16, Item 1). Use hardware from old engine.
c.
Fuel filter drain valve assembly (Figure 16, Item 2).
d.
Oil drain line adapter (WP 00118, Figure 1, Item 4) with hose attached.
e.
Governor actuator bracket (WP 0117, Figure 1, Item 18) with governor actuator (11) and linkage, and
DEAD CRANK switch (WP 0110, Figure 1, Item 11) attached. Use hardware from old engine.
f.
Ether start spray nozzle (WP 0095, Figure 1, Item 9).
g.
Oil pressure sender (WP 0110, Figure 1, Item 2).
h.
Coolant drain valve (WP 0110, Figure 1, Item 3).
i.
Coolant temperature sender (WP 0110, Figure 1, Item 4).
j.
Coolant high temperature switch (WP 0110, Figure 1, Item 5).
k.
Magnetic pickup (WP 0110, Figure 1, Item 6). Screw into flywheel housing until magnetic pickup
bottoms out, back out 1-1/2 turns and tighten jam nut (6A).
l.
Diode assembly (WP 0110, Figure 1, Item 13). Install with band end toward engine.
m.
Fan belt (WP 0084, Figure 1, Item 6).
7.
Install new engine in generator set (Engine Assembly, Installation).
8.
Check and adjust governor actuator as necessary (WP 0117, Adjustment).
9.
Check and adjust magnetic pickup as necessary (WP 0114, Adjustment).
10. Check and adjust fan belt as necessary (WP 0084, Testing and Adjustment).
11. Start generator set, check for leaks and proper operation.
0010-15
TM 9-6115-644-24
Figure 15. Engine Components (Left Side).
0010-16
0010
TM 9-6115-644-24
Figure 16. Engine Components (Right Side).
END OF TASK
END OF WORK PACKAGE
0010-17/(18 blank)
0010
TM 9-6115-644-24
0011
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF DC ELECTRICAL SYSTEM, BATTERY AND SLAVE RECEPTACLE CABLES:
INSPECTION, REMOVAL, CLEANING, REPAIR, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
See "One Qualified Technician" Warning
References
TM 9-6115-644-10
WP 0013, Figure 1, Items: 3 & 4
WP 0129, Illustrated List of Manufactured Items
Equipment Condition
Grounded, Off & Operational
INTRODUCTION
Work packages 0012 through 0014 contain field maintenance procedures for the DC Electrical System.
Deficiencies noted during inspection/repair which are beyond the scope of field maintenance and shall be
reported to the next higher level of maintenance.
NOTE
Refer to TM 9-6115-644-10 for all operator procedures.
WARNING
Slave receptacle (NATO connector) is electrically live at all times and is unfused. The Battery
Disconnect Switch does not remove power from the slave receptacle. NATO slave receptacle has
24 VDC even when Battery Disconnect Switch is set to OFF. This circuit is only dead when the
batteries are fully disconnected. Disconnect the batteries before performing maintenance on the
slave receptacle. Failure to comply with this warning can cause injury or death to personnel.
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
When disconnecting or removing batteries, disconnect the negative lead that connects directly to
the grounding stud first; disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply with this warning can
cause injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
0011-1
TM 9-6115-644-24
NOTE
This procedure is typical for the positive, negative, and interconnect battery cables, and the
positive and negative NATO slave receptacle cables.
INSPECTION
1.
Shut down generator set.
2.
Open battery access door and right side engine access doors.
3.
Inspect battery/slave receptacle cables for security; cracked insulation; broken, burned, or corroded
terminals; missing parts; or other damage. Close access doors.
END OF TASK
REMOVAL
1.
Shut down generator set.
2.
Open battery access door and right side engine access doors.
NOTE
Tag all cables before removal.
3.
Disconnect negative battery cable terminal lug (Figure 1, Item 1) from battery.
4.
Disconnect and remove applicable cable assembly (Figure 1/WP 0013, Figure 1).
END OF TASK
CLEANING
1.
Remove terminal cover(s) (Figure 1, Item 2) from battery post(s), if applicable.
2.
Clean battery post(s) and cable terminals with battery terminal cleaner.
3.
Install terminal cover(s) (2), if removed.
END OF TASK
REPAIR
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
NOTE
If cable cannot be repaired, refer to WP 0129.
1.
Remove nut(s) (Figure 1, Item 5) and battery cable terminal lug(s), as necessary.
2.
Remove broken or damaged terminal (Figure 1, Item 3/WP 0013, Figure 1, Item 3) from cable assembly.
3.
Slide new shrinkable tubing (Figure 1, Item 4/WP 0013, Figure 1, Item 4) over cable end.
4.
Install terminal (3) to cable end (WP 0129).
5.
Heat shrinkable tubing (4) with heat gun until secure.
0011-2
0011
TM 9-6115-644-24
6.
Install battery cable terminal lug(s) with nuts(s) (Figure 1, Item 5), as necessary.
END OF TASK
INSTALLATION
1.
Install applicable cable assembly as shown in Figure 1/WP 0013, Figure 1.
2.
Connect negative battery cable terminal lug (Figure 1, Item 1) to battery. Close access doors.
Figure 1. Batteries and Cables.
0011-3
0011
TM 9-6115-644-24
END OF TASK
END OF WORK PACKAGE
0011-4
0011
TM 9-6115-644-24
0012
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF DC ELECTRICAL SYSTEM, BATTERIES: TESTING, REMOVAL, INSPECTION,
SERVICING, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Batteries
General Purpose Grease
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0011, Figure 1, Items: 1, 2 & 13
WP 0159, Expendable Durable Items List Item 11
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
TESTING
WARNING
Batteries give off a flammable gas. Do not smoke or use open flame when performing
maintenance. Failure to comply with this warning can cause injury or death to personnel, and
damage to the generator set.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove battery vent caps.
4.
Test specific gravity of electrolyte in each battery cell with a hydrometer. Refer to Table 1 for state of charge
with specific gravity corrected to 80 °F (27 °C). Refer to Table 2 for specific gravity temperature corrections.
5.
Recharge or replace batteries, as necessary. Retest batteries per above instructions.
6.
Install battery vent caps.
7.
Connect negative battery cable and close battery access door.
Table 1. State of Charge with Specific Gravity
Corrected to 80 °F (27 °C).
Specific Gravity
Percent Charge
1.280
100
1.250
75
1.220
50
1.190
25
1.160
Little useful capacity
1.130
Discharged
0012-1
TM 9-6115-644-24
0012
Table 2. Specific Gravity Temperature Corrections.
Temperature °F
Correction Factor
+120 °F (49 °C)
+0.016
+115 °F (46 °C)
+0.014
+110 °F (43 °C)
+0.012
+105 °F (41 °C)
+0.010
+100 °F (38 °C)
+0.008
+95 °F (35 °C)
+0.006
+90 °F (32 °C)
+0.004
+85 °F (29 °C)
+0.002
+80 °F (27 °C)
0
+75 °F (24 °C)
-0.002
+70 °F (21 °C)
-0.004
+65 °F (19 °C)
-0.006
+60 °F (16 °C)
-0.008
+55 °F (13 °C)
-0.010
+50 °F (10 °C)
-0.012
+45 °F (7 °C)
-0.014
+40 °F (5 °C)
-0.016
+35 °F (2 °C)
-0.018
+30 °F (-1 °C)
-0.020
+25 °F (-4 °C)
-0.022
+20 °F (-7 °C)
-0.024
+15 °F (-9 °C)
-0.026
+10 °F (-12 °C)
-0.028
+5 °F (-15 °C)
-0.030
0 °F (-18 °C)
-0.032
-5 °F (-20 °C)
-0.034
-10 °F (-23 °C)
-0.036
-15 °F (-26 °C)
-0.038
-20 °F (-29 °C)
-0.040
END OF TASK
REMOVAL
WARNING
Batteries give off a flammable gas. Do not smoke or use open flame when performing
maintenance. Failure to comply with this warning can cause injury or death to personnel, and
damage to the generator set.
0012-2
TM 9-6115-644-24
0012
WARNING
When disconnecting or removing batteries, disconnect the negative lead that connects directly to
the grounding stud first; disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply with this warning can
cause injury to personnel.
WARNING
Each battery weighs more than 70 pounds (32 kg) and requires a two-person lift. Lifting batteries
can cause back strain. Ensure proper lifting techniques are used when lifting batteries. Failure to
comply with this warning can cause injury to personnel.
WARNING
Many components require a two-person lift. Lifting heavy components can cause back strain.
Ensure proper lifting techniques are used when lifting heavy components. Failure to comply with
this warning can cause injury to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery compartment access door and disconnect negative battery cable terminal lug (WP 0011, Figure
1, Item 1).
3.
Disconnect interconnect battery cable terminal lugs (6 and 7) and remove interconnect battery cable
assembly. Disconnect positive battery cable terminal lug (8).
4.
Remove nuts (9), washers (10), lockwashers (14), hook bolts (11), and battery hold-down (12). Discard
lockwashers (14).
5.
Remove batteries (13).
END OF TASK
INSPECTION
1.
Remove batteries (Removal).
2.
Inspect batteries for cracked cases; broken, burned, or corroded posts; missing parts; and other damage.
3.
Install batteries (Installation).
END OF TASK
SERVICING
1.
Remove terminal covers (WP 0011, Figure 1, Item 2).
2.
Clean cable terminal lugs and battery posts.
3.
Install terminal covers (2) on batteries (13).
END OF TASK
INSTALLATION
0012-3
TM 9-6115-644-24
0012
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Position batteries (WP 0011, Figure 1, Item 13) in generator set. Ensure that batteries (13) are serviced and
fully charged.
2.
Apply general purpose grease (WP 0159, Item 11) to battery posts and cable terminal lugs (1, 6, 7, and 8).
(F) Apply petrolatum or equal.
3.
Install hook bolts (11) and battery hold-down (12) with new lockwashers (14), washers (10), and nuts (9).
WARNING
When disconnecting or removing batteries, disconnect the negative lead that connects directly to
the grounding stud first; disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply with this warning can
cause injury to personnel.
4.
Connect positive cable terminal lug (8).
5.
Position interconnect battery cable and connect terminal lugs (6 and 7).
6.
Connect negative battery cable terminal lug (1). Close battery compartment access door.
END OF TASK
END OF WORK PACKAGE
0012-4
TM 9-6115-644-24
0013
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF DC ELECTRICAL SYSTEM, NATO SLAVE RECEPTACLE: INSPECTION, REMOVAL,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
Equipment Condition
Grounded, Off & Operational
See "One Qualified Technician" Warning
INSPECTION
WARNING
Slave receptacle (NATO connector) is electrically live at all times and is unfused. The Battery
Disconnect Switch does not remove power from the slave receptacle. NATO slave receptacle has
24 VDC even when Battery Disconnect Switch is set to OFF. This circuit is only dead when the
batteries are fully disconnected. Disconnect the batteries before performing maintenance on the
slave receptacle. Failure to comply with this warning can cause injury or death to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door.
3.
Inspect NATO slave receptacle for security, corrosion, missing hardware, and other damage. Close battery
access door.
END OF TASK
REMOVAL
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Tag and disconnect battery and slave receptacle cables from slave receptacle (Figure 1, Item 7) by removing
bolts (1) and lockwashers (2). Discard lockwashers (2).
4.
Remove bolts (5), nuts (6), and NATO slave receptacle (7) from generator set housing.
5.
Remove nut (8), bolt (9), and cover (10) from generator set.
END OF TASK
INSTALLATION
1.
Insert NATO slave receptacle (Figure 1, Item 7) into generator set housing.
2.
Secure receptacle (7) with bolts (5) and nuts (6).
0013-1
TM 9-6115-644-24
0013
3.
Connect slave receptacle and battery cables to slave receptacle (7) with bolts (1) and new lockwashers (2).
Remove tags.
4.
Install cover (10) on generator set with bolt (9) and nut (8).
5.
Connect negative battery cable. Close battery access door.
Figure 1. NATO Slave Receptacle and Cables.
0013-2
TM 9-6115-644-24
END OF TASK
END OF WORK PACKAGE
0013-3/(4 blank)
0013
TM 9-6115-644-24
0014
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF HOUSING, ACCESS DOORS: REMOVAL, INSPECTION, REPAIR, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
CARC Paint
Protective Eye Wear, Mask & Gloves
Fine Grit Abrasive Paper
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0159, Expendable and Durable Items List
TM 43-0139
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
NOTE
This procedure is written for the left engine access door, but is typical for all access doors,
hinges, latches, and data plates. When removing and installing battery access door, note
position of spacers for door hold open mechanism.
REMOVAL
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
components have been heated. Wear additional protective clothing as required. Failure to comply
with this warning can cause injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
0014-1
TM 9-6115-644-24
0014
1.
Shut down generator set.
2.
Open left side engine access doors.
3.
Remove nuts (Figure 1, Item 1), lockwashers (2), bolts (3), washers (4), and hinges (5). Discard lockwashers
(2).
4.
Remove left rear engine access door (6) from generator set.
5.
Remove assembled nuts (7), bolts (8), and document box (9) from engine access door (6).
6.
Drill out rivets (10) and remove fuel system diagram (11) from document box (9).
7.
Remove assembled nuts (12), bolts (13), bracket (14), and holding rod (15) from engine access door (6).
8.
Remove assembled nuts (16), bolts (17), and bracket (18) from engine access door (6).
9.
Remove nuts (19), screws (20), and latches (21) from engine access door (6).
END OF TASK
INSPECTION
1.
Shut down generator set.
2.
Inspect access doors, hinges, latches, and baffles for loose and missing hardware, cracks, dents, loose paint,
and corrosion.
3.
Inspect data plates for readability and loose or missing rivets.
END OF TASK
REPAIR
WARNING
CARC paint is a health hazard, and is irritating to eyes, skin, and respiratory system. Wear
protective eyewear, mask, and gloves when applying or removing CARC paint. Failure to comply
with this warning can cause injury to personnel.
WARNING
Solvent used to clean parts is potentially dangerous to personnel and property. Clean parts in a
well-ventilated area. Avoid inhalation of solvent fumes. Wear goggles and rubber gloves to
protect eyes and skin. Wash exposed skin thoroughly. Do not smoke or use near open flame or
excessive heat. Failure to comply with this warning can cause injury to personnel, and damage to
the equipment.
1.
Repair all dents and cracks and remove loose paint.
2.
Remove light corrosion with fine grit abrasive paper (WP 0159, Item 17).
3.
Repaint surfaces in accordance with TM 43-0139. (F) Use applicable directives.
4.
Replace unreadable data plates.
5.
Replace loose or missing rivets.
END OF TASK
INSTALLATION
1.
Install latches (Figure 1, Item 21) in left rear engine access door (6) with screws (20) and nuts (19).
2.
Install bracket (18) on engine access door (6) with bolts (17) and assembled nuts (16).
3.
Install bracket (14) and holding rod (15) on engine access door (6) with bolts (13) and assembled nuts (12).
4.
Install fuel system diagram (11) on document box (9) with rivets (10).
0014-2
TM 9-6115-644-24
5.
Install document box (9) on engine access door (6) with bolts (8) and assembled nuts (7).
6.
Install left rear engine access door (6) and hinges (5) on generator set with bolts (3), washers (4), new
lockwashers (2), and nuts (1). Close left side engine access doors.
Figure 1. Generator Set Access Doors.
END OF TASK
END OF WORK PACKAGE
0014-3/(4 blank)
0014
TM 9-6115-644-24
0015
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF HOUSING, CONTROL BOX TOP PANEL: REMOVAL, INSPECTION, REPAIR,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Protective Eye Wear, Mask & Gloves
CARC Paint
Fine Grit Abrasive Paper
New Lockwashers
New Gasket
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0014, Maintenance of Housing, Access Doors
WP 0159, Expendable & Durable Items List, Item 17
TM 43-139
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control panel access door (WP 0014, Removal).
0015-1
TM 9-6115-644-24
4.
0015
Lower control panel and remove bolts (Figure 1, Item 1), flat washers (2), lockwashers (3), and assembled
nuts (4) from top panel (5). Discard lockwashers (3).
CAUTION
The control box top panel is attached to the generator set with a silicone sealant to prevent water
from entering the control box. Care must be taken not to bend or scratch the control box top panel
when separating.
5.
Separate and remove control box top panel (5).
6.
Remove gasket (15), if damaged.
7.
Remove bolts (6), washers (7), lockwashers (8), nuts (9), and stiffener (10) from control box assembly.
Discard lockwashers (8).
8.
Remove bolts (11), assembled nuts (12), bracket (13), and ring (14) from control box top panel
END OF TASK
INSPECTION
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Inspect control box top panel (Figure 1, Item 5) for dents, cracks, loose paint, and corrosion.
END OF TASK
REPAIR
WARNING
CARC paint is a health hazard, and is irritating to eyes, skin, and respiratory system. Wear
protective eyewear, mask, and gloves when applying or removing CARC paint. Failure to comply
with this warning can cause injury to personnel.
WARNING
Solvent used to clean parts is potentially dangerous to personnel and property. Clean parts in a
well-ventilated area. Avoid inhalation of solvent fumes. Wear goggles and rubber gloves to
protect eyes and skin. Wash exposed skin thoroughly. Do not smoke or use near open flame or
excessive heat. Failure to comply with this warning can cause injury to personnel, and damage to
the equipment.
1.
Repair all dents and cracks, and remove all loose paint.
2.
Remove light corrosion with fine grit abrasive paper (WP 0159, Item 17).
3.
Repaint surfaces in accordance with TM 43-0139. (F) Refer to applicable directives.
END OF TASK
INSTALLATION
1.
Install ring (Figure 1, Item 14) and bracket (13) on control box top panel (5) with bolts (11) and assembled
nuts (12).
2.
Install stiffener (10) in control box assembly with bolts (6), washers (7), new lockwashers (8), and nuts (9).
NOTE
When replacing old sealant with new gasket, ensure all old sealant residue is completely
removed.
0015-2
TM 9-6115-644-24
0015
3.
Install new gasket (15), if removed.
4.
Immediately install top panel (5) with bolts (1), flat washers (2), new lockwashers (3), and assembled nuts
(4).
5.
Install control panel access door (WP 0014, Installation).
6.
Connect negative battery cable. Close battery access door
Figure 1. Control Box Top Panel.
END OF TASK
END OF WORK PACKAGE
0015-3/(4 blank)
TM 9-6115-644-24
0016
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF HOUSING, TOP HOUSING SECTION: REMOVAL, INSPECTION, REPAIR,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
CARC Paint
Protective Eye Wear, Mask & Gloves
Fine Grit Abrasive Paper
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0019, Maintenance of Control Box Assembly,
Control Box Assembly
WP 0071, Maintenance of Air Intake & Exhaust
System, Muffler & Exhaust Pipe
WP 0159, Expendable & Durable Items List, Item 17
WP 0129, Fabrication of Insulation
TM 43-0139
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
0016-1
TM 9-6115-644-24
0016
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Remove control box assembly (WP 0019, Removal).
3.
Remove bolts (Figure 1, Item 1), flat washers (3), lockwashers (2), mount (4), and exhaust cover (5) from top
housing panel (6). Discard lockwashers (2).
4.
Remove bolts (7 and 10), flat washers (9 and 12), lockwashers (8 and 11), and top housing panel (6) from
generator set. Discard lockwashers (8 and 11).
5.
Disconnect radiator fill hose and overflow hose from radiator fill panel (13) and remove radiator fill panel (13)
from generator set.
6.
Remove bolts (14), flat washers (16), lockwashers (15), and frame (17) from generator set. Discard
lockwashers (15).
7.
Remove muffler (WP 0071, Removal).
8.
Remove bolts (18), assembled nuts (19), and air duct channels (20 and 21).
9.
Remove bolts (22 and 24), assembled nuts (23 and 25), and panel (26).
10. Remove bolts (27, 29 and 33), flat washers (30 and 35), lockwashers (31 and 34), assembled nuts (28), nuts
(32), and top side panels (36 and 37) with top section floor panel (38). Discard lockwashers (31 and 34).
11. Remove bolts (39), assembled nuts (40), and panel (41) from floor panel (38).
12. Remove bolts (42), assembled nuts (43), and support (44) from panel (41).
13. Remove bolts (45), assembled nuts (46), and side panels (36 and 37) from floor panel (38).
14. Remove bolt (47), assembled nut (48), and bracket (49) from angle (52).
NOTE
Open output box access door to reach assembled nuts (51).
15. Remove bolts (50), assembled nuts (51), and angle (52) from generator set.
16. Remove clip halves (53) and insulation (54 through 64) from top panel (6) as necessary.
17. Remove clip halves (65) and insulation (66 and 67) from side panels (36 and 37) as necessary.
END OF TASK
INSPECTION
1.
Shut down generator set.
2.
Inspect all top housing section panels for dents, cracks, loose paint, and corrosion.
3.
Inspect sound insulation for damage and missing clip halves.
4.
Inspect seal (Figure 1, Item 69) for tears, looseness, and deterioration.
END OF TASK
REPAIR
WARNING
CARC paint is a health hazard, and is irritating to eyes, skin, and respiratory system. Wear
protective eyewear, mask, and gloves when applying or removing CARC paint. Failure to comply
with this warning can cause injury to personnel.
0016-2
TM 9-6115-644-24
0016
WARNING
Solvent used to clean parts is potentially dangerous to personnel and property. Clean parts in a
well-ventilated area. Avoid inhalation of solvent fumes. Wear goggles and rubber gloves to
protect eyes and skin. Wash exposed skin thoroughly. Do not smoke or use near open flame or
excessive heat. Failure to comply with this warning can cause injury to personnel, and damage to
the equipment.
1.
Repair all dents and cracks, and remove all loose paint.
2.
Remove light corrosion with fine grit abrasive paper (WP 0159, Item 17).
3.
Repaint surfaces in accordance with TM 43-0139. (F) Refer to applicable directives.
4.
Replace any cage nuts (Figure 1, Item 68) that are stripped or cracked.
5.
Replace damaged sound insulation and missing clip halves. Refer to WP 0129 for fabrication of insulation.
6.
Replace loose or damaged seal (69).
END OF TASK
INSTALLATION
1.
Install angle (Figure 1, Item 52) in generator set with bolts (50) and assembled nuts (51).
2.
Install bracket (49) to angle (52) with bolt (47) and assembled nut (48).
3.
Install insulation (54 through 64) on top panel (6) with clip halves (53) as required.
4.
Install insulation (66 and 67) on side panels (36 and 37) with clip halves (65) as required.
5.
Install top side panels (36 and 37) on top section floor panel (38) with bolts (45) and assembled nuts (46).
0016-3
TM 9-6115-644-24
Figure 1. Generator Set Top Housing Section (Sheet 1 of 2).
0016-4
0016
TM 9-6115-644-24
Figure 1. Generator Set Top Housing Section (Sheet 2 of 2).
6.
Install support (44) on panel (41) with bolts (42) and assembled nuts (43).
7.
Install panel (41) on top section floor panel (38) with bolts (39) and assembled nuts (40).
0016-5
0016
TM 9-6115-644-24
0016
8.
Position top section floor panel (38), with side and front panels attached, in generator set and secure with
bolts (27, 29 and 33), flat washers (30 and 35), new lockwashers (31 and 34), assembled nuts (28), and nuts
(32).
9.
Install panel (26) with bolts (22 and 24) and assembled nuts (23 and 25).
10. Install air duct channels (20 and 21) with bolts (18) and assembled nuts (19).
11. Install muffler (WP 0071, Installation).
12. Install frame (17) with bolts (14), flat washers (16), and new lockwashers (15).
13. Install radiator fill panel (13) in generator set and connect radiator fill hose and overflow hose to panel (13).
14. Install top housing panel (6) with bolts (7 and 10), flat washers (9 and 12), and new lockwashers (8 and 11).
15. Install mount (4) and exhaust cover (5) with bolts (1), flat washers (3), and new lockwashers (2).
16. Install control box assembly (WP 0019, Installation).
END OF TASK
END OF WORK PACKAGE
0016-6
TM 9-6115-644-24
0017
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF HOUSING, FRONT HOUSING SECTION: REMOVAL, INSPECTION, REPAIR,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
CARC Paint
Protective Eye Wear, Mask & Gloves
Fine Grit Abrasive Paper
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0012, Maintenance of DC Electrical System,
Batteries
WP 0013, Maintenance of DC Electrical System,
NATO Slave Receptacle
WP 0014, Maintenance of Housing, Access Doors
WP 0016, Maintenance of Housing, Top Housing
Section
WP 0129, Fabrication & Insulation
WP 0159, Expendable & Durable Items List, Item 17
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
0017-1
TM 9-6115-644-24
0017
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Remove battery box access door (WP 0014, Removal).
3.
Remove engine access doors (WP 0014, Removal).
4.
Remove top housing section (WP 0016, Removal).
5.
Remove batteries (WP 0012, Removal) and slave receptacle (WP 0013, Removal).
6.
Remove bolts (Figure 1, Item 1) and ground rods (2) from brackets (54).
7.
Remove bolts (3, 6, and 10), flat washers (5, 7, and 11), lockwashers (4, 8, and 12), nuts (9 and 13), and
front panel (14) from generator set. Discard lockwashers (4, 8, and 12).
8.
Remove bolts (15 and 18), flat washers (17 and 19), lockwashers (16 and 20), nuts (21), and side panels (22
and 23) from generator set. Discard lockwashers (16 and 20).
9.
Remove clip halves (24) and insulation (25) from front panel (14).
10. Remove bolts (26 and 29), washers (28), lockwashers (27), assembled nuts (30), and air deflector (31) from
front panel (14). Discard lockwashers (27).
11. Remove bolts (32), lockwashers (33), washers (34), and panels (35 and 36) from front panel (14). Discard
lockwashers (33).
12. Remove bolts (37), assembled nuts (38), and supports (39 and 40) from panels (35 and 36).
13. Remove bolts (41) and panel (42) from front panel (14).
14. Remove bolts (43), assembled nuts (44), and support (45) from panel (42).
15. Remove bolts (46), assembled nuts (47), and support channel (48) from front panel (14).
16. Remove bolts (49), assembled nuts (50), and slave receptacle box (51) from front panel (14).
17. Remove bolts (52), assembled nuts (53), and brackets (54) from panels (14 and 22).
18. If necessary, drill out rivets (55, 56, and 57); remove identification plates (58, 59, and 60).
END OF TASK
INSPECTION
1.
Shut down generator set.
2.
Inspect all front housing section panels for dents, cracks, loose paint, corrosion, and other damage.
3.
Inspect all cage nuts (Figure 1, Item 61) for cracking or stripped threads.
4.
Inspect insulation for damage and missing clip halves (24).
5.
Inspect seals (62 and 63) for tears, looseness, and deterioration.
END OF TASK
REPAIR
WARNING
CARC paint is a health hazard, and is irritating to eyes, skin, and respiratory system. Wear
protective eyewear, mask, and gloves when applying or removing CARC paint. Failure to comply
with this warning can cause injury to personnel.
0017-2
TM 9-6115-644-24
0017
WARNING
Solvent used to clean parts is potentially dangerous to personnel and property. Clean parts in a
well-ventilated area. Avoid inhalation of solvent fumes. Wear goggles and rubber gloves to
protect eyes and skin. Wash exposed skin thoroughly. Do not smoke or use near open flame or
excessive heat. Failure to comply with this warning can cause injury to personnel, and damage to
the equipment.
1.
Repair all dents and cracks and remove ail loose paint.
2.
Remove light corrosion with fine grit abrasive paper (WP 0159, Item 17).
3.
Repaint surfaces in accordance with TM 43-0139. (F) Refer to applicable directives.
4.
Replace any cracked or stripped cage nuts (Figure 1, Item 61).
5.
Replace damaged insulation and missing clip halves (24). Refer to WP 0129 for fabrication of insulation.
6.
Replace loose or damaged seals (62 and 63).
END OF TASK
INSTALLATION
1.
Install identification plates (Figure 1, Items 58, 59, and 60) on front panel (14) and side panel (22) with rivets
(55, 56, and 57), if removed.
2.
Install brackets (54) on panels (14 and 22) with bolts (52) and assembled nuts (53).
3.
Install slave receptacle box (51) on front housing panel (14) with bolts (49) and assembled nuts (50).
4.
Install side panels (22 and 23) on generator set with bolts (15 and 18), flat washers (17 and 19), new
lockwashers (16 and 20), and nuts (21).
5.
Install support channel (48) on front panel (14) with bolts (46) and assembled nuts (47).
6.
Install support (45) on panel (42) with bolts (43) and assembled nuts (44).
7.
Install panel (42) on front panel (14) with bolts (41).
8.
Install supports (39 and 40) on panels (35 and 36) with bolts (37) and assembled nuts (38).
9.
Install panels (35 and 36) on front panel (14) with bolts (32), new lockwashers (33), and washers (34).
10. Install air deflector (31) on front panel (14) with bolts (26 and 29), washers (28), new lockwashers (27), and
assembled nuts (30).
11. Install insulation (25) on front panel (14) with clip halves (24).
12. Install front housing panel (14) on generator set with bolts (3, 6, and 10), flat washers (5, 7, and 11), new
lockwashers (4, 8, and 12), and nuts (9 and 13).
13. Install slave receptacle (WP 0013, Installation) and batteries (WP 0012, Installation).
14. Install battery box access door and engine access doors (WP 0014, Installation).
15. Install top housing section (WP 0016, Installation).
16. Install ground rods (2) in brackets (54) and secure with bolts (1). Close all access doors.
0017-3
TM 9-6115-644-24
Figure 1. Generator Set Front Housing Section.
END OF TASK
END OF WORK PACKAGE
0017-4
0017
TM 9-6115-644-24
0018
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, REAR HOUSING SECTION: REMOVAL, INSPECTION,
REPAIR, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
New Lockwashers
Adhesive
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
TM 43-0139
WP 0016, Maintenance of Housing, Top housing
Section: Steps 4 & 14
WP 0019, Maintenance of Control Box Assembly,
Control Box Assembly
WP 0073, Maintenance of Air Intake & Exhaust
System, Air Cleaner Assembly
WP 0087, Maintenance of Fuel System, Auxiliary
Fuel Pump
WP 0088, Maintenance of Fuel System, Fuel Tank
Filler Neck
WP 0093, Maintenance of Fuel System, Fuel Float
Module
WP 0096, Maintenance of Fuel System, Ether
Solenoid Valve
WP 0159, Expendable & Durable Items List, Items: 2
& 17
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
0018-1
TM 9-6115-644-24
0018
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Remove control box assembly (WP 0019, Removal).
3.
Remove air cleaner assembly (WP 0073, Removal).
4.
Remove output box access door and load terminal board access door (WP 0014, Removal).
5.
Remove rear engine access doors and air cleaner access door (WP 0014, Removal).
6.
Remove fuel tank filler neck (WP 0088, Removal).
7.
Remove auxiliary fuel pump (WP 0087, Removal).
8.
Remove fuel float module (WP 0093, Removal).
9.
Remove ether solenoid valve (WP 0096, Removal).
10. Remove top housing panel (WP 0016, Removal, Step 4).
11. Remove bolts (Figure 1, Items 1 and 4), flat washers (3 and 5), lockwashers (2 and 6), nuts (7), and rear
panel (8) from generator set. Discard lockwashers (2 and 6).
12. Remove bolts (9), assembled nuts (10), and load cable entrance box (11) from rear panel (8).
13. Remove bolts (12 and 16), flat washers (13 and 17), lockwashers (14 and 18), nuts (15), and left side rear
panel (19) from generator set. Discard lockwashers (14 and 18).
14. Remove bolts (20), assembled nuts (21), and baffle (22) from left side rear panel (19).
15. Remove clip halves (23) and insulation (24) from baffle (22).
16. Remove bolts (25), assembled nuts (26), and fuel tank filler neck panel (27) from left side rear panel (19).
NOTE
Ensure output box assembly is secured prior to removal of corner post and door sills.
17. Remove bolts (28, 32, and 34), flat washers (29), lockwashers (30), nuts (31), assembled nuts (33 and 35),
corner post (36), and door sills (37 and 38) from generator set. Discard lockwashers (30).
18. Remove bolts (39, 42, 46, and 48), flat washers (41 and 43), lockwashers (40 and 44), nuts (45), assembled
nuts (47 and 49), and right side panel (50) from generator set. Discard lockwashers (40 and 44).
19. If necessary, drill out rivets (51) and remove plate (52) from left side rear panel (19).
20. If necessary, drill out rivets (53) and remove plate (54) from fuel filler neck panel (27).
21. If necessary, remove output box EMI seals (55) from door sill (37), corner post (36), and right side panel (50).
END OF TASK
INSPECTION
0018-2
TM 9-6115-644-24
1.
Shut down generator set.
2.
Inspect rear housing section panels for dents, cracks, loose paint, corrosion, and other damage.
3.
Inspect all cage nuts (Figure 1, Item 57) for cracking or stripped threads.
4.
Inspect all insulation for damage and missing clip halves.
5.
Inspect EMI seals (55) for tears, looseness, and deterioration.
6.
Inspect door seals (56) for tears, looseness, and deterioration.
END OF TASK
REPAIR
WARNING
CARC paint is a health hazard, and is irritating to eyes, skin, and respiratory system. Wear
protective eyewear, mask, and gloves when applying or removing CARC paint. Failure to comply
with this warning can cause injury to personnel.
WARNING
Solvent used to clean parts is potentially dangerous to personnel and property. Clean parts in a
well-ventilated area. Avoid inhalation of solvent fumes. Wear goggles and rubber gloves to
protect eyes and skin. Wash exposed skin thoroughly. Do not smoke or use near open flame or
excessive heat. Failure to comply with this warning can cause injury to personnel, and damage to
the equipment.
1.
Repair all dents and cracks, and remove all loose paint.
2.
Remove light corrosion with fine grit abrasive paper (WP 0159, Item 17).
0018-3
0018
TM 9-6115-644-24
Figure 1. Generator Set Rear Housing Section.
0018-4
0018
TM 9-6115-644-24
0018
3.
Repaint surfaces in accordance with TM 43-0139. (F) Use applicable directives.
4.
Replace all cracked or stripped cage nuts (Figure 1, Item 57).
5.
Replace damaged insulation (24) and missing clip halves (23). Refer to WP 0129 for fabrication of insulation.
6.
Replace EMI seals (55) that are loose or show any evidence of damage.
7.
Replace damaged door seals (56).
END OF TASK
INSTALLATION
1.
If removed, install plate (Figure 1, Item 54) on fuel tank filler neck panel (27) with rivets (53).
2.
If removed, install plate (52) on left side rear panel (19) with rivets (51).
3.
Install right side panel (50) on generator set with bolts (39, 42, 46, and 48), flat washers (41 and 43), new
lockwashers (40 and 44), nuts (45), and assembled nuts (47 and 49).
4.
Install door sills (37 and 38) and corner post (36) on generator set with bolts (28, 32, and 34), flat washers
(29), new lockwashers (30), nuts (31), and assembled nuts (33 and 35).
5.
Install fuel filler neck panel (27) on left side rear panel (19) with bolts (25) and assembled nuts (26).
6.
Install insulation (24) on baffle (22) with clip halves (23).
7.
Install baffle (22) on left side rear panel (19) with bolts (20) and assembled nuts (21).
8.
Install left side rear panel (19) on generator set with bolts (12 and 16), flat washers (13 and 17), new
lockwashers (14 and 18), and nuts (15).
9.
Install load entrance box (11) on rear panel (8) with bolts (9) and assembled nuts (10).
10. Install rear panel (8) on generator set with bolts (1 and 4), flat washers (3 and 5), new lockwashers (2 and 6),
and nuts (7).
11. If removed, install output box EMI seals (55) on door sill (37), corner post (36), and right side panel (50) with
adhesive (WP 0159, Item 2). Ensure closed side of seal faces outward.
12. Install top housing panel (WP 0016, Installation, Step 14).
13. Install ether solenoid valve (WP 0096, Installation).
14. Install fuel float module (WP 0093, Installation).
15. Install auxiliary fuel pump (WP 0087, Installation).
16. Install fuel tank filler neck (WP 0088, Installation).
17. Install air cleaner access door and engine access doors (WP 0014, Installation).
18. Install load terminal board access door and output box access door (WP 0014, Installation).
NOTE
Output box EMI seals are primary suppression components. Ensure that a complete seal is made
between output box door and generator set.
19. Install air cleaner assembly (WP 0073, Installation).
20. Install control box assembly (WP 0019, Installation).
END OF TASK
END OF WORK PACKAGE
0018-5/(6 blank)
TM 9-6115-644-24
0019
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, CONTROL BOX ASSEMBLY: INSPECTION, REMOVAL,
REPAIR, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0015, Maintenance of Housing, Control Box Top
Panel
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL Switch OFF/RESET
Battery Disconnect Switch is OFF
DEAD CRANK SWITCH is OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect control box assembly for cracks, breaks, corrosion, loose paint, and missing parts.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
0019-1
TM 9-6115-644-24
0019
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Open output box access door and disconnect two control box harness connectors.
5.
Remove bolts (Figure 1, Items 1 and 5), lockwashers (2), flat washers (3), nuts (4), and control box assembly
(6) from generator set. Discard lockwashers (2).
END OF TASK
REPAIR
Repair control box assembly by replacing damaged terminals, damaged or missing hardware, and damaged or
defective components.
END OF TASK
INSTALLATION
1.
Install control box assembly (Figure 1, Item 6) on generator set with bolts (1 and 5), flat washers (3), new
lockwashers (2), and nuts (4).
2.
Connect two control box harness connectors.
3.
Install control box top panel (WP 0015, Installation).
4.
Connect negative battery cable and close battery access door.
0019-2
TM 9-6115-644-24
Figure 1. Control Box Assembly.
END OF TASK
END OF WORK PACKAGE
0019-3/(4 blank)
0019
TM 9-6115-644-24
0020
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, PANEL LIGHTS: INSPECTION, REMOVAL,
DISASSEMBLY, ASSEMBLY, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
See "Never Work Alone" Warning
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL Switch OFF/RESET
Battery Disconnect Switch is OFF
DEAD CRANK SWITCH is OFF
INSPECTION
Inspect panel light holder and directional cap for cracks, corrosion, stripped threads, and other damage.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
0020-1
TM 9-6115-644-24
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect panel light (Figure 1, Item 1) electrical leads.
5.
Remove nut (2) and washer (3).
6.
Remove panel light (1) from control panel.
END OF TASK
DISASSEMBLY
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
1.
Remove panel light directional cap (Figure 1, Item 4) from panel light housing (1).
2.
Remove panel light bulb (5).
END OF TASK
ASSEMBLY
1.
Install panel light bulb (Figure 1, Item 5) into panel light housing (1).
2.
Install panel light directional cap (4).
END OF TASK
INSTALLATION
1.
Insert panel light (Figure 1, Item 1) into control panel.
2.
Install washer (3) and nut (2).
3.
Connect panel light electrical leads. Remove tags.
4.
Raise and secure control panel.
5.
Connect negative battery cable and close battery access door.
0020-2
0020
TM 9-6115-644-24
Figure 1. Control Panel Lights.
END OF TASK
END OF WORK PACKAGE
0020-3/(4 blank)
0020
TM 9-6115-644-24
0021
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, PRESS-TO-TEST LIGHTS: INSPECTION, TESTING,
REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0020, Figure 1, Items: 6 & 10
See "Never Work Alone" Warning
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL Switch set to OFF/RESET
Equipment Condition
Battery Disconnect Switch is OFF
DEAD CRANK SWITCH is OFF
INSPECTION
1.
Inspect lights for cracks, corrosion, evidence of shorting, and other damage.
2.
Replace or repair lights as necessary.
END OF TASK
TESTING
1.
Place MASTER SWITCH in PRIME & RUN position.
2.
Press in lamp holders (WP 0020, Figure 1, Item 6) and check that lamps are illuminated.
3.
If lamp (7) fails to light, perform Steps 4 through 5 below.
4.
Release control panel by turning two fasteners and lower control panel slowly.
5.
Set multimeter for DC volts and check for voltage at terminals 1 and 3 on receptacle (10).
6.
If voltage is present, replace press-to-test light assembly.
7.
Raise and secure control panel.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
0021-1
TM 9-6115-644-24
0021
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect electrical leads to light receptacles (WP 0020, Figure 1, Item 10).
5.
Remove lamp holders (6), nuts (8), lockwashers (9), and receptacles (10) from control panel. Discard
lockwashers (9).
6.
If necessary, remove lamps (7) from lamp holders (6).
END OF TASK
INSTALLATION
1.
Install press-to-test light receptacles (WP 0020, Figure 1, Item 10) in control panel with new lockwashers (9)
and nuts (8).
2.
If removed, install lamps (7) in lamp holders (6).
3.
Install lamp holders (6) on receptacles (10).
0021-2
TM 9-6115-644-24
4.
Connect electrical leads. Remove tags.
5.
Raise and secure control panel.
6.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0021-3/(4 blank)
0021
TM 9-6115-644-24
0022
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, SYNCHRONIZING LIGHTS: INSPECTION, REMOVAL,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
References
WP 0020, Figure 1, Item 13
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL switch OFF/RESET
Battery Disconnect Switch is OFF
DEAD CRANK SWITCH is OFF
INSPECTION
Inspect synchronizing lights for cracks, corrosion, evidence of shorting, and other damage.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
0022-1
TM 9-6115-644-24
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect synchronizing lights (WP 0020, Figure 1, Item 13) electrical connections.
5.
Remove nuts (11) and washers (12).
6.
Remove synchronizing lights (13) from control panel.
7.
Unscrew lenses (14) and remove lamps (15) from light receptacles (13).
END OF TASK
INSTALLATION
1.
Insert synchronizing lights (WP 0020, Figure 1, Item 13) into control panel.
2.
Install washers (12) and nuts (11).
3.
Connect electrical leads. Remove tags.
4.
Raise and secure control panel.
5.
Install lamps (15) and screw lenses (14) on light receptacles (13).
6.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0022-2
0022
TM 9-6115-644-24
0023
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, FUEL LEVEL INDICATOR: INSPECTION, TESTING,
REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL switch OFF/RESET
Battery Disconnect Switch is OFF
DEAD CRANK SWITCH is OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect indicator for broken lens, cracked housing, and other damage.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
NOTE
For MEP-805A, ensure frequency selector switch is in 50 Hz position.
4.
Isolate generator set VOLTAGE adjust potentiometer by disconnecting wire 137A from AC voltage regulator
terminal 5 and wire 107G from kilowatt transducer terminal V1.
5.
Disconnect and isolate electrical lead from terminal S of FUEL LEVEL indicator.
6.
Set multimeter for ohms and connect between wires 137A and 107G.
7.
Adjust potentiometer until multimeter indicates between 216 and 264 ohms resistance.
8.
Remove multimeter, but do not disturb potentiometer adjustment.
9.
Connect jumper wire between disconnected wire 107G and terminal G of FUEL LEVEL indicator.
10. Connect jumper wire between disconnected wire 137A and terminal S of FUEL LEVEL indicator.
11. Connect negative battery cable and move MASTER SWITCH to PRIME & RUN position.
12. FUEL LEVEL indicator should indicate EMPTY (±1/8 inch).
13. Move MASTER SWITCH to OFF position, disconnect negative battery cable, and remove jumper wires.
14. Repeat Steps 6 through 10 above, setting potentiometer between 29.7 and 36.3 ohms resistance.
15. Connect negative battery cable and move MASTER SWITCH to PRIME & RUN position.
0023-1
TM 9-6115-644-24
0023
16. FUEL LEVEL indicator should indicate FULL (±1/8 inch).
17. Move MASTER SWITCH to OFF position and disconnect negative battery cable.
18. Replace FUEL LEVEL indicator if it fails to function properly.
19. Remove jumper wires and connect electrical leads to FUEL LEVEL indicator, voltage regulator, and kilowatt
transducer.
20. Raise and secure control panel.
21. Connect negative battery cable and close battery access door.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
0023-2
TM 9-6115-644-24
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect FUEL LEVEL indicator (Figure 1, Item 4) electrical leads.
5.
Remove nuts (1), washers (2), and clamp (3).
6.
Remove FUEL LEVEL indicator (4) from control panel.
END OF TASK
0023-3
0023
TM 9-6115-644-24
Figure 1. Control Panel Indicators.
0023-4
0023
TM 9-6115-644-24
INSTALLATION
1.
Insert FUEL LEVEL indicator (Figure 1, Item 4) into control panel.
2.
Install clamp (3), washers (2), and nuts (1).
3.
Connect electrical leads. Remove tags.
4.
Raise and secure control panel.
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0023-5/(6 blank)
0023
TM 9-6115-644-24
0024
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, TEMPERATURE INDICATOR: INSPECTION, TESTING,
REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
References
WP 0023, Figure 1, Item 8
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL Switch is OFF/RESET
Battery Disconnect Switch is OFF
DEAD CRANK SWITCH is OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect indicator for broken lens, cracked housing, and other damage.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
NOTE
For MEP-805A, ensure frequency selector switch is in 50 Hz position.
4.
Isolate generator set VOLTAGE adjust potentiometer by disconnecting wire 137A from AC voltage regulator
terminal 5 and wire 107G from kilowatt transducer terminal V1.
5.
Disconnect and isolate electrical lead from terminal S of TEMPERATURE indicator.
6.
Set multimeter for ohms and connect between wires 137A and 107G.
7.
Adjust potentiometer until multimeter indicates between 117 and 143 ohms resistance.
8.
Disconnect multimeter but do not disturb potentiometer setting.
9.
Connect jumper wire between disconnected wire 137A and terminal S of TEMPERATURE indicator.
10. Connect jumper wire between disconnected wire 107G and terminal G of TEMPERATURE indicator.
11. Connect negative battery cable and move MASTER SWITCH to PRIME & RUN position.
12. TEMPERATURE indicator should indicate between 116 °F and 164 °F (46 °C and 73 °C).
13. Move MASTER SWITCH to OFF position, disconnect negative battery cable, and remove jumper wires.
14. Repeat Steps 6 through 10 above, setting potentiometer between 58.5 and 71.5 ohms resistance.
15. Connect negative battery cable and move MASTER SWITCH to PRIME & RUN position.
0024-1
TM 9-6115-644-24
0024
16. TEMPERATURE indicator should indicate between 156 °F and 204 °F (68 °C and 95 °C).
17. Move MASTER SWITCH to OFF position and disconnect negative battery cable.
18. Replace TEMPERATURE indicator if indications are other than above.
19. Remove jumper wires and connect electrical leads to TEMPERATURE indicator, AC Voltage Regulator, and
kilowatt transducer.
20. Raise and secure control panel.
21. Connect negative battery cable and close battery access door.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
0024-2
TM 9-6115-644-24
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect TEMPERATURE indicator (WP 0023, Figure 1, Item 8) electrical leads.
5.
Remove nuts (5), washers (6), and clamp (7).
6.
Remove TEMPERATURE indicator (8) from control panel.
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Insert TEMPERATURE indicator (WP 0023, Figure 1, Item 8) in control panel.
2.
Install clamp (7), washers (6), and nuts (5).
3.
Connect electrical leads. Remove tags.
4.
Raise and secure control panel.
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0024-3/(4 blank)
0024
TM 9-6115-644-24
0025
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, OIL PRESSURE INDICATOR: INSPECTION, TESTING,
REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
References
WP 0023, Figure 1, Item 12
WP 0043, Figure 1, Item 40
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL Switch is OFF/RESET
Battery Disconnect Switch is OFF
DEAD CRANK SWITCH is OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect indicator for broken lens, cracked housing, and other damage.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
NOTE
For MEP-805A, ensure frequency selector switch is in 50 Hz position.
4.
Isolate generator set VOLTAGE adjust potentiometer by disconnecting wire 137A from AC Voltage Regulator
terminal 5 and wire 107G from kilowatt transducer (WP 0043, Figure 1, Item 40) terminal V1.
5.
Disconnect and isolate electrical lead from terminal S of OIL PRESSURE indicator.
6.
Set multimeter for ohms and connect between wires 137A and 107G.
7.
Adjust potentiometer until multimeter indicates between 92.7 and 113.3 ohms resistance.
8.
Disconnect multimeter, but do not disturb potentiometer adjustment.
9.
Connect jumper wire between disconnected wire 137A and terminal S of OIL PRESSURE indicator.
10. Connect jumper wire between disconnected wire 107G and terminal G of OIL PRESSURE indicator.
11. Connect negative battery cable and move MASTER SWITCH to PRIME & RUN position.
12. OIL PRESSURE indicator should indicate between 32 and 48 PSI.
13. Move MASTER SWITCH to OFF position, disconnect negative battery cable, and remove jumper wires.
14. Repeat Steps 6 through 10 above, setting potentiometer to between 30.15 and 36.85 ohms resistance.
15. Connect negative battery cable and move MASTER SWITCH to PRIME & RUN position.
0025-1
TM 9-6115-644-24
0025
16. OIL PRESSURE indicator should indicate between 72 and 80 PSI.
17. Move MASTER SWITCH to OFF position and disconnect negative battery cable.
18. Replace OIL PRESSURE indicator if it does not function properly.
19. Remove jumper wires and connect electrical leads to OIL PRESSURE indicator, AC Voltage Regulator, and
kilowatt transducer.
20. Raise and secure control panel.
21. Connect negative battery cable and close battery access door.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
0025-2
TM 9-6115-644-24
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect OIL PRESSURE indicator (WP 0023, Figure 1, Item 12) electrical leads.
5.
Remove nuts (9), washers (10), and clamp (11).
6.
Remove OIL PRESSURE indicator (12) from control panel.
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Insert OIL PRESSURE indicator (WP 0023, Figure 1, Item 12) into control panel.
2.
Install clamp (11), washers (10), and nuts (9).
3.
Connect electrical leads. Remove tags.
4.
Raise and secure control panel.
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0025-3/(4 blank)
0025
TM 9-6115-644-24
0026
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, TIME METER (TOTAL HOURS): INSPECTION, TESTING,
REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic & (1)
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
References
WP 0023, Figure 1, Item 15
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL Switch is OFF/RESET
INSPECTION
1.
Shut down generator set.
2.
Inspect meter for broken lens, cracked housing, and other damage.
END OF TASK
TESTING
1.
Release control panel by turning two fasteners and lower control panel slowly.
2.
Turn MASTER SWITCH to PRIME & RUN position.
3.
Crank engine momentarily to energize time meter relay.
4.
Set multimeter for DC volts and connect across terminals 1 and 2 of time meter (TOTAL HOURS).
5.
If 24 VDC is present, wait approximately 6 minutes. Time meter (TOTAL HOURS) should move 1/10 of an
hour.
6.
If time meter (TOTAL HOURS) does not operate properly, meter is defective and must be replaced.
7.
Raise and secure control panel.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
0026-1
TM 9-6115-644-24
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect time meter (TOTAL HOURS) (WP 0023, Figure 1, Item 15) electrical leads.
5.
Remove screws (14), washers (32), and nuts (13).
6.
Remove time meter (TOTAL HOURS) (15) from control panel.
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
0026-2
0026
TM 9-6115-644-24
1.
Insert time meter (TOTAL HOURS) (WP 0023, Figure 1, Item 15) into control panel.
2.
Install screws (14), washers (32), and nuts (13).
3.
Connect electrical leads. Remove tags.
4.
Raise and secure control panel.
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0026-3/(4 blank)
0026
TM 9-6115-644-24
0027
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, BATTERY CHARGE AMMETER: INSPECTION, TESTING,
REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic & (1)
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
References
WP 0023, Figure 1, Items: 18 & 21
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL Switch OFF/RESET
INSPECTION
1.
Shut down generator set.
2.
Inspect ammeter for broken lens, cracked housing, and other damage.
END OF TASK
TESTING
1.
Start and operate generator set at rated voltage and frequency.
2.
Release control panel by turning two fasteners and lower control panel slowly.
3.
Set multimeter for DC volts and connect across BATTERY CHARGE ammeter terminals. Connect positive
lead to positive terminal and negative lead to negative terminal if you observe or think battery is charging.
Multimeter should indicate up to 50 mV (25 mV equals +10 amps on BATTERY CHARGE ammeter).
4.
Reverse multimeter leads if you observe or think battery is discharging. Multimeter should indicate up to 25
mV (25 mV equals -10 amps on BATTERY CHARGE ammeter).
5.
lf multimeter indicates millivolt reading and BATTERY CHARGE ammeter is not within ±10% of equal ampere
reading, or ammeter is not indicating, replace BATTERY CHARGE ammeter.
6.
Raise and secure control panel.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
0027-1
TM 9-6115-644-24
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect BATTERY CHARGE ammeter (WP 0023, Figure 1, Item 18) electrical leads.
5.
Remove nuts (16), washers (33 and 34), and screws (17).
6.
Remove BATTERY CHARGE ammeter (18).
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
0027-2
0027
TM 9-6115-644-24
1.
Insert BATTERY CHARGE ammeter (WP 0023, Figure 1, Item 18) into control panel.
2.
Install screws (17), washers (33 and 34), and nuts (16).
3.
Connect electrical leads and remove tags.
4.
Raise and secure control panel.
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0027-3/(4 blank)
0027
TM 9-6115-644-24
0028
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, FREQUENCY METER (HERTZ): INSPECTION, TESTING,
REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
See "One Qualified Technician
See "Never Work Alone" Warning
References
Equipment Condition
WP 0023, Figure 1, Item 21
Grounded, Off & Operational
WP 0052, Testing MEP-805A or Testing MEP-815A
ENGINE CONTROL Switch OFF/RESET
Battery Disconnect Switch is OFF
DEAD CRANK SWITCH is OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect meter for broken lens, cracked housing, and other damage.
END OF TASK
TESTING 50/60 Hz
NOTE
Test frequency transducer in accordance with WP 0052, Testing MEP-805A or Testing
MEP-815A prior to testing FREQUENCY meter (HERTZ).
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Disconnect wire 181A from positive (+) terminal of FREQUENCY meter (HERTZ).
5.
Set multimeter for DC milliamps and connect negative lead to positive (+) terminal of FREQUENCY meter
(HERTZ) and positive lead to wire 181A.
6.
Position FREQUENCY SELECT switch to 60 Hz.
7.
Connect negative battery cable, start and operate generator set at rated voltage, and adjust frequency to 60
Hz.
8.
Multimeter indication should be between 0.781 and 0.923 DC milliamps.
9.
Position FREQUENCY SELECT switch to 50 Hz and adjust frequency to 50 Hz.
10. Multimeter indication should be between 0.071 and 0.213 DC milliamps.
11. Replace FREQUENCY meter (HERTZ) if meter readings are not as stated above.
12. Raise and secure control panel.
END OF TASK
0028-1
TM 9-6115-644-24
0028
TESTING 400 Hz
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Disconnect wire 181A from positive (+) terminal of FREQUENCY meter (HERTZ).
5.
Set multimeter for DC milliamps and connect negative lead to positive (+) terminal of FREQUENCY meter
(HERTZ) and positive lead to wire 181A.
6.
Connect negative battery cable, start and operate generator set at rated voltage, and adjust frequency to 400
Hz.
7.
Multimeter indication should be between 0.240 and 0.260 DC milliamps.
8.
Replace FREQUENCY meter (HERTZ) if multimeter readings are not as stated above.
9.
Raise and secure control panel.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
0028-2
TM 9-6115-644-24
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect FREQUENCY meter (HERTZ) (WP 0023, Figure 1, Item 21) electrical leads.
5.
Remove nuts (19), washers (38), and screws (20).
6.
Remove FREQUENCY meter (HERTZ) (21) from control panel.
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Insert FREQUENCY meter (HERTZ) (WP 0023, Figure 1, Item 21) into control panel.
2.
Install screws (20), washers (38), and nuts (19).
3.
Connect electrical leads. Remove tags.
4.
Raise and secure control panel.
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0028-3/(4 blank)
0028
TM 9-6115-644-24
0029
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, AMMETER (PERCENT RATED CURRENT): INSPECTION,
TESTING, REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic & (1)
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
References
WP 0023, Figure 1, Item 24
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL Switch OFF/RESET
Battery Disconnect Switch is OFF
DEAD CRANK SWITCH is OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect ammeter for broken lens, cracked housing, and other damage.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open battery access and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect wire 183A from terminal 1 of ammeter (PERCENT RATED CURRENT).
5.
Set multimeter for AC amperes and connect between disconnected wire 183A and terminal 1 of ammeter
(PERCENT RATED CURRENT). Place VM-AM transfer switch in L1 - L0 position.
6.
Connect negative battery cable, start and operate generator set at rated voltage and frequency, and apply
some load to generator set.
7.
Observe and note indications on multimeter and ammeter (PERCENT RATED CURRENT).
8.
Shut down generator set.
9.
Calculate percent of current from multimeter indication using the following formula:
10. Compare calculated percent of current to ammeter (PERCENT RATED CURRENT) indication noted during
operation. If difference is greater than 10 percent, replace ammeter.
11. Disconnect negative battery cable.
12. Remove multimeter and connect wire 183A to ammeter (PERCENT RATED CURRENT).
13. Raise and secure control panel.
14. Connect negative battery cable and close battery access door.
0029-1
TM 9-6115-644-24
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
0029-2
0029
TM 9-6115-644-24
0029
4.
Tag and disconnect ammeter (PERCENT RATED CURRENT) (WP 0023, Figure 1, Item 24) electrical leads.
5.
Remove nuts (22), washers (35), and screws (23).
6.
Remove ammeter (PERCENT RATED CURRENT) (24) from control panel.
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Insert ammeter (PERCENT RATED CURRENT) (WP 0023, Figure 1, Item 24) into control panel.
2.
Install screws (23), washers (35), and nuts (22).
3.
Connect electrical leads. Remove tags.
4.
Raise and secure control panel.
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0029-3/(4 blank)
TM 9-6115-644-24
0030
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, KILOWATTMETER (PERCENT POWER): INSPECTION,
TESTING, REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52D) &
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
References
WP 0023, Figure 1, Item 27
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL Switch OFF/RESET
Battery Disconnect Switch is OFF
DEAD CRANK SWITCH is OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect meter for broken lens, cracked housing, and other damage.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect wire 120A from positive terminal of kilowattmeter (PERCENT POWER).
5.
Set multimeter for milliamperes and connect between disconnected wire 120A and positive terminal of
kilowattmeter.
6.
Connect negative battery cable, start and operate generator set at rated voltage and frequency, and apply
some load to generator set.
7.
Observe and note indications on multimeter and kilowattmeter.
8.
Shut down generator set.
9.
Calculate percent of power from multimeter indication using the following formula:
10. Compare calculated percent of power to kilowattmeter indication noted during operation. If difference is
greater than 13%, replace kilowattmeter (PERCENT POWER).
11. Disconnect negative battery cable.
12. Remove multimeter and connect wire 120A to kilowattmeter (PERCENT POWER).
13. Raise and secure control panel.
14. Connect negative battery cable and close battery access door.
0030-1
TM 9-6115-644-24
END OF TASK
REMOVAL
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
0030-2
0030
TM 9-6115-644-24
4.
Tag and disconnect kilowattmeter (PERCENT POWER) (WP 0023, Figure 1, Item 27) electrical leads.
5.
Remove nuts (25), washers (36), and screws (26).
6.
Remove kilowattmeter (PERCENT POWER) (27) from control panel.
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Insert kilowattmeter (PERCENT POWER) (WP 0023, Figure 1, Item 27) into control panel.
2.
Install screws (26), washers (36), and nuts (25).
3.
Connect electrical leads. Remove tags.
4.
Raise and secure control panel.
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0030-3/(4 blank)
0030
TM 9-6115-644-24
0031
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, AC VOLTMETER (VOLTS AC): INSPECTION, TESTING,
REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
References
WP 0023, Figure 1, Item 31
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL Switch OFF/RESET
Battery Disconnect Switch is OFF
DEAD CRANK SWITCH is OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect AC Voltmeter (Volts AC) for broken lens, cracked housing, and other damage.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Release control panel by turning two fasteners and lower control panel slowly.
3.
Set multimeter for AC volts and connect to AC Voltmeter (Volts AC) terminals.
4.
Move voltage reconnection board to 120/208 position.
5.
Start and operate generator set at rated voltage and frequency.
6.
Move VM-AM transfer switch to L3-L1 position. Note indications on multimeter and AC Voltmeter (Volts AC).
7.
Move VM-AM transfer switch to L3-L0 position. Note indications on multimeter and AC Voltmeter (Volts AC).
8.
Shut down generator set.
9.
Move voltage reconnection board to 240/416 position.
10. Start and operate generator set at rated voltage and frequency.
11. Repeat Steps 6 and 7 above.
12. Shut down generator set.
13. Compare AC Voltmeter (Volts AC) readings to multimeter in each position.
14. Replace AC Voltmeter (Volts AC) if readings differ more than ±5 VAC between 115-125 VAC or ±10 VAC
between 200-250 VAC.
15. Remove multimeter.
16. Raise and secure control panel.
END OF TASK
0031-1
TM 9-6115-644-24
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect AC Voltmeter (Volts AC) (WP 0023, Figure 1, Item 31) electrical leads and remove
sleeves (28).
0031-2
0031
TM 9-6115-644-24
5.
Remove nuts (29), washers (37), and screws (30).
6.
Remove AC Voltmeter (Volts AC) (31) from control panel.
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Insert AC Voltmeter (Volts AC) (WP 0023, Figure 1, Item 31) into control panel.
2.
Install screws (30), washers (37), and nuts (29).
3.
Connect electrical leads, remove tags, and install sleeves (28) over terminals.
4.
Raise and secure control panel.
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0031-3/(4 blank)
0031
TM 9-6115-644-24
0032
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, MASTER SWITCH: INSPECTION, REMOVAL, TESTING,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
References
FO-1 Electrical Schematic
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL Switch OFF/RESET
Battery Disconnect Switch is OFF
DEAD CRANK SWITCH is OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect switch for loose connections/mounting and other damage.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
0032-1
TM 9-6115-644-24
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Loosen setscrew (Figure 1, Item 1) and remove knob (2) from MASTER SWITCH (5).
5.
Remove nuts (3) and screws (4).
6.
Remove MASTER SWITCH (5) from control panel.
7.
Tag and disconnect MASTER SWITCH (5) electrical leads.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect MASTER SWITCH (Figure 1, Item 5) electrical leads.
5.
Set multimeter for ohms and check switch for continuity. Refer to Electrical Schematic FO-1 (S-1 Circuit
Schedule) to determine circuits made to corresponding switch positions.
6.
Check continuity until all four positions have been checked.
7.
If open circuit is noted in any switch position switch is unserviceable and must be replaced.
8.
Connect electrical leads to MASTER SWITCH (5). Remove tags.
9.
Raise and secure control panel.
10. Connect negative battery cable and close battery access door.
END OF TASK
INSTALLATION
0032-2
0032
TM 9-6115-644-24
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Connect electrical leads to MASTER SWITCH (Figure 1, Item 5). Remove tags.
2.
Insert MASTER SWITCH (5) into control panel.
3.
Install screws (4) and nuts (3).
4.
Install knob (2) and tighten setscrew (1).
5.
Raise and secure control panel.
6.
Connect negative battery cable and close battery access door.
0032-3
0032
TM 9-6115-644-24
Figure 1. Control Panel Switches.
END OF TASK
END OF WORK PACKAGE
0032-4
0032
TM 9-6115-644-24
0033
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, ETHER SWITCH: INSPECTION, REMOVAL, TESTING,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Ether Switch (if indications during testing are not
inaccordance to this work package)
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0032, Figure 1, Items: 8 & 9
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL Switch OFF/RESET
Battery Disconnect Switch is OFF
DEAD CRANK SWITCH is OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect switch for loose connections/mounting and other damage.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
0033-1
TM 9-6115-644-24
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect ETHER switch (WP 0032, Figure 1, Item 8) electrical leads.
5.
Remove nut (6) and washer (7).
6.
Remove ETHER switch (8) from control panel and remove tab washer (9).
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect ETHER switch (WP 0032, Figure 1, Item 8) electrical leads.
5.
Set multimeter for ohms and connect across ETHER switch terminals. Multimeter should indicate open
circuit.
6.
Hold ETHER switch in ON position. Multimeter should indicate continuity.
7.
Replace ETHER switch if indications are not as above.
8.
Connect electrical leads to ETHER switch (8). Remove tags.
9.
Raise and secure control panel.
10. Connect negative battery cable and close battery access door.
END OF TASK
0033-2
0033
TM 9-6115-644-24
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install tab washer (WP 0032, Figure 1, Item 9) and insert ETHER switch (8) into control panel.
2.
Install washer (7) and nut (6).
3.
Connect electrical leads. Remove tags.
4.
Raise and secure control panel.
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0033-3/(4 blank)
0033
TM 9-6115-644-24
0034
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, VOLTAGE ADJUST POTENTIOMETER: INSPECTION,
REMOVAL, TESTING, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Potentiometer (if defective)
New Shrinkable Tubing
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
References
WP 0032, Figure 1, Item 14
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL Switch is OFF/RESET
Battery Disconnect Switch is OFF
DEAD CRANK SWITCH is OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect potentiometer for loose connections/mounting and other damage.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
0034-1
TM 9-6115-644-24
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect VOLTAGE adjust potentiometer (WP 0032, Figure 1, Item 14) electrical leads using
soldering gun. Remove shrinkable tubing.
5.
Remove setscrews (10) and knob (11).
6.
Remove nut (12) and washer (13).
7.
Remove VOLTAGE adjust potentiometer (14) from control panel.
END OF TASK
TESTING
1.
Remove VOLTAGE adjust potentiometer (Removal).
2.
Set multimeter for ohms and connect across two outer terminals of potentiometer (WP 0032, Figure 1).
Indication shall be as follows:
10,000 ohms (part number RV4NAYSD103A installed)
20,000 ohms (part number RV4NAYSD203A installed)
3.
Rotate potentiometer shaft counterclockwise (CCW) as far as it will go.
4.
Connect multimeter between center terminal and either outer terminal.
5.
Slowly and at an even rate, rotate potentiometer shaft clockwise (CW) as far as it will go while observing
multimeter.
6.
Multimeter indication shall increase at an even rate as follows:
0 to 10,000 ohms (part number RV4NAYSD103A installed)
0034-2
0034
TM 9-6115-644-24
0 to 20,000 ohms (part number RV4NAYSD203A installed)
7.
If multimeter indication changes erratically or is not at maximum ohms when rotation is complete,
potentiometer is defective and must be replaced.
8.
Install VOLTAGE adjust potentiometer (Installation).
END OF TASK
INSTALLATION
1.
Insert VOLTAGE adjust potentiometer (WP 0032, Figure 1, Item 14) into control panel.
2.
Install washer (13) and nut (12).
3.
Install knob (11) and setscrews (10).
4.
Install new shrinkable tubing and connect electrical leads using soldering gun. Remove tags.
5.
Raise and secure control panel.
6.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0034-3/(4 blank)
0034
TM 9-6115-644-24
0035
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, FREQUENCY ADJUST POTENTIOMETER: INSPECTION,
REMOVAL, TESTING, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
New Shrinkable Tubing
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0032, Figure 1, Item 19
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL Switch is OFF/RESET
Battery Disconnect Switch is OFF
DEAD CRANK SWITCH is OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect switch for loose connections/mounting and other damage.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
0035-1
TM 9-6115-644-24
0035
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect FREQUENCY adjust potentiometer (WP 0032, Figure 1, Item 19) electrical leads using
soldering gun. Remove shrinkable tubing.
5.
Remove setscrews (15) and knob (16).
6.
Remove nut (17) and washer (14).
7.
Remove FREQUENCY adjust potentiometer (19) from control panel.
END OF TASK
TESTING
1.
Remove FREQUENCY adjust potentiometer (Removal).
2.
Set multimeter for ohms and connect across outer terminals of potentiometer (WP 0032, Figure 1, Item 19).
Multimeter should indicate between 4,500 and 5,500 ohms resistance.
3.
Rotate potentiometer shaft CCW as far as it will go.
4.
Connect multimeter between center terminal and either outer terminal. Multimeter should indicate 0 ohms
resistance.
5.
Slowly and at an even rate, rotate potentiometer shaft CW as far as it will go. Multimeter should increase at
an even rate from 0 to 5,000 ohms.
6.
If multimeter indication changes erratically or is not between 4,500 and 5,500 ohms when rotation is
completed, potentiometer is defective and must be replaced.
7.
Install FREQUENCY adjust potentiometer (Installation).
0035-2
TM 9-6115-644-24
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Insert FREQUENCY adjust potentiometer (WP 0032, Figure 1, Item 19) into control panel.
2.
Install washer (18) and nut (17).
3.
Install knob (16) and setscrews (15).
4.
Install new shrinkable tubing and solder leads. Remove tags.
5.
Raise and secure control panel.
6.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0035-3/(4 blank)
0035
TM 9-6115-644-24
0036
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, BATTLE SHORT SWITCH: INSPECTION, TESTING,
REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
References
WP 0032, Figure 1, Item 23
FO-3 Wiring Diagram
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL Switch is OFF
Battery Disconnect Switch is OFF
DEAD CRANK SWITCH is OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect switch for loose connections/mounting and other damage.
END OF TASK
TESTING
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
0036-1
TM 9-6115-644-24
0036
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect BATTLE SHORT switch (WP 0032, Figure 1, Item 23) electrical leads.
5.
Place switch in ON position.
NOTE
Refer to Wiring Diagram FO-3 for terminal positions.
6.
Set multimeter for ohms and check for continuity between terminals 2 and 3, 5 and 6, 8 and 9, and 11 and
12.
7.
Place switch in OFF position.
8.
Check for continuity between terminals 1 and 2, 4 and 5, 7 and 8, and 10 and 11.
9.
Replace switch if any open circuit is indicated.
10. Connect electrical leads to switch (23). Remove tags.
11. Raise and secure control panel.
12. Connect negative battery cable and close battery access door.
END OF TASK
REMOVAL
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect BATTLE SHORT switch (WP 0032, Figure 1, Item 23) electrical leads.
5.
Remove nut (20), washer (21), and protective cover (22).
6.
Remove BATTLE SHORT switch (23) from control panel and tab washer (24) from switch stem.
END OF TASK
0036-2
TM 9-6115-644-24
0036
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install tab washer (WP 0032, Figure 1, Item 24) and insert BATTLE SHORT switch (23) into control panel.
2.
Install protective cover (22), washer (21), and nut (20).
3.
Connect electrical leads. Remove tags.
4.
Raise and secure control panel.
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0036-3/(4 blank)
TM 9-6115-644-24
0037
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, AC CIRCUIT INTERRUPTER SWITCH: INSPECTION,
TESTING, REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
AC Circuit Interrupter Switch (If continuity check
does not comply with testing procedures in this work
package)
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0032, Figure 1, Item 27
FO-2 Wiring Diagram
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH is OFF/RESET
Battery Disconnect Switch is OFF
DEAD CRANK SWITCH is OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect switch for loose connections/mounting and other damage.
END OF TASK
TESTING
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
0037-1
TM 9-6115-644-24
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect AC CIRCUIT INTERRUPTER switch (WP 0032, Figure 1, Item 27) electrical leads.
NOTE
Refer to Wiring Diagram FO-2 for terminal positions.
5.
Set multimeter for ohms and check for continuity between terminals 5 and 4 and terminals 2 and 3.
6.
Check for open circuits between terminals 5 and 6 and terminals 1 and 2.
7.
Place and hold AC CIRCUIT INTERRUPTER switch in CLOSED position.
8.
Check for continuity between terminals 5 and 6 and terminals 2 and 3.
9.
Check for open circuits between terminals 5 and 4 and terminals 2 and 1.
10. Place and hold AC CIRCUIT INTERRUPTER switch in OPEN position.
11. Check for continuity between terminals 5 and 4 and terminals 1 and 2.
12. Check for open circuits between terminals 5 and 6 and terminals 3 and 1.
13. Replace switch if any continuity check is other than indicated above.
14. Connect electrical leads to switch (27). Remove tags.
15. Raise and secure control panel.
16. Connect negative battery cable and close battery access door.
END OF TASK
REMOVAL
0037-2
0037
TM 9-6115-644-24
0037
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect AC CIRCUIT INTERRUPTER switch (WP 0032, Figure 1, Item 27) electrical leads.
5.
Remove nut (25) and washer (26).
6.
Remove AC CIRCUIT INTERRUPTER switch (27) from control panel and tab washer (28) from switch stem.
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install tab washer (WP 0032, Figure 1, Item 28) and insert AC CIRCUIT INTERRUPTER switch (27) into
control panel.
2.
Install washer (26) and nut (25).
3.
Connect electrical leads. Remove tags.
4.
Raise and secure control panel.
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0037-3/(4 blank)
TM 9-6115-644-24
0038
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, PARALLEL-UNIT SWITCH: INSPECTION, REMOVAL,
TESTING, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Parellel-Unit Switch (If any open circuit is indicated
during testing)
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0032, Figure 1, Items: 28 & 31
FO-2 Wiring Diagram
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect switch for loose connections/mounting and other damage.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
0038-1
TM 9-6115-644-24
0038
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect PARALLEL-UNIT switch (WP 0032, Figure 1, Item 31) electrical leads.
5.
Remove nut (29) and washer (30).
6.
Remove PARALLEL-UNIT switch (31) from control panel and tab washer (32) from switch stem.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect PARALLEL-UNIT switch (WP 0032, Figure 1, Item 31) electrical leads.
NOTE
Refer to Wiring Diagram FO-2 for terminal positions.
5.
Place switch in PARALLEL position.
6.
Set multimeter for ohms and check for continuity between terminals 1 and 2, 4 and 5, 7 and 8, and 10 and
11.
7.
Place switch in UNIT position.
8.
Check for continuity between terminals 2 and 3, 5 and 6, 8 and 9, and 11 and 12.
0038-2
TM 9-6115-644-24
9.
0038
Replace switch if any open circuit is indicated.
10. Connect electrical leads to switch (31). Remove tags.
11. Raise and secure control panel.
12. Connect negative battery cable and close battery access door.
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install tab washer (WP 0032, Figure 1, Item 28) and insert PARALLEL-UNIT switch (27) into control panel.
2.
Install washer (26) and nut (25).
3.
Connect electrical leads. Remove tags.
4.
Raise and secure control panel.
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0038-3/(4 blank)
TM 9-6115-644-24
0039
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, VM-AM TRANSFER SWITCH: INSPECTION, REMOVAL,
TESTING, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
VA-AM Transfer Switch (if open circuit is indicated
during testing)
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
FO-1 Electrical Schematic
WP 0032, Figure 1, Item 37
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect switch for loose connections/mounting and other damage.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
0039-1
TM 9-6115-644-24
0039
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Remove setscrew (WP 0032, Figure 1, Item 33) and knob (34).
5.
Remove nuts (35) and screws (36).
6.
Remove VM-AM Transfer Switch (37) from control panel.
7.
Tag and disconnect VM-AM Transfer Switch (37) electrical leads.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Remove VM-AM Transfer Switch (Removal).
3.
Set multimeter for ohms and check VM-AM Transfer Switch for continuity. Refer to Electrical Schematic FO-1
(S-6 Circuit Schedule) to determine circuits made to corresponding switch positions.
4.
Check continuity in all six switch positions.
5.
Replace VM-AM Transfer Switch If open circuit is indicated.
6.
Install VM-AM Transfer Switch (Installation).
END OF TASK
INSTALLATION
0039-2
TM 9-6115-644-24
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Connect electrical leads to VM-AM Transfer Switch (WP 0032, Figure 1, Item 37). Remove tags.
2.
Insert VM-AM Transfer Switch (37) into control panel.
3.
Install screws (36) and nuts (35).
4.
Install knob (34) and setscrew (33).
5.
Raise and secure control panel.
6.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0039-3/(4 blank)
0039
TM 9-6115-644-24
0040
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, PANEL LIGHTS SWITCH: INSPECTION, REMOVAL,
TESTING, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Panel Light Switch (if readings don't comply during
testing)
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0032, Figure 1, Items: 40 & 41
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect switch for loose connections/mounting and other damage.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
0040-1
TM 9-6115-644-24
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect PANEL LIGHTS switch (WP 0032, Figure 1, Item 40) electrical leads.
5.
Remove nut (38) and washer (39).
6.
Remove PANEL LIGHTS switch (40) from control panel and tab washer (41) from switch stem.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect PANEL LIGHTS switch (WP 0032, Figure 1, Item 40) electrical leads.
5.
Set multimeter for ohms and connect across switch terminals.
6.
Place switch in ON position. Multimeter should indicate continuity.
7.
Place switch in OFF position. Multimeter should indicate open circuit.
8.
Replace PANEL LIGHTS switch if readings are not as above.
9.
Connect electrical leads to switch (40). Remove tags.
10. Raise and secure control panel.
11. Connect negative battery cable and close battery access door.
END OF TASK
0040-2
0040
TM 9-6115-644-24
0040
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install tab washer (WP 0032, Figure 1, Item 41) and insert PANEL LIGHTS switch (40) into control panel.
2.
Install washer (39) and nut (38).
3.
Install electrical leads. Remove tags.
4.
Raise and secure control panel.
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0040-3/(4 blank)
TM 9-6115-644-24
0041
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, EMERGENCY STOP SWITCH ASSEMBLY: INSPECTION,
REMOVAL, TESTING, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Emergency Stop Switch (if no continuity is indicated
during testing)
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0032, Figure 1, Item 44
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect switch assembly for loose connections/mounting and other damage.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
0041-1
TM 9-6115-644-24
0041
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect EMERGENCY STOP switch assembly (WP 0032, Figure 1, Item 44) electrical leads.
5.
Remove knob (42) and nut (43).
6.
Remove EMERGENCY STOP switch assembly (40) from control panel.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect EMERGENCY STOP switch assembly (WP 0032, Figure 1, Item 44) electrical leads.
5.
With switch in normal (out) position, set multimeter for ohms and check circuit between switch terminals. If no
continuity is indicated, EMERGENCY STOP switch assembly is defective.
6.
Push EMERGENCY STOP switch assembly to in position.
7.
Check for continuity between switch terminals. Replace EMERGENCY STOP switch assembly if continuity is
indicated.
8.
Connect electrical leads to EMERGENCY STOP switch assembly (44). Remove tags.
9.
Raise and secure control panel.
10. Connect negative battery cable and close battery access door.
0041-2
TM 9-6115-644-24
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Insert EMERGENCY STOP switch assembly (WP 0032, Figure 1, Item 44) into control panel.
2.
Install nut (43) and knob (42).
3.
Connect electrical leads. Remove tags.
4.
Raise and secure control panel.
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0041-3/(4 blank)
0041
TM 9-6115-644-24
0042
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, REACTIVE CURRENT ADJUST RHEOSTAT: INSPECTION,
TESTING, REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
New Shrinkable Tubing
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0015, Maintenance of Housing, Control Box Top
Panel
WP 0043, Figure 1, Item 3
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect rheostat for loose connections/mounting and other damage.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Disconnect wires 143C from TB4 terminal 21, 142A from TB6 terminal 12, and 135B from TB5 terminal 4.
5.
Mark reading of REACTIVE CURRENT ADJUST rheostat to reposition at conclusion of testing steps.
6.
Set multimeter for ohms and connect to wires 135B and 142A. Multimeter reading should be between 4.5 and
5.5 ohms.
7.
Connect multimeter to wires 135B and 143C and turn REACTIVE CURRENT ADJUST rheostat to full CW
position. Multimeter reading should be approximately 0 ohms. Turn REACTIVE CURRENT ADJUST rheostat
slowly to full CCW position and observe multimeter. Multimeter reading should evenly increase to between
4.5 and 5.5 ohms.
8.
Connect multimeter to wires 142A and 143C and turn REACTIVE CURRENT ADJUST rheostat to full CW
position. Multimeter reading should be between 4.5 and 5.5 ohms. Turn REACTIVE CURRENT ADJUST
rheostat slowly to full CCW position and observe multimeter. Multimeter reading should evenly decrease to
approximately 0 ohms.
9.
Replace REACTIVE CURRENT ADJUST rheostat if multimeter readings are other than above.
10. Reposition REACTIVE CURRENT ADJUST rheostat as marked in Step 5 above.
11. Connect electrical wires as tagged.
12. Install control box top panel (WP 0015, Installation).
0042-1
TM 9-6115-644-24
13. Connect negative battery cable and close battery access door.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
0042-2
0042
TM 9-6115-644-24
0042
3.
Remove control box top panel (WP 0015, Removal).
4.
Tag and disconnect REACTIVE CURRENT ADJUST rheostat (WP 0043, Figure 1, Item 3) electrical leads by
unsoldering and remove shrinkable tubing.
5.
Remove nuts (1 and 2) and rheostat (3).
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install rheostat (WP 0043, Figure 1, Item 3) in mounting bracket.
2.
Install nuts (1 and 2).
3.
Install new shrinkable tubing and solder electrical leads. Remove tags.
4.
Install control box top panel (WP 0015, Installation).
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0042-3/(4 blank)
TM 9-6115-644-24
0043
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, LOAD SHARING ADJUST RHEOSTAT: INSPECTION,
TESTING, REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0015, Maintenance of Housing, Control Box Top
Panel
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect rheostat for loose connections/mounting and other damage.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Tag and disconnect wire 161B from reverse power relay terminal 2. Insulate end of wire.
5.
Disconnect wire 159A from governor control unit terminal 11.
6.
Set multimeter for ohms and connect positive lead to wire 159A and negative lead of multimeter to terminal
12 of governor control unit. Record reading of rheostat.
7.
Turn LOAD SHARING ADJUST rheostat to full CCW position. Multimeter reading should be between 4,500
and 5,500 ohms.
8.
Turn LOAD SHARING ADJUST rheostat to full CW position. Multimeter reading should be approximately 0
ohms.
9.
Replace LOAD SHARING ADJUST rheostat if multimeter readings are other than above.
10. If readings are within tolerance, return rheostat to reading recorded in Step 6 above.
11. Connect electrical wires as tagged.
12. Install control box top panel (WP 0015, Installation).
13. Connect negative battery cable and close battery access door.
END OF TASK
0043-1
TM 9-6115-644-24
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Tag and disconnect LOAD SHARING ADJUST rheostat (Figure 1, Item 7) electrical leads.
0043-2
0043
TM 9-6115-644-24
5.
Remove nuts (4 and 5), lockwasher (6), and rheostat (7). Discard lockwasher (6).
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install LOAD SHARING ADJUST rheostat (Figure 1, Item 7) in mounting bracket.
2.
Install new lockwasher (6) and nuts (5 and 4).
3.
Connect electrical leads. Remove tags.
Figure 1. Control Box Components.
0043-3
0043
TM 9-6115-644-24
4.
Install control box top panel (WP 0015, Installation).
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0043-4
0043
TM 9-6115-644-24
0044
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, OVERSPEED RESET SWITCH: INSPECTION, TESTING,
REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0015, Maintenance of Housing, Control Box Top
Panel
WP 0043, Figure 1, Item 10
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect rheostat for loose connections/mounting and other damage.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Tag and disconnect OVERSPEED RESET switch (WP 0043, Figure 1, Item 10) electrical leads.
5.
Set multimeter for ohms and connect across switch terminals. Multimeter should indicate continuity.
6.
Position and hold switch in up position. Multimeter should indicate open circuit.
7.
Replace OVERSPEED RESET switch if indications are other than above.
8.
Connect electrical leads to switch (10). Remove tags.
9.
Install control box top panel (WP 0015, Installation).
10. Connect negative battery cable and close battery access door.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
0044-1
TM 9-6115-644-24
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Tag and disconnect OVERSPEED RESET switch (WP 0043, Figure 1, Item 10) electrical leads.
5.
Remove nut (8), lockwasher (9), and switch (10). Discard lockwasher (9).
END OF TASK
INSTALLATION
0044-2
0044
TM 9-6115-644-24
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install OVERSPEED RESET switch (WP 0043, Figure 1, Item 10) in mounting bracket.
2.
Install new lockwasher (9) and nut (8).
3.
Connect electrical leads. Remove tags.
4.
Install control box top panel (WP 0015, Installation).
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0044-3/(4 blank)
0044
TM 9-6115-644-24
0045
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, FREQUENCY SELECT SWITCH (MEP-805A):
INSPECTION, TESTING, REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0015, Maintenance of Housing, Control Box Top
Panel
WP 0043, Figure 1, Item 14
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
INSPECTION
1.
Shut down generator set.
2.
Inspect switch for loose connections/mounting and other damage.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Tag and disconnect FREQUENCY SELECT switch (WP 0043, Figure 1, Item 14) electrical leads.
5.
Set multimeter for ohms and connect across switch terminals.
6.
Place switch in up (60 Hz) position. Multimeter should indicate continuity.
7.
Place switch in down (50 Hz) position. Multimeter should indicate continuity.
8.
Replace FREQUENCY SELECT switch (14) if indications are other than above.
9.
Connect electrical leads to switch (14). Remove tags.
10. Install control box top panel (WP 0015, Installation)
11. Connect negative battery cable and close battery access door.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
0045-1
TM 9-6115-644-24
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Tag and disconnect electrical leads from FREQUENCY SELECT switch (WP 0043, Figure 1, Item 14).
5.
Tag and remove resistor (11) from FREQUENCY SELECT switch (14).
6.
Remove nut (12), lockwasher (13), and FREQUENCY SELECT switch (14). Discard lockwasher (13).
END OF TASK
INSTALLATION
0045-2
0045
TM 9-6115-644-24
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Position FREQUENCY SELECT switch (WP 0043, Figure 1, Item 14) in mounting bracket.
2.
Install new lockwasher (13) and nut (12).
3.
Install resistor (11) on FREQUENCY SELECT switch (14). Remove tags.
4.
Connect electrical leads. Remove tags.
5.
Install control box top panel (WP 0015, Installation).
6.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0045-3/(4 blank)
0045
TM 9-6115-644-24
0046
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, CONVENIENCE RECEPTACLE: INSPECTION, TESTING,
REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Convenience Receptacle (if continuity is indicated
during testing)
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0015, Maintenance of Housing, Control Box Top
Panel
WP 0043, Figure 1, Items: 15 & 20
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect CONVENIENCE RECEPTACLE for cracks, breaks, corrosion, bent terminals, and other damage.
3.
Inspect cover for cracks, corrosion, or damaged springs.
4.
Replace defective parts.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Remove control box top panel (WP 0015, Removal).
3.
Tag and disconnect CONVENIENCE RECEPTACLE (WP 0043, Figure 1, Item 20) electrical leads.
4.
Set multimeter for ohms and check for continuity between upper side terminals and lower side terminals of
each plug outlet.
5.
Replace CONVENIENCE RECEPTACLE (20) if continuity is indicated between terminals.
6.
Connect electrical leads to receptacle (20). Remove tags.
7.
Install control box top panel (WP 0015, Installation).
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
0046-1
TM 9-6115-644-24
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Remove screws (WP 0043, Figure 1, Item 15) and nuts (16).
5.
Remove CONVENIENCE RECEPTACLE cover (17).
6.
Remove machine screws (18), nuts (19), and CONVENIENCE RECEPTACLE (20).
7.
Tag and disconnect CONVENIENCE RECEPTACLE (20) electrical leads.
END OF TASK
INSTALLATION
0046-2
0046
TM 9-6115-644-24
0046
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Connect electrical leads to CONVENIENCE RECEPTACLE (WP 0043, Figure 1, Item 20). Remove tags.
2.
Install CONVENIENCE RECEPTACLE (20) into panel cutout with machine screws (18) and nuts (19).
3.
Install CONVENIENCE RECEPTACLE cover (17) with screws (15) and nuts (16).
4.
Install control box top panel (WP 0015, Installation).
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0046-3/(4 blank)
TM 9-6115-644-24
0047
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, GROUND FAULT CIRCUIT INTERRUPTER: INSPECTION,
TESTING, REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52D) &
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
References
Equipment Condition
TM 9-6115-644-24P
Grounded, Off & Operational
WP 0015, Maintenance of Housing, Control Box Top
ENGINE CONTROL SWITCH OFF/RESET
Panel
Battery Disconnect Switch OFF
WP 0043, Figure 1, Items: 23, 24 & 27
DEAD CRANK SWITCH OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect GROUND FAULT CIRCUIT INTERRUPTER for cracks, corrosion, frayed wires, and other damage.
END OF TASK
TESTING
1.
Start and operate generator set at rated voltage and frequency.
2.
Set multimeter for AC volts, press TEST button, and check for zero voltage at CONVENIENCE
RECEPTACLE.
3.
Press RESET button on GROUND FAULT CIRCUIT INTERRUPTER and use multimeter to check for 120
VAC at CONVENIENCE RECEPTACLE.
4.
Replace GROUND FAULT CIRCUIT INTERRUPTER if indications are other than above.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
0047-1
TM 9-6115-644-24
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Tag and disconnect GROUND FAULT CIRCUIT INTERRUPTER (WP 0043, Figure 1, Item 23) electrical
leads from TB4 and K5 and CONVENIENCE RECEPTACLE (20).
5.
Remove screws (21) and nuts (22).
6.
Remove GROUND FAULT CIRCUIT INTERRUPTER (23) from malfunction indicator panel (27).
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
0047-2
0047
TM 9-6115-644-24
0047
1.
Install GROUND FAULT CIRCUIT INTERRUPTER (WP 0043, Figure 1, Item 23) in malfunction indicator
panel (27) with screws (21) and nuts (22).
2.
Connect electrical leads to TB4 and K5 and CONVENIENCE RECEPTACLE (20). Remove tags.
3.
Install control box top panel (WP 0015, Installation).
END OF TASK
0047-3
TM 9-6115-644-24
0047
IN-LINE FUSE INSTALLATION
NOTE
The following procedure applies to generator sets under contract number DAAK01-88-D-0082.
NOTE
When replacing GROUND FAULT CIRCUIT INTERRUPTER, use new GROUND FAULT
CIRCUIT INTERRUPTER with integral circuit breaker. Refer to TM 9-6115-644-24P for new part
number.
1.
Shut down generator set.
2.
Open left side engine access door and disconnect negative battery cable.
3.
Remove malfunction indicator panel screws (WP 0043, Figure 1, Item 24), washers (25), and nuts (26). Lay
malfunction indicator panel (27) to the side.
4.
Cut black wire on load side of GROUND FAULT CIRCUIT INTERRUPTER (23).
5.
Strip wires on in-line fuse holder (Figure 1, Item 2) and install butt splices (3) at each end. Connect ends of
black wire to in-line fuse holder butt splices (3).
6.
Install fuse (1) in fuse holder (2).
7.
Secure excess wire to wiring harness using tie wrap.
8.
Install malfunction indicator panel (WP 0043, Figure 1, Item 27), screws (24), washers (25), and nuts (26).
9.
Reconnect negative battery cable and close battery access door.
Figure 1. In-Line Fuse Installation.
END OF TASK
END OF WORK PACKAGE
0047-4
TM 9-6115-644-24
0048
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, MALFUNCTION INDICATOR PANEL: INSPECTION,
TESTING, REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
References
WP 0043, Figure 1, Item 27
WP 0047 Maintenance of Control Box Assembly,
Ground Fault Circuit Interrupter
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect malfunction indicator panel for broken indicator lights, cracked housing, corrosion, and other damage.
END OF TASK
TESTING
1.
Depress TEST/RESET button and check that all indicators are illuminated.
2.
Replace malfunction indicator panel if one or more indicators do not illuminate.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
0048-1
TM 9-6115-644-24
0048
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut off generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Remove GROUND FAULT CIRCUIT INTERRUPTER (WP 0047, Removal). (Do not disconnect electrical
leads.)
5.
Disconnect multi-pin connector at rear of malfunction indicator panel (WP 0043, Figure 1, Item 27).
6.
Remove bolts (24), washers (25), and nuts (26).
7.
Remove malfunction indicator panel (27) from control panel.
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install malfunction indicator panel (WP 0043, Figure 1, Item 27) in control panel with bolts (24), washers (25),
and nuts (26).
2.
Install multipin connector at rear of panel.
0048-2
TM 9-6115-644-24
3.
Install GROUND FAULT CIRCUIT INTERRUPTER (WP 0047, Installation).
4.
Raise and secure control panel.
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0048-3/(4 blank)
0048
TM 9-6115-644-24
0049
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, BATTERY CHARGER FUSE: REMOVAL, INSPECTION,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0043, Figure 1, Items: 28 & 32
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
0049-1
TM 9-6115-644-24
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Remove cap (WP 0043, Figure 1, Item 28) and fuse (29) from fuse holder (32).
5.
Tag and unsolder electrical leads from fuse holder (32).
6.
Remove nut (30), lockwasher (31), and fuse holder (32). Discard lockwasher (31).
END OF TASK
INSPECTION
1.
Shut down generator set.
2.
Inspect for blown fuse.
3.
Inspect fuse, fuse holder, and cap for cracks, corrosion, and obvious damage.
4.
Replace defective parts.
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install fuse holder (WP 0043, Figure 1, Item 32) and secure with new lockwasher (31) and nut (30).
2.
Solder electrical leads to fuse holder (32). Remove tags.
3.
Install fuse (29) and cap (28).
4.
Raise and secure control panel.
5.
Connect negative battery cable and close battery access door.
0049-2
0049
TM 9-6115-644-24
END OF TASK
END OF WORK PACKAGE
0049-3/(4 blank)
0049
TM 9-6115-644-24
0050
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, DC CONTROL POWER CIRCUIT BREAKER: INSPECTION,
TESTING, REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Circuit Breaker (If indications do no comply with
testing
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0043, Figure 1, Items: 33 & 35
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect circuit breaker for loose connections and mounting, cracked housing, and other damage.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect DC CONTROL POWER circuit breaker (WP 0043, Figure 1, Item 35) electrical leads.
5.
Place circuit breaker in OPEN position.
6.
Set multimeter for ohms and connect across circuit breaker terminals. Multimeter should indicate open circuit.
7.
Place circuit breaker in CLOSED position. Multimeter should indicate continuity.
8.
Replace circuit breaker if indications are not as above.
9.
Connect electrical leads to circuit breaker (35). Remove tags.
10. Raise and secure control panel.
11. Connect negative battery cable and close battery access door.
END OF TASK
REMOVAL
0050-1
TM 9-6115-644-24
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Remove nut (WP 0043, Figure 1, Item 33) and flat washer (34).
5.
Remove DC CONTROL POWER circuit breaker (35) from mounting bracket.
6.
Tag and disconnect DC CONTROL POWER circuit breaker (35) electrical leads.
0050-2
0050
TM 9-6115-644-24
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Connect electrical leads. Remove tags.
2.
Insert DC CONTROL POWER circuit breaker (WP 0043, Figure 1, Item 35) into mounting bracket.
3.
Install flat washer (34) and nut (33).
4.
Raise and secure control panel.
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0050-3/(4 blank)
0050
TM 9-6115-644-24
0051
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, AC VOLTAGE REGULATOR: INSPECTION, TESTING,
REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Heat Resistant Gloves
AC Voltage Regulator (If defective)
Personnel Required
Two: (1) Power Generation Mechanic (52D) &
Assistant/Operator
References
WP 0043, Figure 1, Item 36
WP 0061, Governor Control Unit
WP 0062, Figure 1, Item 2
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. Make sure generator set is
completely shut down and free of any power source before attempting any repair or maintenance
on the set, or when connecting or disconnecting load cables. Failure to comply with this warning
can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
0051-1
TM 9-6115-644-24
0051
INSPECTION
Inspect AC Voltage Regulator (WP 0043, Figure 1, Item 36) for cracked case, broken wires, security, and other
damage.
END OF TASK
TESTING
AC Voltage Regulator, P/N 112-3055, for MEP-805A
1.
Shut down generator set.
2.
Open output box access door.
3.
Note position of voltage reconnection terminal board and set FREQUENCY SELECT switch to 60 Hz
position.
4.
Start generator set and turn VOLTAGE adjust potentiometer to ensure adjustment ranges on Table 1 are
met, depending on position of voltage reconnection terminal board.
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
High voltage is produced when the generator set is in operation. DO NOT touch live voltage
connections. Never attempt to connect or disconnect load cables or paralleling cables while the
generator set is running. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
components have been heated. Wear additional protective clothing as required. Failure to comply
with this warning can cause injury to personnel.
5.
Shut down generator set.
6.
If no voltage or low voltage was indicated, or voltage adjustment range could not be achieved, perform the
following steps. Otherwise, AC Voltage Regulator (WP 0062, Figure 1, Item 2) is serviceable.
7.
Disconnect wire 141A from terminal 1 of AC Voltage Regulator.
8.
Set multimeter for DC volts and connect positive lead to wire 141A. Connect negative lead of multimeter to
terminal 3 of AC Voltage Regulator. Start generator set and operate at rated frequency. Move and hold
MASTER SWITCH in START position. Multimeter should indicate between 4 and 12 VDC. If no voltage is
indicated, proceed to troubleshooting the Governor Control Unit, WP 0061.
9.
Shut down generator set. Isolate wire 141A.
0051-2
TM 9-6115-644-24
0051
10. Set multimeter for AC volts and connect to terminals 10 and 11 of AC Voltage Regulator. Start generator set
and operate at rated frequency. Move and hold MASTER SWITCH in START position. Multimeter should
indicate 230 to 380 VAC. If no voltage or low voltage is indicated, proceed to troubleshooting the droop
current transformer, WP 0102.
11. Shut down generator set.
12. Disconnect wire 137A from terminal 5 of AC Voltage Regulator. Set multimeter for ohms and connect positive
lead to wire 137A and negative lead to terminal 4 of AC Voltage Regulator. Move VOLTAGE adjust
potentiometer to full counterclockwise (CCW) position. Multimeter should indicate approximately 3,000 ohms
with FREQUENCY SELECT switch in 60 Hz position, and approximately 0 ohms with FREQUENCY SELECT
switch in 50 Hz position. Move VOLTAGE adjust potentiometer slowly clockwise (CW) while observing
multimeter. Multimeter should increase smoothly to approximately 10,000 ohms.
13. If Steps 8, 10, and 12 are as indicated above, AC Voltage Regulator is defective and must be replaced
(Removal and Installation).
14. Connect all wires previously disconnected. Close output box access door.
Table 1. Voltage Adjustment Range (MEP-805A).
Voltage Reconnection Terminal Board Position
Adjustment Range
120/208
197-240 volts
240/416
395-480 volts
END OF TASK
AC Voltage Regulator, P/N 19880-001, for MEP-805A.
1.
Shut down generator set.
2.
Open output box access door.
3.
Note position of voltage reconnection terminal board and set FREQUENCY SELECT switch to 60 Hz
position.
4.
Start generator set and turn VOLTAGE adjust potentiometer to ensure adjustment ranges on Table 1 are
met, depending on position of voltage reconnection terminal board.
5.
Shut down generator set.
6.
If no voltage or low voltage was indicated or voltage adjustment range could not be achieved, perform the
following steps. Otherwise, AC Voltage Regulator (WP 0062, Figure 1, Item 2) is serviceable.
7.
Disconnect wire 141A from terminal 1 of AC Voltage Regulator.
8.
Set multimeter for DC volts and connect positive lead to wire 141A. Connect negative lead of multimeter to
terminal 3 of AC Voltage Regulator. Start generator set and operate at rated frequency. Move and hold
MASTER SWITCH in START position. Multimeter should indicate between 4 and 12 VDC.
9.
Shut down generator set. Isolate wire 141A.
10. Set multimeter for AC volts and connect to terminals 10 and 11 of AC Voltage Regulator. Start generator set
and operate at rated frequency. Move and hold MASTER SWITCH in START position. Multimeter should
indicate 110 to 160 VAC.
11. Shut down generator set.
12. Disconnect wire 137A from terminal 5 of AC Voltage Regulator. Set multimeter for ohms and Set multimeter
for ohms and connect positive lead to wire 137A and negative lead to terminal 4 of AC Voltage Regulator.
Move VOLTAGE adjust potentiometer to full CCW position. Multimeter should indicate no more than 2 ohms
with FREQUENCY SELECT switch in 60 Hz position or 50 Hz position. Move VOLTAGE adjust potentiometer
slowly CW while observing multimeter. Multimeter should increase smoothly to approximately 20,000 ohms.
13. If Steps 8, 10, and 12 are as indicated above, AC Voltage Regulator is defective and must be replaced (WP
0051, Removal and Installation).
0051-3
TM 9-6115-644-24
0051
14. Connect all wires previously disconnected. Close output box access door.
END OF TASK
AC Voltage Regulator, P/N 19890-002, for MEP-815A
1.
Shut down generator set.
2.
Open output box access door.
3.
Note position of voltage reconnection terminal board.
4.
Start generator set and turn VOLTAGE adjust potentiometer to ensure adjustment ranges on Table 2 are
met, depending on position of voltage reconnection terminal board.
5.
Shut down generator set.
6.
If no voltage or low voltage was indicated or voltage adjustment range could not be achieved, perform the
following steps. Otherwise, AC Voltage Regulator (WP 0062, Figure 1, Item 2) is serviceable.
7.
Disconnect wire 141A from terminal 1 of AC Voltage Regulator.
8.
Set multimeter for DC volts and connect positive lead to wire 141A. Connect negative lead of multimeter to
terminal 3 of AC Voltage Regulator. Start generator set and operate at rated frequency. Move and hold
MASTER SWITCH in START position. Multimeter should indicate between 4 and 12 VDC.
9.
Shut down generator set. Isolate wire 141A.
10. Set multimeter for AC volts and connect to terminals 10 and 11 of AC Voltage Regulator. Start generator set
and operate at rated frequency. Move and hold MASTER SWITCH in START position. Multimeter should
indicate 110 to 160 VAC.
11. Shut down generator set.
12. Disconnect wire 137A from terminal 5 of AC Voltage Regulator. Set multimeter for ohms and connect positive
lead to wire 137A and negative lead to terminal 4 of AC Voltage Regulator. Move VOLTAGE adjust
potentiometer to full CCW position. Multimeter should indicate approximately 0 ohms. Move VOLTAGE adjust
potentiometer slowly CW while observing multimeter. Multimeter should increase smoothly to approximately
20,000 ohms.
13. If Steps 8, 10, and 12 are as indicated above, AC Voltage Regulator is defective and must be replaced
(Removal and Installation).
14. Connect all wires previously disconnected. Close output box access door.
Table 2. Voltage Adjustment Range (MEP-815A).
Voltage Reconnection Terminal Board Position
Adjustment Range
120/208
197-229 volts
240/416
395-458 volts
END OF TASK
REMOVAL
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect AC Voltage Regulator (WP 0062, Figure 1, Item 2) electrical leads.
5.
Remove screws (1) and AC Voltage Regulator (2).
END OF TASK
0051-4
TM 9-6115-644-24
INSTALLATION
CAUTION
The components of the AC voltage regulator kit are not interchangeable. Ensure the part number
of the component to be installed is the same as the removed component. Failure to observe this
caution will result in equipment damage.
1.
Install AC Voltage Regulator (WP 0062, Figure 1, Item 2) with screws (1).
2.
Connect electrical leads. Remove tags.
3.
Raise and secure control panel.
4.
Connect negative battery cable. Close battery access door.
END OF TASK
END OF WORK PACKAGE
0051-5/(6 blank)
0051
TM 9-6115-644-24
0052
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, FREQUENCY TRANSDUCER: INSPECTION, TESTING,
REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52D) &
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
References
Equipment Condition
WP 0015, Maintenance of Housing, Control Box Top
Grounded, Off & Operational
Panel
ENGINE CONTROL SWITCH OFF/RESET
WP 0043, Figure 1, Item 38
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect transducer for cracked casing, burned or broken terminals, and other damage.
END OF TASK
TESTING
MEP-805A
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Release control panel by turning two fasteners and lower control panel slowly.
5.
Disconnect wire 181A from positive (+) terminal of FREQUENCY meter (HERTZ).
6.
Set multimeter for DC milliamperes (0 to 2 Ma range) and connect positive lead to disconnected wire 181A
and negative lead to vacant terminal of FREQUENCY meter (HERTZ).
7.
Move FREQUENCY SELECT switch to 60 Hz position.
8.
Connect negative battery cable.
9.
Start generator set and adjust frequency to 60 Hz.
10. Multimeter indication should be between 0.781 and 0.923 Ma.
11. Adjust frequency to 62 Hz and multimeter indication should be between 0.875 and 1.125 Ma.
12. Move FREQUENCY SELECT switch to 50 Hz position.
13. Adjust frequency to 50 Hz and multimeter indication should be between 0.071 and 0.213 Ma.
14. Adjust frequency to 52 Hz and multimeter indication should be between 0.213 and 0.284 Ma.
15. Shut down generator set.
16. Replace frequency transducer if readings are other than above.
17. If no repair is needed, remove multimeter and connect wire 181A to positive (+) terminal of FREQUENCY
0052-1
TM 9-6115-644-24
0052
meter (HERTZ).
18. Raise and secure control panel.
19. Install control box top panel (WP 0015, Installation).
END OF TASK
MEP-815A
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Release control panel by turning two fasteners and lower control panel slowly.
5.
Disconnect wire 181A from positive terminal (+) of FREQUENCY meter (HERTZ).
6.
Set multimeter for DC milliamperes (0 to 2 Ma range) and connect positive lead to free end of wire 181A and
connect negative lead to positive terminal (+) of FREQUENCY meter (HERTZ).
7.
Connect negative battery cable.
8.
Start and operate generator set at rated voltage and adjust frequency to 400 Hz.
9.
Multimeter indication should be between 0.229 and 0.271 Ma.
10. Adjust frequency to 412 Hz. Multimeter indication should be between 0.479 and 0.521 Ma.
11. Shut down generator set.
12. Replace frequency transducer if readings are other than above.
13. If no repair is needed, remove multimeter and connect wire 181A to positive terminal (+) of FREQUENCY
meter (HERTZ).
14. Raise and secure control panel.
15. Install control box top panel (WP 0015, Installation).
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
0052-2
TM 9-6115-644-24
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Tag and disconnect frequency transducer (WP 0043, Figure 1, Item 38) electrical leads.
5.
Remove screws (37) and frequency transducer (38).
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install frequency transducer (WP 0043, Figure 1, Item 38) with screws (37).
2.
Connect all electrical leads. Remove tags.
3.
Install control box top panel (WP 0015, Installation).
4.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0052-3/(4 blank)
0052
TM 9-6115-644-24
0053
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, KILOWATT TRANSDUCER: INSPECTION, TESTING,
REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Kilowatt Transducer (If indications do not comply
with testing)
Personnel Required
Two: (1) Power Generation Mechanic (52D) &
Assistant/Operator
References
WP 0015, Maintenance of Housing, Control Box Top
Panel
WP 0043, Figure 1, Item 40
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect transducer for cracked casing, burned or broken terminals, and other damage.
END OF TASK
TESTING
1.
Start and operate generator set at rated voltage and frequency.
2.
Apply some load to generator set.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Set multimeter for AC volts and take readings between terminals V1 and N1, V2 and N2, and V3 and N3.
Multimeter indication should be 120 VAC between each set of terminals.
5.
Take readings between terminals S1 and -, S2 and -, S3 and -, L1 and -, L2 and -, and L3 and -. Multimeter
indication should be 0.1 to 3 VAC. (Reading will vary depending on amount of load applied to generator set.)
6.
Change multimeter setting to DC millivolts and take reading between terminals + and -. Multimeter indication
should be 0.1 to 50 mV (dependent on amount of load applied to generator set).
7.
Shut down generator set.
8.
Replace kilowatt transducer if multimeter indications are within ranges stated in Steps 4 and 5 above, but not
within range stated in Step 6 above.
9.
If no repair is needed, raise and secure control panel.
END OF TASK
0053-1
TM 9-6115-644-24
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Tag and disconnect kilowatt transducer (WP 0043, Figure 1, Item 40) electrical leads.
0053-2
0053
TM 9-6115-644-24
5.
Remove screws (39) and kilowatt transducer (40).
END OF TASK
INSTALLATION
1.
Install kilowatt transducer (WP 0043, Figure 1, Item 40) with screws (39).
2.
Connect electrical leads. Remove tags.
3.
Install control box top panel (WP 0015, Installation).
4.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0053-3/(4 blank)
0053
TM 9-6115-644-24
0054
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, SHUNT: INSPECTION, TESTING, REMOVAL,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Shunt (If multimeter indicates less than 0.5 ohms)
Personnel Required
Two: (1) Power Generation Mechanic (52D) &
Assistant/Operator
References
WP 0015, Maintenance of Housing, Control Box Top
Panel
WP 0019, Maintenance of Control Box Assembly,
Panel Lights
WP 0043, Figure 1, Item 43
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect shunt for cracked casing, burned or broken terminals, and other damage.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Remove control box top panel (WP 0015, Removal).
3.
Open battery access door and disconnect negative battery cable.
4.
Tag and disconnect shunt (WP 0043, Figure 1, Item 43) electrical leads.
5.
Set multimeter for ohms and connect to shunt terminals 1 and 4. Multimeter should indicate less than 0.5
ohms.
6.
Replace shunt if multimeter indication is greater than above.
7.
If no repair is needed, connect electrical leads to shunt (43). Remove tags.
8.
Install control box top panel (WP 0015, Installation).
9.
Connect negative battery cable and close battery access door.
END OF TASK
0054-1
TM 9-6115-644-24
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Tag and disconnect shunt (WP 0043, Figure 1, Item 43) electrical leads.
0054-2
0054
TM 9-6115-644-24
5.
Remove control box assembly (WP 0019, Removal).
6.
Remove screws (41), nuts (42), and shunt (43).
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install shunt (WP 0043, Figure 1, Item 43) and secure with screws (41) and nuts (42).
2.
Install control box assembly (WP 0019, Installation).
3.
Connect all electrical leads. Remove tags.
4.
Install control box top panel (WP 0015, Installation).
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0054-3/(4 blank)
0054
TM 9-6115-644-24
0055
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, OVERVOLTAGE/UNDERVOLTAGE RELAY: INSPECTION,
TESTING, REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Overvoltage/Undervoltage Relay (If no compliance
during testing)
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0015, Maintanance of Housing, Control Box Top
Panel
WP 0043, Figure 1, Item 45
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect relay for cracked casing, burned or broken terminals, and other damage.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
CAUTION
The following procedure disables AC voltage regulator and allows generator to reach an
overvoltage condition. Do not allow generator set to operate for an extended period of time in an
extreme overvoltage condition.
4.
Disconnect wire 137A from AC Voltage Regulator terminal 5 and insulate wire end.
5.
Connect negative battery cable.
6.
Start generator set. As generator set accelerates to rated speed, it should instantly shut down and the
OVERVOLTAGE lamp on malfunction indicator panel should illuminate. If this does not occur, immediately
shut down generator set.
7.
Reconnect wire 137A and disconnect wire 141A from AC Voltage Regulator terminal 1. Insulate wire end.
8.
Start generator set. As generator set accelerates to rated speed, the UNDERVOLTAGE lamp on malfunction
indicator should illuminate. Move AC CIRCUIT INTERRUPTER switch to CLOSED position. AC circuit
interrupter relay should not close.
9.
Shut down generator set.
10. Replace overvoltage/undervoltage relay if generator set does not operate as above.
0055-1
TM 9-6115-644-24
11. If no repair is needed, reconnect wire 141A at AC Voltage Regulator.
12. Raise and secure control panel.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
0055-2
0055
TM 9-6115-644-24
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Tag and disconnect overvoltage/undervoltage relay (WP 0043, Figure 1, Item 45) electrical leads.
5.
Remove screws (44) and overvoltage/undervoltage relay (45).
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install overvoltage/undervoltage relay (WP 0043, Figure 1, Item 45) with screws (44).
2.
Connect electrical leads. Remove tags.
3.
Install control box top panel (WP 0015, Installation).
4.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0055-3/(4 blank)
0055
TM 9-6115-644-24
0056
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, SHORT CIRCUIT/OVERLOAD RELAY: INSPECTION,
TESTING, REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Relay (Replace any found to be defective)
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0043, Figure 1, Item 47
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect relay for cracked casing, burned or broken terminals, and other damage.
END OF TASK
TESTING
CAUTION
Make sure battery cable is disconnected prior to removing wires. Failure to observe this caution
could result in equipment damage.
1.
Tag and remove all wires from terminals 5 through 12.
2.
Set multimeter for ohms and check for open circuits between terminals 5 and 6, 9 and 10. Check for closed
circuits between terminals 7 and 8, 11 and 12. Replace any relay that fails the above tests. If a problem still
exists, go to Step 4.
3.
If no repair is needed reconnect wires as tagged.
CAUTION
Make sure negative battery cable is disconnected prior to removing wires. Failure to observe this
caution could result in equipment damage.
4.
Remove short circuit/overload relay (Removal).
5.
Install relay in test circuit (Figure 1)
6.
Set multimeter for OHMS and check for open circuits between terminals 5 and 6, 9 and 10. Check for closed
circuits between terminals 7 and 8, 11 and 12. If relay fails the above test, replace relay. If relay tests good,
continue with remainder of test.
7.
Activate power source G1. Adjust voltage to 0 volts.
8.
Place switch S2 in the “A” position and close S1.
0056-1
TM 9-6115-644-24
9.
0056
Slowly increase output voltage of G1 to 6.18 VAC (110% rated load). Leave G1 at this setting for 10 minutes.
Relay should not trip; circuits should remain as indicated in Step 3 above.
10. Set multimeter for OHMS and check across terminals 5 and 6 while slowly increasing output voltage of G1 to
7.30 VAC (130% rated load). The relay should trip within 8 +/-2 minutes. When relay trips circuit 5 and 6
should close, circuit 7 and 8 should open.
11. With multimeter set on OHMS, check across terminals 9 and 10. Slowly increase output voltage of G1. When
voltage reaches 23.9 +/-1.4 VAC the relay should trip. When relay trips, circuit 9 and 10 should close and
circuit 11 and 12 should open.
12. Return output voltage of G1 to 0 and open S1, allowing relay to reset.
13. Place switch S2 in “B” position and close switch S1.
14. Repeat Steps 6 through 9.
15. Place switch S2 in “C” position and close switch S1.
16. Repeat Steps 6 through 9.
17. The voltages at which relay trips in positions A, B, and C should be within 1 volt.
18. Replace any relay found to be defective.
19. Install short circuit/overload relay (Installation).
Figure 1. Test Circuit.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
0056-2
TM 9-6115-644-24
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect short circuit/overload relay (WP 0043, Figure 1, Item 47) electrical leads.
5.
Remove screws (46) and short circuit/overload relay (47).
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install short circuit/overload relay (WP 0043, Figure 1, Item 47) with screws (46).
0056-3
0056
TM 9-6115-644-24
2.
Connect electrical leads. Remove tags.
3.
Raise and secure control panel.
4.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0056-4
0056
TM 9-6115-644-24
0057
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, PERMISSIVE PARALLELING RELAY: INSPECTION,
TESTING, REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Permissive Paralleling Relay (If operation doesn't
comply with this work package)
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0043, Figure 1, Item 49
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect relay for cracked casing, burned or broken terminals, and other damage.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Disconnect and insulate wires 102D from terminal 1, and 196A and 196B from terminal 2 of permissive
paralleling relay.
5.
Mark a 10,000 ohm potentiometer as follows:
Center terminal = C
Two outside terminals = L and R
6.
Set up a test circuit (Figure 1). Connect 120 VAC source (can be obtained from CONVENIENCE
RECEPTACLE) to terminals L and R of potentiometer. Connect a wire from terminal C of potentiometer to
terminal 1 of permissive paralleling relay. Connect a second wire from terminal R of potentiometer to terminal
2 of permissive paralleling relay. Set multimeter for AC volts and connect to terminals 1 and 2 of permissive
paralleling relay.
7.
Adjust 10,000 ohm potentiometer to full CCW position.
8.
Connect negative battery cable.
9.
Start and operate generator set at rated frequency and voltage. Multimeter indication should be 0 volts.
10. Move AC CIRCUIT INTERRUPTER switch to CLOSED position; AC circuit interrupter relay should close.
Move AC CIRCUIT INTERRUPTER switch to OPEN position; AC circuit interrupter relay should open.
Observe AC CIRCUIT INTERRUPTER light for actuation of relay.
0057-1
TM 9-6115-644-24
0057
11. Adjust 10,000 ohm potentiometer CW until multimeter indicates 10 VAC.
12. Move AC CIRCUIT INTERRUPTER switch to CLOSED position. AC circuit interrupter relay should not close
(AC CIRCUIT INTERRUPTER light should remain dark).
13. Shut down generator set.
14. Disconnect negative battery cable.
15. Replace permissive paralleling relay if operation is not as above.
16. If no repair is needed, remove multimeter and test circuit wires. Reconnect wires 102D, 196A and 196B to
permissive paralleling relay.
17. Raise and secure control panel.
18. Connect negative battery cable and close battery access door.
Figure 1. Permissive Paralleling Relay Test Setup.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
0057-2
TM 9-6115-644-24
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect permissive paralleling relay (WP 0043, Figure 1, Item 49) electrical leads.
5.
Remove screws (48) and permissive paralleling relay (49).
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install permissive paralleling relay (WP 0043, Figure 1, Item 49) with screws (48).
2.
Connect all electrical leads. Remove tags.
3.
Raise and secure control panel.
4.
Connect negative battery cable and close battery access door.
END OF TASK
0057-3
0057
TM 9-6115-644-24
END OF WORK PACKAGE
0057-4
0057
TM 9-6115-644-24
0058
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, REVERSE POWER RELAY: INSPECTION, TESTING,
REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Reverse Power Relay (If operation does not comply
with testing procedures in this work package
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0043, Figure 1, Item 51
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect relay for cracked casing, burned or broken terminals, and other damage.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Disconnect and insulate wires 158B and 158C from terminal 1 and wires 161A and 161B from terminal 2 of
reverse power relay.
5.
Mark a 5,000 ohm potentiometer as follows:
Center terminal = C
Two outside terminals = L and R
CAUTION
Voltage polarity is very important to prevent damage to generator set.
6.
Set up a test circuit (Figure 1). Connect 24 VDC source to terminals L and R of potentiometer. Connect a
wire between terminal C of potentiometer and terminal 1 of reverse power relay. Connect a second wire
between terminal R of potentiometer and terminal 2 of reverse power relay. Set multimeter for DC volts and
connect positive lead of multimeter to terminal 1 and negative lead to terminal 2 of reverse power relay.
7.
Adjust 5,000 ohm potentiometer to full CCW position. Multimeter should indicate 0 volts.
8.
Connect negative battery cable.
9.
Start and operate generator set at rated frequency and voltage.
0058-1
TM 9-6115-644-24
0058
10. Move AC CIRCUIT INTERRUPTER switch to CLOSED position. AC CIRCUIT INTERRUPTER light should
illuminate.
11. Adjust 5,000 ohm potentiometer CW and at same time observe multimeter and AC CIRCUIT INTERRUPTER
light. AC CIRCUIT INTERRUPTER light should go out at between 1.7 and 2.3 VDC, indicating that AC circuit
interrupter relay is open.
12. Shut down generator set.
13. Disconnect negative battery cable.
14. Replace reverse power relay if operation is not as above.
15. Remove multimeter and test circuit wires. Reconnect wires 158B, 158C, 161A, and 161B at reverse power
relay.
16. Raise and secure control panel.
17. Connect negative battery cable and close battery access door.
Figure 1. Reverse Power Relay Test Setup.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
0058-2
TM 9-6115-644-24
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect reverse power relay (WP 0043, Figure 1, Item 51) electrical leads.
5.
Remove screws (50) and reverse power relay (51).
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install reverse power relay (WP 0043, Figure 1, Item 51) with screws (50).
0058-3
0058
TM 9-6115-644-24
2.
Connect electrical leads. Remove tags.
3.
Raise and secure control panel.
4.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0058-4
0058
TM 9-6115-644-24
0059
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, VOLTAGE SENSING RELAY: INSPECTION, TESTING,
REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Voltage Sensing Relay (If indications do not comply
with testing in this work package)
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0043, Figure 1, Items: 52 & 53
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect relay for cracks, loose mounting, and other damage.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Remove voltage sensing relay (K-11) (Removal).
3.
Set multimeter for ohms and check for open circuits between terminals 1 and 3 and terminals 8 and 6 of
voltage sensing relay.
4.
Check for continuity between terminals 1 and 4 and terminals 8 and 5.
5.
Connect multimeter between terminals 2 and 7 of relay and check for between 1,260 and 1,890 ohms.
6.
Depress reset button; check for open circuits between terminals 1 and 4 and terminals 8 and 5.
7.
Continue to depress reset button and check for continuity between terminals 1 and 3 and terminals 8 and 6.
8.
Replace voltage sensing relay if indications are not as above.
9.
If no repair is needed, install voltage sensing relay (Installation).
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
0059-1
TM 9-6115-644-24
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Release wire clip (WP 0043, Figure 1, Item 52) and remove voltage sensing relay (K-11) (53) by gently
pulling from socket.
END OF TASK
INSTALLATION
0059-2
0059
TM 9-6115-644-24
0059
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install voltage sensing relay (K-11) (WP 0043, Figure 1, Item 53) in socket and secure by snapping wire clip
(55) over relay.
2.
Raise and secure control panel.
3.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0059-3/(4 blank)
TM 9-6115-644-24
0060
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, RELAYS: INSPECTION, TESTING, REMOVAL,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Relay (If indications do not comply with this work
package)
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0043, Figure 1, Item 54
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect relays for cracks, loose mounting, and other damage.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Remove applicable relay (Removal).
3.
Set multimeter for ohms and check for open circuits between terminals 7 and 4, 8 and 5, and 9 and 6. Check
for closed circuits between terminals 7 and 1, 8 and 2, and 9 and 3.
4.
Connect multimeter between terminals A and B and check for between 427.5 and 522.5 ohms.
5.
Apply battery voltage across terminals A and B. Using multimeter, check for open circuits between terminals
7 and 1, 8 and 2, and 9 and 3. Check for closed circuits between terminals 7 and 4, 8 and 5, and 9 and 6.
6.
Replace relay if indications are other than above.
7.
If no repair is needed, install relay (Installation).
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
0060-1
TM 9-6115-644-24
0060
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Locate suspected defective relay (WP 0043, Figure 1, Item 54), release wire clip (52), and remove relay by
gently pulling from socket.
END OF TASK
INSTALLATION
0060-2
TM 9-6115-644-24
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install relay (WP 0043, Figure 1, Item 54) in socket and secure by snapping wire clip (52) over relay.
2.
Raise and secure control panel.
3.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0060-3/(4 blank)
0060
TM 9-6115-644-24
0061
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, GOVERNOR CONTROL UNIT (GCU): INSPECTION,
TROUBLESHOOTING PROCEDURES, TESTING, ADJUSTMENT, REMOVAL, INSTALLATION,
REPLACEMENT
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Governor Control Unit (If functional criteria does not
comply with this work package)
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0043, Figure 1, item 56
WP 0062, Figure 1, Item 3
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. Make sure generator set is
completely shut down and free of any power source before attempting any repair or maintenance
on the set, or when connecting or disconnecting load cables. Failure to comply with this warning
can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
0061-1
TM 9-6115-644-24
0061
INSPECTION
1.
Shut down generator set.
2.
Inspect governor control unit for loose connections and mounting, and other damage.
END OF TASK
TROUBLESHOOTING PROCEDURES
1.
While holding master switch (S-1) in START position, check for voltage from pin positions 1, 3, 5 on GCU
(A-5) to ground. Readings should be battery voltage. If there is no voltage between any connections, GCU
(A-5) is not receiving proper voltage and wiring harness should be checked. Refer to Electrical Schematic
FO-1.
NOTE
With the generator set running, the voltage will read zero.
2.
Place master switch (S-1) in OFF position. Connect multimeter leads to terminals 19 and 20 on GCU (A-5);
then, move master switch (S-1) to START position. Reading should be battery voltage when generator set
does not crank. If there is no voltage between terminal positions, GCU (A-5) is not functioning properly and
should be replaced (Replacement).
NOTE
With the generator set running, there will be battery voltage.
3.
Place master switch (S-1) in OFF position. Connect multimeter leads to terminals 19 and 18 on GCU (A-5);
then move master switch (S-1) to START position. Reading should be ZERO voltage when generator set
does not crank. If there is voltage between terminal positions, GCU (A-5) is not functioning properly and
should be replaced (Replacement).
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open output box access door. Remove protective cover and attach voltage and frequency recorder to
terminals 9 and 12 of voltage reconnection terminal board.
3.
Open load terminal board access door and attach load bank to generator set (4-wire connection).
NOTE
Ensure load bank and generator set voltage reconnection terminal board are set for same
configuration (i.e., 120/208 or 240/416 VAC).
4.
Start and operate generator set at rated voltage and frequency.
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
0061-2
TM 9-6115-644-24
0061
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
High voltage is produced when the generator set is in operation. DO NOT touch live voltage
connections. Never attempt to connect or disconnect load cables or paralleling cables while the
generator set is running. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
components have been heated. Wear additional protective clothing as required. Failure to comply
with this warning can cause injury to personnel.
WARNING
Operating the generator set exposes personnel to a high noise level. Hearing protection must be
worn when operating or working near the generator set when the generator set is running. Failure
to comply with this warning can cause hearing damage to personnel.
5.
Turn on voltage and frequency recorder and operate at minimum chart speed of 5 mm/sec (chart resolution
of 0.2 mm/sec). Adjust recorder voltage amplifier for a minimum chart resolution of 1.0 volt/mm, and
frequency deviation amplifier for a minimum resolution of 0.2 Hz/mm.
WARNING
High voltage power is available when the main contactor is closed. Avoid accidental contact with
live components. Ensure load cables are properly connected and the load cable door is shut
before closing main contactor. Ensure load is turned off before closing main contactor. Ensure
that soldiers working with/on loads connected to the generator set are aware that main contactor
is about to be closed before closing main contactor. Failure to comply with this warning can cause
injury or death to personnel.
6.
Set load bank for a load equal to 75% of generator set rated load.
7.
Apply and remove 75% load to generator set at 40-second intervals three times.
8.
Repeat Steps 6 and 7 above at 50 percent rated load.
9.
Repeat Steps 6 and 7 above at 25 percent rated load.
10. Repeat Steps 6 and 7 above at 100 percent rated load.
11. Shut down generator set.
12. Turn off voltage and frequency recorder.
13. Examine voltage and frequency recorder chart. Generator set should meet the following performance criteria:
a.
Frequency regulation shall not exceed 1/4 of 1 percent of rated frequency.
b.
Frequency short-term stability (30 seconds): frequency will remain constant within a bandwidth equal to
1/2 of 1 percent rated frequency, without repetitive frequency variations, commonly called hunting.
c.
Generator set will reestablish stable engine operating conditions within 2 seconds of a sudden load
change (within 1 second for 400 Hz unit). Maximum transient frequency change above or below
(overshoot or undershoot) new steady state frequency shall not be more than 4 percent of rated
frequency (not more than 1-1/2 percent for 400 Hz unit).
14. If above criteria is not met, adjust GCU (WP 0062, Figure 1, Item 3) (Adjustment).
15. If above criteria cannot be met by adjustment, GCU must be replaced (Replacement).
16. Disconnect load bank. Close load terminal board access door.
0061-3
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0061
17. Disconnect voltage and frequency recorder and install voltage reconnection terminal board protective cover.
Close output box access door.
END OF TASK
ADJUSTMENT
1.
Shut down generator set.
2.
Open output box access door, remove cover from voltage reconnection terminal board, and attach voltage
and frequency recorder to terminals 9 and 12 of voltage reconnection terminal board.
NOTE
The following procedures require monitoring frequency, voltage, cur-rent, and power. All readings
except for frequencies will utilize the generator set control panel gauges. However, since the
designed overspeed trip frequency is greater than the range of the control panel FREQUENCY
meter (HERTZ), a frequency counter will be required.
3.
Attach frequency counter to voltage reconnection terminal board terminals 9 and 12.
4.
Open load terminal board access door and attach load bank to generator set (4-wire connection).
NOTE
Ensure load bank and generator set voltage reconnection are set for same configuration (i.e.,
120/208 or 240/416 VAC).
5.
Check for proper adjustment of governor actuator (WP 0117, Adjustment). Adjust as necessary.
6.
Check for proper adjustment of magnetic pickup (WP 0114, Adjustment). Adjust as necessary.
7.
Lower generator set control panel and turn INTEG, GOV GAIN, and LOAD PULSE potentiometer on GCU to
their full CCW positions.
8.
Loosen jam nut (Figure 1, Item 1) and back out high idle stop screw (2) on fuel injection pump.
Figure 1. Fuel Injection Pump High Idle Speed Adjustment.
9.
Start generator set and operate at rated voltage and frequency.
10. Observing frequency counter, slowly increase operating frequency of generator set by turning GCU
FREQUENCY range potentiometer CW until frequency counter indicates between 65.94 and 66.06 Hz
(MEP-805A)/436 and 444 Hz (MEP-815A). At this point generator set has reached overspeed trip frequency
and generator set should shut down.
0061-4
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0061
NOTE
Perform Steps 11 and 12 below if generator set does not shut down within limits noted in Step 10
above. Otherwise, proceed to Step 13 below.
11. If generator set has not shut down at upper limit of frequency noted in Step 10 above, proceed as follows:
a.
Turn FREQUENCY range potentiometer CCW until frequency counter indicates midrange of overspeed
trip frequency. (Example: 66 Hz for MEP-805A)
b.
Turn OVERSPEED control potentiometer on GCU CCW until generator set shuts down.
c.
Activate OVERSPEED RESET switch.
d.
Repeat Steps 9 and 10 above.
12. If generator set shuts down prior to reaching lower limit of frequency noted in Step 10 above, proceed as
follows:
a.
Turn OVERSPEED control potentiometer CW one turn for each hertz generator set shut down prior to
lower frequency limit.
b.
Activate OVERSPEED RESET switch.
c.
Repeat Steps 9 and 10 above.
13. Actuate OVERSPEED RESET switch.
14. Loosen jam nut (Figure 1, Item 1), set 8igh idle stop screw (2) to position recorded for Step 8, and tighten jam
nut (1).
15. Turn FREQUENCY range potentiometer on GCU two turns CCW.
16. Start and operate generator set at rated voltage and turn FREQUENCY adjust potentiometer on control panel
to midrange.
17. Turn FREQUENCY range potentiometer until rated frequency (50, 60, or 400 Hz) is indicated on control
panel FREQUENCY meter (HERTZ).
18. Set load bank for generator set rated load and apply load. Observe generator set instruments and adjust load
as needed to ensure rated load is applied.
19. Set multimeter for DC volts and connect to terminals 11 and 12 of GCU (WP 0062, Figure 1, Item 3).
20. Adjust LOAD SHARING ADJUST rheostat until multimeter indicates 6 VDC. Disconnect multimeter.
21. Remove load.
22. Turn on voltage and frequency recorder and operate at minimum chart speed of 5 mm/sec (chart resolution
of 0.2 mm/sec). Adjust recorder voltage amplifier for minimum chart resolution of 1.0 volt/mm and frequency
deviation of 0.2 Hz/mm.
23. Adjust GOV GAIN potentiometer on GCU as follows:
a.
Turn GOV GAIN potentiometer to its full CW position.
b.
Momentarily actuate and turn off LOAD switch on control panel.
c.
Observe strip chart on recorder for frequency oscillation (hunting). If required, slow GOV GAIN CCW
until frequency oscillation disappears.
24. Apply and remove rated load to generator set at 40-second intervals. Repeat this step two more times.
25. Shut down generator set and turn off recorder.
26. Examine voltage and frequency strip chart for the following performance criteria:
a.
Frequency regulation shall not exceed 1/4 of 1 percent of rated frequency.
b.
Frequency short-term stability (30 seconds): bandwidth equal to 1/2 of 1 percent of rated frequency,
without repetitive frequency variations (hunting).
c.
Generator set will reestablish stable engine operation within 2 seconds of a sudden load change (i.e.,
from a load to no-load condition) (within 1 second for 400 Hz units). Maximum transient frequency
change above (overshoot) and below (undershoot) new steady state frequency shall not be more than
4 percent of rated frequency (not more than 1-1/2 percent for 400 Hz units).
0061-5
TM 9-6115-644-24
0061
NOTE
All required INTEG and LOAD PULSE potentiometer adjustments will be in 10 percent
increments.
27. Adjust INTEG potentiometer on GCU CW to decrease recovery time of load transients.
28. Adjust LOAD PULSE potentiometer on GCU CW to decrease frequency overshoot and undershoot and to
decrease recovery time of overshoot/undershoot transients.
29. Start generator set.
NOTE
Steps 23, a and 23, b are not required when doing Step 30.
30. Repeat Steps 22 through 24 until generator set meets performance requirements stated in Step 26.
31. Apply and remove 75 percent rated load to generator set at 40-second intervals. Repeat this step two more
times.
32. Apply and remove 50 percent rated load to generator set at 40-second intervals. Repeat this step two more
times.
33. Apply and remove 25 percent rated load to generator set at 40-second intervals. Repeat this step two more
times.
34. Shut down generator set and turn off strip chart recorder.
35. Examine voltage and frequency strip chart for the following performance criteria:
a.
Frequency regulation shall not exceed 1/4 of 1 percent of rated frequency.
b.
Frequency short-term stability (30 seconds): frequency will remain constant within a bandwidth equal to
1/2 of 1 percent rated frequency, without repetitive frequency variations (hunting).
c.
Generator set will reestablish stable engine operation within 2 seconds of a sudden load change (i.e.,
from a load to no-load condition) (within 1 second for 400 Hz units). Maximum transient frequency
change above (overshoot) and below (undershoot) new steady state frequency shall not be more than
4 percent of rated frequency (not more than 1-1/2 percent for 400 Hz units).
36. Disconnect load bank. Close load terminal board access door.
37. Disconnect frequency counter and voltage and frequency recorder from voltage reconnection terminal board.
38. Install voltage reconnection terminal board cover. Close output box access door.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
0061-6
TM 9-6115-644-24
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Release control panel by turning two fasteners and lower control panel slowly.
4.
Tag and disconnect governor control unit (WP 0043, Figure 1, Item 56) electrical leads.
5.
Remove screws (55) and governor control unit (56).
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install governor control unit (WP 0043, Figure 1, Item 56) with screws (55).
2.
Connect electrical leads. Remove tags.
3.
Raise and secure control panel.
4.
Connect negative battery cable and close battery access door.
END OF TASK
REPLACEMENT
1.
Remove GCU (Removal).
2.
Install new GCU (Installation).
0061-7
0061
TM 9-6115-644-24
3.
Perform adjustment of GCU (Adjustment).
END OF TASK
END OF WORK PACKAGE
0061-8
0061
TM 9-6115-644-24
0062
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, CONTROL BOX WIRING HARNESS: INSPECTION,
TESTING, REPAIR, REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
References
Equipment Condition
WP 0015, Maintenance of Housing, Control Box Top
Grounded, Off & Operational
Panel
ENGINE CONTROL SWITCH OFF/RESET
WP 0019, Maintenance of Control Box Assembly,
Battery Disconnect Switch OFF
Control Box Assembly
DEAD CRANK SWITCH OFF
WP 0043, Figure 1, Item: 27, 43 & 57
WP 0059, Maintenance of Control Box Assembly,
Voltage Sensing Relay
WP 0060, Maintenance of Control Box Assembly,
Relays
FO-2, Wiring Diagram
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. Make sure generator set is
completely shut down and free of any power source before attempting any repair or maintenance
on the set, or when connecting or disconnecting load cables. Failure to comply with this warning
can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
0062-1
TM 9-6115-644-24
0062
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
INSPECTION
1.
Shut down generator set.
2.
Inspect control box harness (WP 0043, Figure 1, Item 57) wiring for breaks, damaged insulation, and loose or
damaged terminals.
3.
Inspect harness connectors, sockets, and terminal boards for cracks, corrosion, stripped threads, broken
pins, and other visible damage.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Set multimeter for ohms.
5.
Check individual wires, connectors, and terminal boards for continuity. Refer to Wiring Diagram FO-2 for wire
identification.
6.
If no repair is needed, install control box top panel (WP 0015, Installation), connect negative battery cable,
and close battery access door.
END OF TASK
REPAIR
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
0062-2
TM 9-6115-644-24
0062
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
1.
Replace individual wires, damaged terminal ends, clamps, and tie wraps.
2.
Ensure proper connection of wires not indicating continuity.
3.
Replace damaged cable assemblies, terminals, connectors, sockets, and terminal boards.
4.
Replace or ensure proper connection of all wires not indicating continuity.
END OF TASK
REMOVAL
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box assembly (WP 0019, Removal).
4.
Remove voltage sensing relay (WP 0059, Removal).
5.
Remove relays (WP 0060, Removal).
6.
Remove screws (Figure 1, Item 4), washers (5), insulators (6), and clips (7).
7.
Tag and remove sockets (8) from tracks (9).
8.
Remove screws (10) and nuts (11) to free terminal boards (12).
9.
Tag and disconnect electrical leads from AC Voltage Regulator (2) and governor control unit (3).
10. Tag and disconnect electrical leads from shunt (WP 0043, Figure 1, Item 43), BATTERY CHARGER FUSE
assembly (32), DC Control Power Circuit Breaker (35), REACTIVE CURRENT ADJUST rheostat (3), LOAD
SHARING ADJUST rheostat (7), FREQUENCY SELECT switch (14), OVERSPEED RESET switch (10),
overvoltage/undervoltage relay (45), frequency transducer (38), short circuit/overload relay (47), permissive
paralleling relay (51), reverse power relay (49), load measuring unit (69), watt transducer (40), and
resistor-diode assembly (71).
11. Tag and disconnect electrical leads to CONVENIENCE RECEPTACLE (20), GROUND FAULT CIRCUIT
INTERRUPTER (23), and connector to malfunction indicator panel (27).
0062-3
TM 9-6115-644-24
0062
12. Tag and disconnect electrical leads to all indicators, switches, and lights on control panel.
13. Remove screws (Figure 1, Items 13 and 17), nuts (14 and 18), caps (16 and 20), diagnostic connector (15),
parallel connector (19), and gaskets (21 and 22) from control box panel.
14. Remove screws (23) and nuts (24) from harness connectors and remove harness assembly (25) from control
box.
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
High voltage is produced when the generator set is in operation. DO NOT touch live voltage
connections. Never attempt to connect or disconnect load cables or paralleling cables while the
generator set is running. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
components have been heated. Wear additional protective clothing as required. Failure to comply
with this warning can cause injury to personnel.
1.
Position control box wiring harness assembly (Figure 1, Item 25) in control box.
2.
Secure harness connectors to control box with screws (23) and nuts (24).
3.
Install gaskets (21 and 22), diagnostic connector (15), parallel connector (19), and caps (16 and 20) in control
box panel with screws (13 and 17) and nuts (14 and 18).
4.
Connect all electrical leads to control panel indicators, switches, and lights as tagged during removal.
Remove tags.
5.
Connect electrical connector to malfunction indicator panel (WP 0043, Figure 1, Item 27) and electrical leads
to CONVENIENCE RECEPTACLE (20) and GROUND FAULT CIRCUIT INTERRUPTER (23).
6.
Connect electrical leads, as tagged during removal, to watt transducer (40), load measuring unit (69), reverse
power relay (49), permissive paralleling relay (51), resistor-diode assembly (71), short circuit/overload relay
(47), frequency transducer (38), overvoltage/undervoltage relay (45), DC Control Power Circuit Breaker (35),
BATTERY CHARGER FUSE assembly (32), OVERSPEED RESET switch (10), FREQUENCY SELECT
switch (14), REACTIVE CURRENT ADJUST rheostat (3), LOAD SHARING ADJUST rheostat (7), and shunt
(43). Remove tags.
7.
Connect electrical leads to AC Voltage Regulator (Figure 1, Item 2) and governor control unit (3). Remove
tags.
8.
Secure terminal boards (12) to control box with screws (10) and nuts (11).
0062-4
TM 9-6115-644-24
9.
Position sockets (8) on tracks (9) as tagged during removal.
10. Secure sockets (8) to tracks (9) with clips (7), insulators (6), washers (5), and screws (4). Remove tags.
11. Install relays (WP 0060, Installation).
12. Install voltage sensing relay (WP 0059, Installation).
13. Install control box assembly (WP 0019, Installation).
14. Connect negative battery cable.
15. Start and operate generator set at rated voltage and frequency.
16. Close battery access door.
Figure 1. Control Box Components.
END OF TASK
END OF WORK PACKAGE
0062-5/(6 blank)
0062
TM 9-6115-644-24
0063
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, DIAGNOSTIC CONNECTOR: INSPECTION, REMOVAL,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52d) & (1)
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
References
Equipment Condition
WP 0015, Maintenance of Housing, Control Box Top
Grounded, Off & Operational
Panel
ENGINE CONTROL SWITCH OFF/RESET
WP 0043, Figure 1, Item 60
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
NOTE
The diagnostic connector can be used as an aid in troubleshooting. Refer to Figure 1 and Table
1. Diagnostic connector is a component of the control box harness assembly, but can be removed
and installed separately.
INSPECTION
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Inspect diagnostic connector for cracks, breaks, corrosion, bent terminals, burns, or other indications of
damage.
4.
Inspect cap for cracks, corrosion, or broken chain.
5.
Inspect gasket for tears and deterioration.
6.
Replace any defective part.
7.
If no repair is needed, connect negative battery cable and close battery access door.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
0063-1
TM 9-6115-644-24
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Loosen rear outer ring and plastic insert from diagnostic connector (WP 0043, Figure 1, Item 60).
5.
Tag and disconnect electrical leads to diagnostic connector (60) by inserting removal tool into pins of
connector.
6.
Remove screws (58) and nuts (59).
7.
Remove diagnostic connector cap (61), diagnostic connector (60), and gasket (62).
END OF TASK
INSTALLATION
0063-2
0063
TM 9-6115-644-24
0063
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install diagnostic connector (WP 0043, Figure 1, Item 60), gasket (62), and cap (61) with screws (58) and
nuts (59).
2.
Connect electrical leads to diagnostic connector (60) by using insert tool. Remove tags.
3.
Install plastic insert and tighten rear outer ring on connector.
4.
Install control box top panel (WP 0015, Installation).
5.
Connect negative battery cable and close battery access door.
Figure 1. Diagnostic Connector Pin Positions.
NOTE
The diagnostic connector can be used as a troubleshooting tool. Refer to Figure 1 for pin
positions.
Table 1. Diagnostic Connector Connection Points.
Pin
Description
Expected Output*
B
Chassis ground (GND)
Continuity 0 volts
C
DC paralleling voltage for governor synchronization
0-20 VDC (*,5)
D
Chassis ground (GND)
Continuity 0 volts
E
Paralleling voltage for AC Voltage Regulator
0-20 VAC set freq. (*,5)
F
DC exciter field voltage (positive)
0-60 VDC (*,6)
G
DC paralleling voltage for governor synchronization
0-20 VDC (*,5)
H
Paralleling voltage for AC Voltage Regulator
0-20 VAC set freq. (*)
J
DC exciter field voltage (negative)
0-60 VDC (*,7)
M
DC voltage input to governor
24 VDC (*)
0063-3
TM 9-6115-644-24
0063
Table 1. Diagnostic Connector Connection Points. - Continued
Pin
Description
Expected Output*
N
DC starter motor solenoid coil
24 VDC (2 or 3)
O
DC voltage across fuel pump (Aux)
24 VDC (1)
P
DC voltage S1 terminal 7
24 VDC (2)
S
DC voltage across engine fuel solenoid coil
24 VDC (*)
T
DC voltage across starter crank relay coil
24 VDC (2 or 3)
U
DC voltage (output of DC circuit breaker)
24 VDC
V
DC voltage across output circuit interrupter coil
24 VDC (*)
X
DC starter motor (motor side of solenoid contacts)
24 VDC (2 or 3)
Z
DC voltage across fuel level contacts
24 VDC (4)
a
DC voltage across low oil pressure switch
0 volts (*)
b
DC voltage across low oil pressure switch
24 VDC (4)
c
DC voltage across ether bottle solenoid coil
24 VDC when selected (2)
d
DC battery charging voltage
24-27.6 VDC
x
Input frequency sensing voltage to governor
2-6 volts, 0-4,000 Hz (3, 8)
y
Input frequency sensing voltage to governor
2-6 volts, 0-4,000 Hz (3, 8)
*
With generator set operating (refers to all others not numbered)
(1)
Auxiliary fuel pump in operation (note fuel level); MASTER SWITCH in PRIME & RUN
AUX FUEL position
(2)
During engine starting
(3)
Use DEAD CRANK switch
(4)
MASTER SWITCH in PRIME & RUN position
(5)
AC circuit interrupter closed
(6)
Read between pins F and J
(7)
Read between pins J and F
(8)
Read between pins x and y
END OF TASK
END OF WORK PACKAGE
0063-4
TM 9-6115-644-24
0064
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, PARALLEL CONNECTOR: INSPECTION, REMOVAL,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
References
Equipment Condition
WP 0015, Maintenance of Housing, Control Box Top
Grounded, Off & Operational
Panel
ENGINE CONTROL SWITCH OFF/RESET
WP 0043, Figure 1, Item 65
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
NOTE
The parallel connector is a component of the control box harness assembly, but can be removed
and installed separately.
INSPECTION
1.
Shut down generator set.
2.
Inspect parallel connector for cracks, corrosion, stripped or damaged threads, evidence of shorting, or other
damage.
3.
Inspect cap for cracks, corrosion, and broken chain.
4.
Inspect gasket for tears and deterioration.
5.
Replace defective parts.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
0064-1
TM 9-6115-644-24
0064
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Tag and disconnect parallel connector (WP 0043, Figure 1, Item 65) electrical leads by inserting removal tool
into pins of connector.
5.
Remove screws (63), nuts (64), and cap (66).
6.
Remove parallel connector (65) and gasket (67).
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install parallel connector (WP 0043, Figure 1, Item 65), gasket (67), and cap (66) with screws (63) and nuts
(64).
2.
Connect electrical leads using insert tool. Remove tags.
3.
Install control box top panel (WP 0015, Installation).
0064-2
TM 9-6115-644-24
4.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0064-3/(4 blank)
0064
TM 9-6115-644-24
0065
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, LOAD MEASURING UNIT: INSPECTION, REMOVAL,
INSTALLATION, TESTING, REPLACEMENT
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
References
Equipment Condition
WP 0015, Maintenance of Housing, Control Box Top
Grounded, Off & Operational
Panel
ENGINE CONTROL SWITCH OFF/RESET
WP 0043, Figure 1, Item 69
Battery Disconnect Switch OFF
WP 0062, Figure 1, Item 26
DEAD CRANK SWITCH OFF
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. Make sure generator set is
completely shut down and free of any power source before attempting any repair or maintenance
on the set, or when connecting or disconnecting load cables. Failure to comply with this warning
can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
0065-1
TM 9-6115-644-24
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
WARNING
High voltage is produced when the generator set is in operation. DO NOT touch live voltage
connections. Never attempt to connect or disconnect load cables or paralleling cables while the
generator set is running. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
INSPECTION
1.
Shut down generator set.
2.
Inspect load measuring unit for damaged case, cracked or broken terminal lugs, and loose or missing
hardware.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
0065-2
0065
TM 9-6115-644-24
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Release control panel by turning two fasteners and lower control panel slowly.
5.
Tag and disconnect load measuring unit (WP 0043, Figure 1, Item 69) electrical leads.
6.
Remove screws (68) and load measuring unit (69).
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install load measuring unit (WP 0043, Figure 1, Item 69) with screws (68).
2.
Connect all electrical leads. Remove tags.
3.
Install control box top panel (WP 0015, Installation)
4.
Raise and secure control panel.
5.
Connect negative battery cable and close battery access door.
END OF TASK
TESTING
1.
Start and operate generator set at rated frequency and voltage.
2.
Apply a resistive load to generator set.
3.
Note reading on kilowattmeter (PERCENT POWER).
4.
Determine DC voltage (calculated value) from kilowattmeter reading using the following formula:
0065-3
0065
TM 9-6115-644-24
0065
10.8 X (kilowattmeter reading)
100
5.
Release control panel by turning two fasteners and lower control panel slowly.
6.
Set multimeter for DC volts and connect positive lead to terminal 11 of load measuring unit (WP 0062, Figure
1, Item 26) and negative lead to terminal 12.
7.
Compare DC voltage (calculated value) to multimeter reading.
8.
Load measuring unit (26) must be replaced if difference is more than ±1.2 VDC.
9.
Shut down generator set.
10. Remove multimeter from load measuring unit (26) terminals.
11. Raise and secure control panel.
END OF TASK
REPLACEMENT
1.
Remove load measuring unit (WP 0062, Figure 1, Item 26) (Removal).
2.
Install new load measuring unit (26) (Installation).
END OF TASK
END OF WORK PACKAGE
0065-4
TM 9-6115-644-24
0066
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, RESISTOR-DIODE ASSEMBLY: INSPECTION, TESTING,
REMOVAL, REPAIR, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
References
Equipment Condition
WP 0015, Maintenance of Housing, Control Box Top
Grounded, Off & Operational
Panel
ENGINE CONTROL SWITCH OFF/RESET
WP 0043, Figure 1, Item 71
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
1.
Shut down generator set.
2.
Inspect resistor-diode assembly for cracks, breaks, corrosion, bent terminals, and other damage.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Release control panel by turning two fasteners and lower control panel slowly.
NOTE
Isolate component before testing.
5.
Set multimeter for ohms and measure resistance across resistors R10, R11, and R12. Multimeter indication
should be between 7.125 and 7.875 ohms for each resistor.
6.
Using multimeter, measure resistance across resistor R14. Multimeter indication should be between 61.75
and 68.25 ohms for MEP-805A generator set, and between 38.00 and 42.00 ohms for MEP-815A generator
set.
7.
Using multimeter, measure resistance across resistor R15. Multimeter indication should be between 1,235
and 1,365 ohms.
8.
Using multimeter, measure resistance across resistors R6 and R8. Multimeter indication should be between
4,750 and 5,250 ohms.
9.
Using multimeter, measure resistance across resistors R7 and R9. Multimeter indication should be between
2,850 and 3,150 ohms.
10. Connect positive lead of multimeter to cathode side and negative lead to anode side of each diode (CR1,
CR2, CR3, and CR4). Refer to Figure 1. Note ohms indication on multimeter for each diode.
11. Reverse multimeter leads so positive lead is connected to anode side and negative lead is connected to
0066-1
TM 9-6115-644-24
0066
cathode side of each diode (CR1, CR2, CR3, and CR4). Note ohms indication on multimeter for each diode.
12. Multimeter indications should be 1:10 ratio or greater.
13. If any indications are other than above, replace defective component.
Figure 1. Diode Identification.
14. If no repair is needed, install control box top panel (WP 0015, Installation).
15. Raise and secure control panel.
16. Connect negative battery cable and close battery access door.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
0066-2
TM 9-6115-644-24
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Tag and disconnect resistor-diode assembly (WP 0043, Figure 1, Item 71) electrical leads.
5.
Remove screws (70) and resistor-diode assembly (71).
END OF TASK
REPAIR
Repair resistor-diode assembly (WP 0043, Figure 1, Item 71) by replacing resistors (72) and diodes (73).
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install resistor-diode assembly (WP 0043, Figure 1, Item 71) and secure with screws (70).
2.
Connect electrical leads. Remove tags.
3.
Install control box top panel (WP 0015, Installation).
4.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0066-3/(4 blank)
0066
TM 9-6115-644-24
0067
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, CONTROL PANEL: INSPECTION, REMOVAL, REPAIR,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
CARC Paint
Protective Eyewear, Mask & Gloves
Fine Grit Abrasive Paper
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
TM 43-0139
WP 0021, Maintenance of Control Box Assembly,
Press-To-Test Lights
WP 0034, Maintenance of Control Box Assembly,
Voltage Adjust Potentiometer
WP 0035, Maintenance of Control Box Assembly,
Frequency & Adjust Potentiometer
WP 0159, Item 17
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
Inspect control panel (Figure 1, Item 10) for dents, cracks, loose paint, and corrosion.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
0067-1
TM 9-6115-644-24
0067
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove press-to-test lights from control panel (WP 0021, Removal). (Do not unsolder wires.)
4.
Remove VOLTAGE adjust potentiometer from control panel (WP 0034, Removal). (Do not remove wires.)
5.
Remove FREQUENCY adjust potentiometer from control panel (WP 0035, Removal). (Do not remove wires.)
6.
Tag and disconnect all electrical leads to remaining indicators and switches on control panel.
7.
Remove screw (Figure 1, Item 1), nut (2), and strap (3).
8.
Remove bolts (4 and 6), nuts (5 and 7), bracket (9), clamp (8), and control panel (10) from control box
assembly.
9.
Remove bolts (11), nuts (12), and hinge (13) from control box assembly.
END OF TASK
REPAIR
WARNING
CARC paint is a health hazard, and is irritating to eyes, skin, and respiratory system. Wear
protective eyewear, mask, and gloves when applying or removing CARC paint. Failure to comply
with this warning can cause injury to personnel.
1.
Repair all dents and cracks and remove all loose paint.
2.
Remove light corrosion with fine grit abrasive paper (WP 0159, Item 17).
3.
Repaint surface in accordance with TM 43-0139. (F) Refer to applicable directives.
END OF TASK
0067-2
TM 9-6115-644-24
0067
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
1.
Install hinge (Figure 1, Item 13) on control box assembly with bolts (11) and nuts (12).
2.
Install control panel (10), clamp (8), and bracket (9) on control box assembly with bolts (4 and 6) and nuts (5
and 7).
3.
Install strap (3) on control panel (10) with screw (1) and nut (2).
4.
Connect all electrical wires to indicators and switches as tagged. Remove tags.
5.
Install press-to-test lights (WP 0021, Installation).
6.
Install VOLTAGE adjust potentiometer (WP 0034, Installation).
7.
Install FREQUENCY adjust potentiometer (WP 0035, Installation).
8.
Connect negative battery cable and close battery access door.
0067-3
TM 9-6115-644-24
Figure 1. Control Box Panels.
END OF TASK
END OF WORK PACKAGE
0067-4
0067
TM 9-6115-644-24
0068
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, CONTROL PANEL FRAME: INSPECTION, REMOVAL,
REPAIR, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Grounded, Off & Operational
Materials/Parts
CARC Paint
Protective Eyewear, Mask & Gloves
Fine Grit Abrasive Paper
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0019, Maintenance of Control Box Assembly,
Control Box Assembly
WP 0046, Maintenance of Control Box Assembly,
Convenience Receptacle
WP 0019, Maintenance of Control Box Assembly,
Ground Fault Circuit Interrupter
WP 0063, Maintenance of Control Box Assembly,
Diagnostic Connector
WP 0064, Maintenance of Control Box Assembly,
Parallel Connector
WP 0067, Figure 1, Item 19
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
Inspect control panel frame (WP 0067, Figure 1, Item 19) for dents, cracks, loose paint, and corrosion.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
0068-1
TM 9-6115-644-24
0068
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box assembly (WP 0019, Removal).
4.
Remove control panel (WP 0067, Removal).
5.
Remove diagnostic connector (WP 0063, Removal). (Do not remove wires.)
6.
Remove parallel connector (WP 0064, Removal). (Do not remove wires.)
7.
Remove CONVENIENCE RECEPTACLE (WP 0046, Removal); GROUND FAULT CIRCUIT INTERRUPTER
(WP 0047, Removal); and malfunction indicator panel (WP 0048, Removal).
8.
Remove bolts (WP 0067, Figure 1, Items 14 and 16), nuts (15 and 17), clamp (18), and control panel frame
(19) from control box assembly.
9.
Drill out rivets (20, 22, and 24) and remove identification plates (21, 23, and 25), if necessary.
END OF TASK
REPAIR
WARNING
CARC paint is a health hazard, and is irritating to eyes, skin, and respiratory system. Wear
protective eyewear, mask, and gloves when applying or removing CARC paint. Failure to comply
with this warning can cause injury to personnel.
0068-2
TM 9-6115-644-24
1.
Repair all dents and cracks and remove all loose paint.
2.
Remove light corrosion with fine grit abrasive paper (WP 0159, Item 17).
3.
Repaint surface in accordance with TM 43-0139. (F) Refer to applicable directives.
0068
END OF TASK
INSTALLATION
1.
Install control panel frame (WP 0067, Figure 1, Item 19) and clamp (18) to control box assembly with bolts
(14 and 16) and nuts (15 and 17).
2.
If removed, install identification plates (21, 23, and 25) on control panel frame (19) with rivets (20, 22, and
24).
3.
Install malfunction indicator panel (WP 0048, Installation); GROUND FAULT CIRCUIT INTERRUPTER (WP
0047, Installation); CONVENIENCE RECEPTACLE (WP 0046, Installation); parallel connector (WP 0064,
Installation); and diagnostic connector (WP 0063, Installation).
4.
Install control panel (WP 0067, Installation).
5.
Install control box assembly (WP 0019, Installation).
6.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0068-3/(4 blank)
TM 9-6115-644-24
0069
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, CONTROL BOX SIDE PANELS: INSPECTION, REMOVAL,
REPAIR, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
CARC Paint
Protective Eyewear, Mask & Gloves
Fine Grit Abrasive Paper
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
TM 43-0139
WP 0015, Maintenance of Housing, Control Box Top
Panel
WP 0067, Figure 1, Items: 16, 26, 28, 29, 30, 33 &
43
WP 0159, Item 1
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
1.
Inspect side panels (WP 0067, Figure 1, Items 29 and 30) and air deflector (33) for dents, cracks, loose paint,
and corrosion.
2.
Inspect for missing or damaged cage nuts (43).
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
0069-1
TM 9-6115-644-24
0069
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box top panel (WP 0015, Removal).
4.
Remove bolts (WP 0067, Figure 1, Items 16, 26, and 28), nuts (17 and 27), and control box side panels (29
and 30) from generator set.
5.
Remove bolts (31), nuts (32), and air deflector (33) from side panel (30).
END OF TASK
REPAIR
WARNING
CARC paint is a health hazard, and is irritating to eyes, skin, and respiratory system. Wear
protective eyewear, mask, and gloves when applying or removing CARC paint. Failure to comply
with this warning can cause injury to personnel.
1.
Repair all dents and cracks and remove all loose paint.
2.
Remove light corrosion with fine grit abrasive paper (WP 0159, Item 17).
3.
Repaint surface in accordance with TM 43-0139. (F) Refer to applicable directives.
4.
Replace missing or damaged cage nuts (WP 0067, Figure 1, Item 43).
END OF TASK
0069-2
TM 9-6115-644-24
0069
INSTALLATION
1.
Apply a light coat of sealant (WP 0159, Item 1) to flanges of air deflector (WP 0067, Figure 1, Item 33).
2.
Install air deflector (33) on control box side panel (30) with bolts (31) and nuts (32).
3.
Install control box side panels (29 and 30) on generator set with bolts (16, 26, and 28) and nuts (17 and 27).
Ensure center bolt (16) and nut (17) on left side panel secures clamp (18).
4.
Install control box top panel (WP 0015, Installation).
5.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0069-3/(4 blank)
TM 9-6115-644-24
0070
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF CONTROL BOX ASSEMBLY, CONTROL BOX TRAY (BOTTOM): INSPECTION,
REMOVAL, REPAIR, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
CARC Paint
Protective Eyewear, Mask & Gloves
Fine Grit Abrasive Paper
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
TM 43-0139
WP 0019, Maintenance of Control Box Assembly,
Control Box Assembly
WP 0042 through WP 0050, WP 0052 through WP
0061
WP 0065 & WP 0066
WP 0067, Figure 1, Items: 34, 41, 42 & 43
WP 0068, Maintenance of Control Box Assembly,
Control Panel Frame
WP 0069, Maintenance of Control Box Assembly,
Control Box Side Panels
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
INSPECTION
1.
Inspect control box bottom (WP 0067, Figure 1, Item 42) for dents, cracks, loose paint, and corrosion.
2.
Inspect for missing or damaged cage nuts (43).
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
0070-1
TM 9-6115-644-24
0070
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. SHUT DOWN generator set and
make sure it is free of any power source before attempting any repair or maintenance on the set,
or when connecting or disconnecting load cables. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box assembly (WP 0019, Removal).
4.
Remove control panel frame (WP 0068, Removal).
5.
Remove control box side panels (WP 0069, Removal).
6.
Remove control box components (WP 0042 through WP 0050, WP 0052 through WP 0061, WP 0065 and
WP 0066).
7.
Contact Direct Support Maintenance to remove AC Voltage Regulator and control box harness.
8.
Remove screws (WP 0067, Figure 1, Item 34) and bracket (35) from control box bottom (42).
9.
Remove screws (36), nuts (37), and relay tracks (38) from control box bottom (42).
10. Remove screws (39), nuts (40), and latch plate (41) from control box bottom (42).
END OF TASK
REPAIR
WARNING
CARC paint is a health hazard, and is irritating to eyes, skin, and respiratory system. Wear
protective eyewear, mask, and gloves when applying or removing CARC paint. Failure to comply
with this warning can cause injury to personnel.
0070-2
TM 9-6115-644-24
1.
Repair all dents and cracks and remove all loose paint.
2.
Remove light corrosion with fine grit abrasive paper (WP 0159, Item 17).
3.
Repaint surface in accordance with TM 43-0139. (F) Refer to applicable directives.
4.
Replace missing or damaged cage nuts (WP 0067, Figure 1, Item 43).
0070
END OF TASK
INSTALLATION
1.
Install latch plate (WP 0067, Figure 1, Item 41) on control box bottom (42) with screws (39) and nuts (40).
2.
Install relay tracks (38) on control box bottom (42) with screws (36) and nuts (37).
3.
Install bracket (35) on control box bottom (42) with screws (34).
4.
Contact Direct Support Maintenance to install control box harness and AC Voltage Regulator.
5.
Install control box components (WP 0042 through WP 0050, WP 0052 through WP 0061, WP 0065 and WP
0066).
6.
Install control box side panels (WP 0069, Installation).
7.
Install control panel frame (WP 0068, Installation).
8.
Install control box assembly (WP 0019, Installation).
9.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0070-3/(4 blank)
TM 9-6115-644-24
0071
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF AIR INTAKE AND EXHAUST SYSTEM, MUFFLER AND EXHAUST PIPE: INSPECTION,
REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Heat Resistant Gloves
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0016, Maintenance of Housing, Top Housing
Section
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
INSPECTION
1.
Shut down generator set.
2.
Remove top housing panel and top housing frame (WP 0016, Removal) and open engine access doors.
3.
Inspect muffler (Figure 1, Item 3) and pipe (4) for cracks, excessive corrosion, clogging, and other damage.
4.
Replace damaged parts.
5.
Install top housing frame and top housing panel (WP 0016, Installation) and close engine access doors.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
0071-1
TM 9-6115-644-24
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
components have been heated. Wear additional protective clothing as required. Failure to comply
with this warning can cause injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
0071-2
0071
TM 9-6115-644-24
0071
Figure 1. Muffler and Exhaust Pipe.
1.
Shut down generator set.
2.
Remove top housing panel and top housing frame (WP 0016, Removal) and open engine access doors.
3.
Loosen nuts and remove clamp (Figure 1, Item 1).
4.
Open bands (2) and separate muffler (3) and pipe (4). Remove muffler (3) from generator set.
5.
Remove bolts (5), lockwashers (6), washers (7), nuts (10), and muffler supports (8). Discard lockwashers (6).
6.
Loosen exhaust pipe clamp (9) at turbocharger outlet.
7.
Remove left side air deflector and sufficient hardware securing top housing section panel (WP 0016,
Removal) to allow removal of exhaust pipe (4) from generator set.
0071-3
TM 9-6115-644-24
END OF TASK
INSTALLATION
1.
Install muffler supports (Figure 1, Item 8) with bolts (5), new lockwashers (6), washers (7) and nuts (10).
2.
Install pipe (4) with clamp (9). Do not tighten clamp (9).
3.
Install left side air deflector and hardware securing top housing section panel (WP 0016, Installation).
4.
Couple muffler (3) to exhaust adapter (12) with clamp (1). Do not tighten clamp.
5.
Secure muffler (3) to supports (8) with bands (2).
6.
Tighten clamp (1).
7.
Install top housing frame and top housing panel (WP 0016, Installation). Close engine access doors.
END OF TASK
END OF WORK PACKAGE
0071-4
0071
TM 9-6115-644-24
0072
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF AIR INTAKE AND EXHAUST SYSTEM, AIR RESTRICTION INDICATOR: INSPECTION,
REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Heat Resistant Gloves
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0073, Figure 1, Item 1
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
INSPECTION
1.
Shut down generator set.
2.
Open left side engine access doors.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
3.
Inspect air restriction indicator (WP 0073, Figure 1, Item 1) for cracks, stripped threads, or other obvious
damage.
4.
Close engine access doors.
END OF TASK
REMOVAL
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
0072-1
TM 9-6115-644-24
0072
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
components have been heated. Wear additional protective clothing as required. Failure to comply
with this warning can cause injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open left side engine access doors.
3.
Unscrew air restriction indicator (WP 0073, Figure 1, Item 1) from air cleaner housing (7).
END OF TASK
INSTALLATION
1.
Install air restriction indicator (WP 0073, Figure 1, Item 1) on air cleaner housing (7). Hand tighten only. Close
engine access doors.
END OF TASK
END OF WORK PACKAGE
0072-2
TM 9-6115-644-24
0073
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF AIR INTAKE AND EXHAUST SYSTEM, AIR CLEANER ASSEMBLY: INSPECTION,
SERVICING, REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Heat Resistant Gloves
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0019, Maintenance of Control Box Assembly,
Control Box Assembly
WP 0074, Maintenance of Air Intake & Exhaust
System, Air Cleaner Element
WP 0159, Item 9
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
INSPECTION
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box assembly (WP 0019, Removal).
4.
Inspect air cleaner assembly and mounting bracket for cracks, dents, and other damage.
5.
Install control box assembly (WP 0019, Installation).
6.
Connect negative battery cable and close battery access door.
END OF TASK
SERVICING
1.
Remove air cleaner element (WP 0074, Removal).
2.
Wipe inside of air cleaner housing with cleaning cloth (WP 0159, Item 9).
3.
Install new air cleaner element (WP 0074, Installation).
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
0073-1
TM 9-6115-644-24
0073
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
components have been heated. Wear additional protective clothing as required. Failure to comply
with this warning can cause injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box assembly (WP 0019, Removal).
4.
Loosen clamp (Figure 1, Item 2) and remove hose (15) from air cleaner housing (7).
5.
Remove bolts (3), washers (4), lockwashers (5), nuts (6), mounting bracket (11), and air cleaner assembly
from generator set. Discard lockwashers (5).
6.
Remove bolts (8), nuts (10), lockwashers (9), and mounting bracket (11) from air cleaner assembly. Discard
lockwashers (9).
END OF TASK
INSTALLATION
1.
Install mounting bracket (Figure 1, Item 11) on air cleaner assembly with bolts (8), new lockwashers (9), and
nuts (10).
2.
Install air cleaner assembly and mounting bracket (11) on generator set with bolts (3), washers (4), new
lockwashers (5), and nuts (6).
3.
Install hose (15) and clamp (2) on air cleaner housing (7). Tighten clamp (2).
4.
Install control box assembly (WP 0019, Installation).
5.
Connect negative battery cable and close battery access door.
0073-2
TM 9-6115-644-24
Figure 1. Air Cleaner Assembly.
END OF TASK
END OF WORK PACKAGE
0073-3/(4 blank)
0073
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF AIR INTAKE AND EXHAUST SYSTEM, AIR CLEANER ELEMENT: REMOVAL,
INSPECTION, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Heat Resistant Gloves
Clean Cloth
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0073, Figure 1, Items: 12 & 14
WP 0159, Item 9
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
components have been heated. Wear additional protective clothing as required. Failure to comply
with this warning can cause injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
0074-1
0074
TM 9-6115-644-24
2.
Open air cleaner access door.
3.
Loosen wing nut caged to cover (WP 0073, Figure 1, Item 12) and remove cover (12) from air cleaner
housing (7).
4.
Remove wing nut (13) and air cleaner element (14) from air cleaner housing (7).
END OF TASK
INSPECTION
1.
Shut down generator set.
2.
Remove air cleaner element (Removal).
3.
Inspect element (WP 0073, Figure 1, Item 14) for debris and damage. Replace, as necessary.
4.
Wipe inside of air cleaner housing (7) with cleaning cloth (WP 0159, Item 9).
5.
Install air cleaner element (Installation).
END OF TASK
INSTALLATION
1.
Install air cleaner element (WP 0073, Figure 1, Item 14) in air cleaner housing (7). Tighten wing nut (13).
2.
Install cover (12) on air cleaner housing (7). Tighten caged wing nut.
3.
Close air cleaner access door.
END OF TASK
END OF WORK PACKAGE
0074-2
0074
TM 9-6115-644-24
0075
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF AIR INTAKE AND EXHAUST SYSTEM, AIR CLEANER TUBING AND BREATHER:
INSPECTION, SERVICING, REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Goggles & Heat Resistant Gloves
Cleaning Cloth & Dry Cleaning Solvent
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0073, Figure 1, Items: 2, 18, 20 & 25
WP 0159, Items: 9 & 21
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
INSPECTION
1.
Shut down generator set.
2.
Open engine access doors.
3.
Inspect all tubing for cracks, tears, and holes.
4.
Inspect clamps for cracks.
5.
Inspect breather (WP 0073, Figure 1, Item 20) and cover (23) for dents, cracks, and corrosion.
6.
Remove wing nut (21), washer (22), cover (23), rubber seal (24), and element (25) from breather (20).
7.
Inspect breather element (25) for clogs, tears, or other damage.
8.
Inspect threaded parts for damaged or stripped threads.
9.
Replace parts, as necessary.
10. Install element (25), rubber seal (24), cover (23), washer (22), and wing nut (21) on breather (20).
11. Close engine access doors.
END OF TASK
SERVICING
1.
Remove air cleaner tubing and breather (Removal).
WARNING
Solvent used to clean parts is potentially dangerous to personnel and property. Clean parts in a
well-ventilated area. Avoid inhalation of solvent fumes. Wear goggles and rubber gloves to
protect eyes and skin. Wash exposed skin thoroughly. Do not smoke or use near open flame or
excessive heat. Failure to comply with this warning can cause injury to personnel, and damage to
the equipment.
2.
Clean air cleaner tubing and breather housing with cleaning cloth (WP 0159, Item 9) dampened with dry
cleaning solvent (WP 0159, Item 21).
3.
Replace breather element (WP 0073, Figure 1, Item 25).
4.
Install air cleaner tubing and breather (Installation).
0075-1
TM 9-6115-644-24
0075
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Top housing panels and exhaust system can get very hot. Shut down generator set, and allow
system to cool before performing checks, services, and maintenance. Failure to comply with this
warning can cause severe burns and injury to personnel.
WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
components have been heated. Wear additional protective clothing as required. Failure to comply
with this warning can cause injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open engine access doors.
3.
Loosen clamps (WP 0073, Figure 1, Items 2 and 18).
4.
Remove hose (15) and clamps (2) from air cleaner housing (7) and tube (16).
5.
Remove tube (16) and clamps (18 and 2) from breather hose (19) and hump hose (17).
6.
Remove hump hose (17) and clamp (2) from turbocharger.
7.
Remove breather hose (19) and clamp (18) from breather (20).
8.
Remove breather (20) from valve cover.
9.
Remove wing nut (21), washer (22), cover (23), rubber seal (24), and element (25) from breather (20).
END OF TASK
INSTALLATION
1.
Install element (WP 0073, Figure 1, Item 25), rubber seal (24), cover (23), washer (22), and wing nut (21) on
breather (20).
2.
Install breather (20) in valve cover.
0075-2
TM 9-6115-644-24
3.
Install breather hose (19) and clamp (18) on breather (20).
4.
Install hump hose (17) and clamp (2) on turbocharger.
5.
Install tube (16) and clamp (2) on hump hose (17).
6.
Install breather hose (19) and clamp (18) on tube (16).
7.
Install hose (15) and clamps (2) on tube (16) and air cleaner housing (7).
8.
Tighten clamps (2 and 18).
9.
Close engine access doors.
END OF TASK
END OF WORK PACKAGE
0075-3/(4 blank)
0075
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF COOLANT SYSTEM, COOLANT SYSTEM: TESTING, SERVICING
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Gloves & Protective Clothing
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
TM 750-254
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool
before performing checks, services and maintenance, or wear gloves and additional protective
clothing and goggles as required. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Always remove radiator cap slowly to permit any pressure to escape. Failure to comply with this
warning can cause injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
TESTING
1.
Shut down generator set.
2.
Slowly remove radiator cap (Figure 1, Item 1).
3.
Install coolant system pressure tester (ST255) in radiator neck and open engine access doors.
4.
Pump pressure tester until 8 psi is indicated and check coolant system for leaks.
5.
Pump pressure tester until 7 psi (±1) is indicated and ensure radiator cap releases.
6.
Release pressure from pressure tester and remove from radiator neck.
7.
Install radiator cap (1). Close engine access doors.
0076-1
0076
TM 9-6115-644-24
END OF TASK
SERVICING
1.
Shut down generator set.
2.
Open left side engine access door.
3.
Flush or drain coolant system in accordance with TM 750-254.
4.
Close left side engine access door.
Figure 1. Coolant System.
END OF TASK
0076-2
0076
TM 9-6115-644-24
END OF WORK PACKAGE
0076-3/(4 blank)
0076
TM 9-6115-644-24
0077
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF COOLANT SYSTEM, RADIATOR FILLER HOSE AND PANEL ASSEMBLY: REMOVAL,
INSPECTION AND CLEANING, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Suitable Container for Coolant/Antifreeze Drainage
Protective Eyewear
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0006, Service Upon Receipt
WP 0016, Maintenance of Housing, Top Housing
Section
WP 0076, Figure 1, Item 1, 3 & 9
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool
before performing checks, services and maintenance, or wear gloves and additional protective
clothing and goggles as required. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Always remove radiator cap slowly to permit any pressure to escape. Failure to comply with this
warning can cause injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open engine access doors.
3.
Remove generator housing top panel (WP 0016, Removal).
4.
Slowly remove radiator cap (WP 0076, Figure 1, Item 1).
5.
Open radiator drain valve (28) and drain coolant/antifreeze into suitable container to a level below radiator
0077-1
TM 9-6115-644-24
0077
filler hose (3) connection at radiator (31).
6.
Loosen clamps (2) and remove radiator filler hose (3) and clamps (2).
7.
Loosen clamp (4) and disconnect overflow hose (5) from radiator filler neck (9).
8.
Remove radiator fill panel (6) and filler neck (9) from generator set.
9.
Remove bolts (7), nuts (8), cap (1), and radiator filler neck (9) from radiator fill panel (6).
END OF TASK
INSPECTION AND CLEANING
1.
Shut down generator set.
2.
Remove radiator filler hose and panel (Removal).
3.
Inspect radiator filler hose (WP 0076, Figure 1, Item 3) for cracks, holes, and dry rot.
4.
Inspect filler panel (6), filler neck (9), and cap (1) for cracks, excessive corrosion, and other damage.
5.
Clean light corrosion from filler hose attaching points with fine grit abrasive paper (WP 0159, Item 17).
6.
Replace damaged parts.
7.
Install radiator filler hose and panel (Installation).
END OF TASK
INSTALLATION
WARNING
Avoid breathing fumes generated by soldering. Eye protection is required. Good general
ventilation is normally adequate. Failure to comply with this warning can cause injury to
personnel.
1.
Install radiator filler neck (WP 0076, Figure 1, Item 9) and cap (1) on radiator fill panel (6) with bolts (7) and
nuts (8).
2.
Position radiator fill panel (6) and filler neck (9) in generator set and attach overflow hose (5) with clamp (4).
3.
Install radiator filler hose (3) on filler neck (9) and radiator (31) with clamps (2).
4.
Install generator housing top panel (WP 0016, Installation).
5.
Close radiator drain valve (28) and add coolant/antifreeze to proper level (WP 0006, Radiator).
6.
Solder tab (Figure 1) and hook chain to tab if replacing radiator cap (WP 0076, Figure 1, Item 1).
7.
Install radiator cap (1).
8.
Start generator set and allow unit to reach operating temperature and check for leaks.
9.
Add coolant/antifreeze to overflow bottle, as required. Close engine access doors.
0077-2
TM 9-6115-644-24
Figure 1. Radiator Cap.
END OF TASK
END OF WORK PACKAGE
0077-3/(4 blank)
0077
TM 9-6115-644-24
0078
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF COOLANT SYSTEM, FAN GUARDS: INSPECTION, REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Gloves
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
Equipment Condition
Grounded, Off & Operational
See "One Qualified Technician" Warning
INSPECTION
1.
Shut down generator set.
2.
Open both side engine access doors.
3.
Inspect fan guards, brackets, and attaching hardware for damage, corrosion, and loose or missing hardware.
4.
Replace all damaged and missing components and tighten all loose attaching hardware. Close both side
engine access doors.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Fan has sharp blades. Use caution and wear gloves when removing or installing belts. Failure to
comply with this warning can cause injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open both side engine access doors.
3.
Remove bolts (Figure 1, Item 1), washers (2), nuts (3), and lockwashers (4) securing fans guards (5 and 6).
Discard lockwashers (4).
4.
Remove bolts (7), lockwashers (8), washers (9), and brackets (10 and 11) from radiator shroud. Discard
0078-1
TM 9-6115-644-24
0078
lockwashers (8).
5.
Remove bolt (12), lockwasher (13), and bracket (14) from engine head. Discard lockwasher (13).
6.
Remove nut (15), lockwasher (16), washer (17), and bracket (18) from injection pump mount. Discard
lockwasher (16).
7.
Remove nut (19), lockwasher (20), bolt (21), and bracket (22) from alternator mount. Discard lockwasher
(20).
END OF TASK
0078-2
TM 9-6115-644-24
Figure 1. Fan Guards and Coolant Recovery System.
INSTALLATION
1.
Install bolts (Figure 1, Item 7), new lockwashers (8), and washers (9) securing brackets (10 and 11) to
radiator shroud.
0078-3
0078
TM 9-6115-644-24
2.
Install bracket (14) to engine head with bolt (12) and new lockwasher (13).
3.
Install bracket (18) to injection pump mount with nut (15), new lockwasher (16), and washer (17).
4.
Install bracket (22) to alternator mount with bolt (21), new lockwasher (20), and nut (19).
NOTE
If damaged or if replacing fan guards, install protective edging. Cut to fit.
5.
Install bolts (1), washers (2), nuts (3), and new lockwashers (4) securing fan guards (5 and 6).
6.
Close both side engine access doors, connect negative battery cable, and close battery access door.
END OF TASK
END OF WORK PACKAGE
0078-4
0078
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF COOLANT SYSTEM, UPPER COOLANT HOSE: REMOVAL, INSPECTION AND
CLEANING, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Fine Grit Abrasive Paper
Coolant/Antifreeze
Gloves, Goggles & Protective Clothing
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0006, Service Upon Receipt
WP 0076, Figure 1, Item 1, 11
WP 0078, Maintenance of Coolant System, Fan
Guards
WP 0159, Item 17
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool
before performing checks, services and maintenance, or wear gloves and additional protective
clothing and goggles as required. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Always remove radiator cap slowly to permit any pressure to escape. Failure to comply with this
warning can cause injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open engine access doors.
3.
Slowly remove radiator cap (WP 0076, Figure 1, Item 1).
0079-1
0079
TM 9-6115-644-24
4.
Remove fan guards (WP 0078, Removal).
5.
Open radiator drain valve (28) and drain coolant/antifreeze into suitable container.
6.
Loosen clamps (10) and remove upper coolant hose (11) and clamps (10).
0079
END OF TASK
INSPECTION AND CLEANING
1.
Shut down generator set.
2.
Remove upper coolant hose (Removal).
3.
Inspect upper coolant hose (WP 0076, Figure 1, Item 11) for cracks, holes, and dry rot.
4.
Clean light corrosion from upper coolant hose attaching points with fine grit abrasive paper (WP 0159, Item
17).
5.
Install upper coolant hose (Installation).
END OF TASK
INSTALLATION
1.
Install upper coolant hose (WP 0076, Figure 1, Item 11) on thermostat housing opening and radiator (32) with
clamps (10).
2.
Close radiator drain valve (34) and add coolant/antifreeze to proper level (WP 0006, Radiator).
3.
Install fan guards (WP 0078, Installation).
4.
Install radiator cap (1).
5.
Connect negative battery cable and close battery access door.
6.
Start generator set and allow unit to reach operating temperature and check for leaks.
7.
Add coolant/antifreeze to overflow bottle, as required. Close engine access doors.
END OF TASK
END OF WORK PACKAGE
0079-2
TM 9-6115-644-24
0080
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF COOLANT SYSTEM, LOWER COOLANT HOSE: REMOVAL, INSPECTION AND
CLEANING, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Fine Grit Abrasive Paper
Gloves, Goggles & Protective Clothing
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0076, Figure 1, Items: 1, & 13
WP 0078, Maintenance of Coolant System, Fan
Guards
WP 0159, Item 17
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool
before performing checks, services and maintenance, or wear gloves and additional protective
clothing and goggles as required. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Always remove radiator cap slowly to permit any pressure to escape. Failure to comply with this
warning can cause injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open engine access doors.
3.
Slowly remove radiator cap (WP 0076, Figure 1, Item 1).
4.
Remove fan guards (WP 0078, Removal).
5.
Open radiator drain valve (28) and drain coolant into suitable container.
0080-1
TM 9-6115-644-24
6.
0080
Loosen clamps (12) and remove lower coolant hose (13).
END OF TASK
INSPECTION AND CLEANING
1.
Shut down generator set.
2.
Remove lower coolant hose (Removal).
3.
Inspect lower coolant hose (WP 0076, Figure 1, Item 13) for cracks, holes, and dry rot.
4.
Clean lower coolant hose attaching points with fine grit abrasive paper (WP 0159, Item 17).
5.
Install lower coolant hose (Installation).
END OF TASK
INSTALLATION
1.
Install lower coolant hose (WP 0076, Figure 1, Item 13) on radiator outlet opening and water pump opening
with clamps (12).
2.
Close radiator drain valve (28) and add coolant/antifreeze to proper level (WP 0006, Radiator).
3.
Install fan guards (WP 0078, Installation).
4.
Install radiator cap (1).
5.
Connect negative battery cable and close battery access door.
6.
Start generator set and allow unit to reach operating temperature; check for leaks.
7.
Add coolant/antifreeze to overflow bottle, as required. Close engine access doors.
END OF TASK
END OF WORK PACKAGE
0080-2
TM 9-6115-644-24
0081
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF COOLANT SYSTEM, COOLANT OVERFLOW AND DRAIN HOSES: REMOVAL,
INSPECTION, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Gloves, Goggles, & Protective Clothing
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0076, Maintenance of Coolant System, Coolant
System
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool
before performing checks, services and maintenance, or wear gloves and additional protective
clothing and goggles as required. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Always remove radiator cap slowly to permit any pressure to escape. Failure to comply with this
warning can cause injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open engine access doors.
3.
Locate overflow or drain hose to be removed (WP 0076, Figure 1).
4.
Disconnect hose at both ends and remove from generator set.
END OF TASK
0081-1
TM 9-6115-644-24
INSPECTION
1.
Shut down generator set.
2.
Open engine access doors.
3.
Inspect hoses for cracks, holes, and dry rot. Close engine access doors.
END OF TASK
INSTALLATION
1.
Install overflow or drain hose in generator set as removed.
2.
Close engine access doors, connect negative battery cable, and close battery access door.
END OF TASK
END OF WORK PACKAGE
0081-2
0081
TM 9-6115-644-24
0082
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF COOLANT SYSTEM, RADIATOR: REMOVAL, INSPECTION AND CLEANING, REPAIR,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
New Lockwashers
Protective Eyewear, Mask & Gloves
Dry Cleaning Solvent
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
TM 750-254
WP 0006, Service Upon Receipt
WP 0016, Figure 1, Item 1
WP 0076, Figure 1, Item: 1 & 28
WP 0077, Maintenance of Coolant System, Radiator
Filler Hose & Panel Assembly
WP 0078, Maintenance of Coolant System, Fan
Guards
WP 0079, Maintenance of Coolant System, Upper
Coolant Hose
WP 0080, Maintenance of Coolant System, Lower
Coolant Hose
WP 0159, Item 21
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool
before performing checks, services and maintenance, or wear gloves and additional protective
clothing and goggles as required. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Always remove radiator cap slowly to permit any pressure to escape. Failure to comply with this
warning can cause injury to personnel.
0082-1
TM 9-6115-644-24
0082
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open engine access doors.
3.
Remove generator set top housing section (WP 0016, Removal).
4.
Slowly remove radiator cap (WP 0076, Figure 1, Item 1).
5.
Remove fan guards (WP 0078, Removal).
6.
Open radiator drain valve (28) and drain coolant/antifreeze into suitable container.
7.
Remove radiator filler hose and panel assembly (WP 0077, Removal).
8.
Remove upper coolant hose (WP 0079, Removal).
9.
Remove lower coolant hose (WP 0080, Removal).
10. Remove bolts (14), lockwashers (15), and washers (16); allow shroud (17) to rest on fan (34). Discard
lockwashers (15).
11. Remove nuts (18), lockwashers (19), bolts (20), and washers (21) securing support rods (22) to bracket on
engine. Discard lockwashers (19).
12. Remove bolts (23), lockwashers (24), support rods (22), and spacers (25) from radiator (31). Discard
lockwashers (24).
13. Loosen clamp (26) and disconnect radiator drain hose (27) from radiator drain valve (28).
14. Remove nuts (29) and lockwashers (30) from radiator mounting points. Discard lockwashers (30).
15. Lift radiator (31) up and out of generator set housing.
16. Remove radiator drain valve (28) from radiator (31).
END OF TASK
INSPECTION AND CLEANING
1.
Shut down generator set.
2.
Remove radiator (Removal).
3.
Inspect radiator for excessive corrosion, cracks, or bent cooling fins.
4.
Check inside of radiator for corrosion and scale.
WARNING
Eye protection is required when working with compressed air. Compressed air can propel
particles at high velocity and injure eyes. Do not exceed 15 psi pressure when using compressed
air. Failure to comply with this warning can cause injury to personnel.
WARNING
High pressure steam can blow particles or chemicals into eyes, can cause severe burns, and
creates hazardous noise levels. Wear protective eye, skin, and hearing protection when using
high pressure steam. Failure to comply with this warning can cause injury to personnel.
0082-2
TM 9-6115-644-24
0082
WARNING
Solvent used to clean parts is potentially dangerous to personnel and property. Clean parts in a
well-ventilated area. Avoid inhalation of solvent fumes. Wear goggles and rubber gloves to
protect eyes and skin. Wash exposed skin thoroughly. Do not smoke or use near open flame or
excessive heat. Failure to comply with this warning can cause injury to personnel, and damage to
the equipment.
5.
Clean dirt particles from radiator core air passages using filtered, compressed air.
6.
Clean exterior surface of radiator with dry cleaning solvent (WP 0159, Item 21).
7.
Install radiator (Installation).
END OF TASK
REPAIR
WARNING
Avoid breathing fumes generated by soldering. Eye protection is required. Good general
ventilation is normally adequate. Failure to comply with this warning can cause injury to
personnel.
1.
Repair radiator by straightening bent radiator fins and soldering minor leaks.
2.
Repair radiator in accordance with TM 750-254.
END OF TASK
INSTALLATION
1.
Install drain valve (WP 0076, Figure 1, Item 28) in radiator (31).
2.
Position radiator (31) on radiator mount and install nuts (29) and new lockwashers (30).
3.
Install shroud (17) on radiator (31) with bolts (14), new lockwashers (15), and washers (16).
4.
Connect radiator drain hose (27) on radiator drain valve (28) with clamp (26).
5.
Connect support rods (22) to radiator (31) with spacers (25), new lockwashers (24) and bolts (23).
6.
Attach support rods (22) to bracket on engine with bolts (20), washers (21), new lockwashers (19), and nuts
(18).
7.
Install lower coolant hose (WP 0080, Installation).
8.
Install upper coolant hose (WP 0079, Installation).
9.
Install radiator filler hose and panel assembly (WP 0077, Installation).
10. Install fan guards (WP 0078, Installation).
11. Install generator set top housing section (WP 0016, Installation).
12. Ensure radiator drain valve (28) is closed; add coolant/antifreeze to proper level (WP 0006, Radiator).
13. Install radiator cap (1).
14. Start generator set and allow unit to reach operating temperature; check for leakage.
15. Add coolant to overflow bottle, as required. Close engine access doors.
END OF TASK
END OF WORK PACKAGE
0082-3/(4 blank)
TM 9-6115-644-24
0083
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF COOLANT SYSTEM, GENERATOR SET COOLING FAN: REMOVAL, INSPECTION,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
New Lockwashers
Protective Eyewear, Mask & Gloves
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0076, Figure 1, Items: 14, 34 & 42
WP 0078, Maintenance of Coolant System; Fan
Guards
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Always remove radiator cap slowly to permit any pressure to escape. Failure to comply with this
warning can cause injury to personnel.
WARNING
Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool
before performing checks, services and maintenance, or wear gloves and additional protective
clothing and goggles as required. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open engine access doors.
3.
Remove fan guards (WP 0078, Removal).
4.
Remove bolts (WP 0076, Figure 1, Item 14), washers (16), and lockwashers (15); allow shroud (17) to rest on
fan (34). Discard lockwashers (15).
5.
Remove bolts (32), lockwashers (33), fan (34), spacer (35) and shroud (17) from generator set. Discard
0083-1
TM 9-6115-644-24
0083
lockwashers (33).
6.
Remove nuts (36), screws (37), stiffeners (38 and 39), supports (40 and 41), and seals (42) from each side of
shroud (17).
END OF TASK
INSPECTION
WARNING
Eye protection is required when working with compressed air. Compressed air can propel
particles at high velocity and injure eyes. Do not exceed 15 psi pressure when using compressed
air. Failure to comply with this warning can cause injury to personnel.
WARNING
High pressure steam can blow particles or chemicals into eyes, can cause severe burns, and
creates hazardous noise levels. Wear protective eye, skin, and hearing protection when using
high pressure steam. Failure to comply with this warning can cause injury to personnel.
WARNING
Solvent used to clean parts is potentially dangerous to personnel and property. Clean parts in a
well-ventilated area. Avoid inhalation of solvent fumes. Wear goggles and rubber gloves to
protect eyes and skin. Wash exposed skin thoroughly. Do not smoke or use near open flame or
excessive heat. Failure to comply with this warning can cause injury to personnel, and damage to
the equipment.
1.
Shut down generator set.
2.
Remove cooling fan, Removal.
3.
Inspect fan (WP 0076, Figure 1, Item 34) and blades for cracks, bends, loose rivets, or other damage.
4.
Inspect seals (42), supports (40 and 41), and stiffeners (38 and 39) for damage.
5.
Replace damaged parts.
6.
Install cooling fan (Installation).
END OF TASK
INSTALLATION
1.
Install seals (WP 0076, Figure 1, Item 42), supports (40 and 41), and stiffeners (38 and 39) on each side of
shroud (17) with screws (37) and nuts (36).
2.
Position fan (34), spacer (35), and shroud (17) in generator set and secure with bolts (32) and new
lockwashers (33). Torque bolts (32) to 24 ft•lbs (32.5 N•m).
3.
Install fan shroud (17) with bolts (14), new lockwashers (15), and washers (16).
4.
Install fan guards (WP 0078, Installation).
5.
Close engine access doors, connect negative battery cable, and close battery access door.
END OF TASK
END OF WORK PACKAGE
0083-2
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF COOLANT SYSTEM, FAN BELT: INSPECTION, TESTING AND ADJUSTMENT,
REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Gloves & Protective Clothing
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0076, Figure 1, Item 34
WP 0078, Maintenance of Coolant System, Fan
Guards
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
INSPECTION
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Fan has sharp blades. Use caution and wear gloves when removing or installing belts. Failure to
comply with this warning can cause injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open engine access doors.
3.
Inspect fan belt (Figure 1, Item 6) for frays, cracks, oil soaking, and other damage.
4.
Replace fan belt that shows any of above or cannot be adjusted for proper tension.
5.
Close engine access doors, connect negative battery cable, and close battery access door.
0084-1
0084
TM 9-6115-644-24
0084
Figure 1. Fan Belt.
END OF TASK
TESTING AND ADJUSTMENT
NOTE
Run engine for 5 minutes if belt is cold. If belt is hot, let cool for 10 to 15 minutes.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open engine access doors.
3.
Check fan belt (Figure 1, Item 6) for 1/2 inch (1.27 cm) deflection midway between alternator pulley (3) and
crankshaft pulley (5).
4.
If fan belt needs adjustment, loosen alternator mounting bolt (1) and nut (2).
CAUTION
Do not pry against alternator rear frame. Damage to alternator or mounting brackets could occur.
5.
Apply outward pressure to alternator front frame until belt tension is correct.
6.
Tighten alternator mounting bolt (1) and nut (2).
7.
Close engine access doors, connect negative battery cable, and close battery access door.
END OF TASK
REMOVAL
0084-2
TM 9-6115-644-24
0084
WARNING
Fan has sharp blades. Use caution and wear gloves when removing or installing belts. Failure to
comply with this warning can cause injury to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open engine access doors.
3.
Remove fan guards (WP 0078, Removal).
4.
Loosen alternator mounting bolt (Figure 1, Item 1) and nut (2).
5.
Pivot alternator to relieve tension on fan belt (6) and remove belt (6) from alternator pulley (3), fan pulley (4),
and crankshaft pulley (5).
6.
Slip belt (6) over fan (WP 0076, Figure 1, Item 34) and remove belt from generator set.
END OF TASK
INSTALLATION
WARNING
Fan has sharp blades. Use caution and wear gloves when removing or installing belts. Failure to
comply with this warning can cause injury to personnel.
1.
Slip fan belt (Figure 1, Item 6) over fan (WP 0076, Figure 1, Item 34).
2.
Install belt (Figure 1, Item 6) onto alternator pulley (3), fan pulley (4), and crankshaft pulley (5).
3.
Adjust tension on fan belt (6) (Testing and Adjustment).
4.
Install fan guards (WP 0078, Installation).
5.
Close engine access doors.
6.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0084-3/(4 blank)
TM 9-6115-644-24
0085
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF COOLANT SYSTEM, COOLANT RECOVERY SYSTEM: INSPECTION, REMOVAL,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Gloves & Protective Clothing
New Lockwashers
Suitable Containers for Coolant Drainage
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0006, Table 1
WP 0078, Figure 1, Items: 24 & 36
See "One Qualified Technician" Warning
Equipment Condition
foo eqpconds condition foo eqpconds reason
INSPECTION
WARNING
Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool
before performing checks, services and maintenance, or wear gloves and additional protective
clothing and goggles as required. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
In extreme cold weather, skin can stick to metal. Avoid contacting metal items with bare skin in
extreme cold weather. Failure to comply with this warning can cause injury to personnel.
1.
Shut down generator set.
2.
Open right side engine access doors.
3.
Inspect coolant recovery system components for cracks, holes, or other damage.
4.
Close right side engine access doors.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
0085-1
TM 9-6115-644-24
0085
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool
before performing checks, services and maintenance, or wear gloves and additional protective
clothing and goggles as required. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Always remove radiator cap slowly to permit any pressure to escape. Failure to comply with this
warning can cause injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open right side engine access doors.
3.
Loosen clamp (WP 0078, Figure 1, Item 24) and disconnect hose (25) from overflow bottle (28) and drain
coolant into suitable container.
4.
Loosen clamp (26) and disconnect hose (27) from overflow bottle (28).
5.
Remove overflow bottle (28) from wire holder (33).
6.
Remove bolts (29), nuts (30), lockwashers (31), washers (32), and wire holder (33) from mount (36). Discard
lockwashers (31).
7.
Remove bolts (34), lockwashers (35), clamp (37), and mount (36) from engine. Discard lockwashers (35).
END OF TASK
INSTALLATION
WARNING
Always remove radiator cap slowly to permit any pressure to escape. Failure to comply with this
warning can cause injury to personnel.
1.
Install mount (WP 0078, Figure 1, Item 36) and clamp (37) on engine with bolts (34) and new lockwashers
(35).
2.
Install wire holder (33) on mount (36) with bolts (29), washers (32), new lockwashers (31), and nuts (30).
3.
Install coolant overflow bottle (28) in holder (33) and connect hoses (25 and 27) with clamps (24 and 26).
4.
Fill overflow bottle (28) with coolant to the COLD level. Refer to WP 0006, Table 1 for proper coolant.
5.
Start generator set, check for leaks, and run until normal operating temperature is reached.
6.
Add coolant to HOT level of overflow bottle (28) and close right side engine access doors.
END OF TASK
END OF WORK PACKAGE
0085-2
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF FUEL SYSTEM, LOW PRESSURE FUEL LINES AND FITTINGS: REMOVAL,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Gloves & Protective Clothing
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0087, Figure 1
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Operators are to wash exposed skin and change chemical soaked clothing
promptly if exposed to fuel. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Fuels used in the generator set are flammable. Do not smoke or use open flames when
performing maintenance. Failure to comply with this warning can cause injury or death to
personnel, and damage to the generator set.
WARNING
Fuels used in the generator set are flammable. When filling the fuel tank, maintain metal-to-metal
contact between filler nozzle and fuel tank opening to eliminate static electrical discharge. Failure
to comply with this warning can cause injury or death to personnel, and damage to the generator
set.
0086-1
0086
TM 9-6115-644-24
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set; open battery access door and disconnect negative battery cable.
2.
Identify fuel line or fitting that is damaged or leaking and must be removed (WP 0087, Figure 1).
3.
Disconnect fuel line at both ends and remove any clamps.
4.
Remove fuel line or fitting from generator set.
5.
Cover or cap all openings.
END OF TASK
INSTALLATION
1.
Remove any caps and position fuel line or fitting in generator set.
2.
Install any clamps as removed and connect fuel line at both ends (WP 0087, Figure 1).
3.
Connect negative battery cable and close battery access door.
4.
Start generator set and check for fuel leaks.
5.
Shut down generator set. Close all access doors.
END OF TASK
END OF WORK PACKAGE
0086-2
0086
TM 9-6115-644-24
0087
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF FUEL SYSTEM, AUXILIARY FUEL PUMP: INSPECTION, TESTING, REMOVAL,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Gloves, Protective Clothing & Eyewear
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
Equipment Condition
Grounded, Off & Operational
See "One Qualified Technician" Warning
INSPECTION
1.
Shut down generator set.
2.
Inspect auxiliary fuel pump (Figure 1, Item 8) for leaks, cracks, missing hardware, loose connections, and
other damage.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Connect generator set to auxiliary fuel supply (ensure auxiliary fuel supply is no more than 6 feet (1.83m)
below generator set).
3.
Open left side engine access doors.
4.
Disconnect auxiliary fuel pump outlet line (Figure 1, Item 13) at fuel tank fitting and place disconnected end in
measuring container.
5.
Move generator set MASTER SWITCH to PRIME & RUN AUX FUEL position for 1 minute; return MASTER
SWITCH to OFF position.
6.
Measuring container should have collected at least 36 ounces (1.06 liters) of fuel.
7.
Replace auxiliary fuel pump if delivery amount is other than above.
8.
Connect auxiliary fuel pump outlet line (13) at fuel tank fitting.
9.
Disconnect generator set from auxiliary fuel supply. Close left side engine access doors.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
0087-1
TM 9-6115-644-24
0087
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Operators are to wash exposed skin and change chemical soaked clothing
promptly if exposed to fuel. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Fuels used in the generator set are flammable. Do not smoke or use open flames when
performing maintenance. Failure to comply with this warning can cause injury or death to
personnel, and damage to the generator set.
WARNING
Fuels used in the generator set are flammable. When filling the fuel tank, maintain metal-to-metal
contact between filler nozzle and fuel tank opening to eliminate static electrical discharge. Failure
to comply with this warning can cause injury or death to personnel, and damage to the generator
set.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open left side engine access doors.
3.
Tag and disconnect auxiliary fuel pump (Figure 1, Item 8) electrical connector.
4.
Loosen clamps (1A). Disconnect filter (10) and remove adapter fitting (1B) from filler neck panel fitting (12).
Remove adapter fitting (1B) from fuel inlet hose (1). Remove filter (10) from auxiliary fuel pump (8). Cap fuel
inlet hose (1).
5.
Disconnect auxiliary fuel outlet line (2) from auxiliary fuel pump (8).
6.
Remove nuts (3), lockwashers (4), bolts (5), washers (6), cap and chain assembly (7), and auxiliary fuel
pump (8). Discard lockwashers (4).
7.
If necessary, remove fitting (9) from auxiliary fuel pump (8). Some auxiliary fuel pumps are supplied with
integral 90-degree outlet port fitting.
8.
If necessary, remove nut (11) and fitting (12) from fuel filler panel.
END OF TASK
INSTALLATION
1.
If removed, install fitting (Figure 1, Item 12) and nut (11) in fuel filler panel.
2.
If necessary, install fitting (9) on auxiliary fuel pump (8).
3.
Install auxiliary fuel pump (8) and cap and chain assembly (7) in generator set with bolts (5), washers (6),
new lockwashers (4), and nuts (3).
4.
Connect auxiliary fuel outlet line (2) to auxiliary fuel pump (8).
5.
Remove caps from fuel inlet hose (1). Install filter (10) on auxiliary fuel pump (8). Install adapter fitting (1B) on
0087-2
TM 9-6115-644-24
0087
fuel inlet hose (1) and connect adapter fitting (1B) to filler neck panel fitting (12). Connect other end of fuel
inlet hose (1) to filter (10). Tighten clamps (1A).
6.
Connect auxiliary fuel pump (8) electrical connector. Remove tag.
7.
Connect negative battery cable and close battery access door.
8.
Move generator set MASTER SWITCH to PRIME & RUN AUX FUEL position and check for fuel leaks.
9.
Return MASTER SWITCH to OFF position. Close left side engine access doors.
Figure 1. Fuel Tank Filler Neck and Low Pressure Fuel System.
END OF TASK
END OF WORK PACKAGE
0087-3/(4 blank)
TM 9-6115-644-24
0088
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF FUEL SYSTEM, FUEL TANK FILLER NECK: REMOVAL, INSPECTION, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Gloves, Protective Clothing & Eyewear
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0006, Table 2
WP 0087, Figure 1, Item: 26 & 27
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Fuels used in the generator set are flammable. Do not smoke or use open flames when
performing maintenance. Failure to comply with this warning can cause injury or death to
personnel, and damage to the generator set.
WARNING
Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Operators are to wash exposed skin and change chemical soaked clothing
promptly if exposed to fuel. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Fuels used in the generator set are flammable. When filling the fuel tank, maintain metal-to-metal
contact between filler nozzle and fuel tank opening to eliminate static electrical discharge. Failure
to comply with this warning can cause injury or death to personnel, and damage to the generator
set.
0088-1
TM 9-6115-644-24
0088
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove cap (WP 0087, Figure 1, Item 27), open fuel drain valve (29), and drain fuel into suitable container.
4.
Open left side engine access doors.
5.
Remove filler neck cap and tube assembly (14).
6.
Loosen clamp (15) and disconnect hose (16) from adapter (17).
7.
Remove adapter (17) from fitting (18).
8.
Remove nut (19), washer (20), and fitting (18) from side of filler neck (23).
9.
Remove bolts (21) and nuts (22) securing filler neck (23) to generator set housing.
10. Remove clamps (24 and 25), hose (26), and filler neck (23) from fuel tank opening. Cover fuel tank opening.
END OF TASK
INSPECTION
1.
Shut down generator set.
2.
Remove fuel tank filler neck (Removal).
3.
Inspect hose (WP 0087, Figure 1, Item 26) for cracking, wear, or other damage.
4.
Inspect filler neck (23) for corrosion, cracking, or other damage.
5.
Inspect filler neck cap and tube assembly (14) for damage.
6.
Install fuel tank filler neck (Installation).
END OF TASK
INSTALLATION
1.
Position hose (WP 0087, Figure 1, Item 26), clamps (24 and 25), and filler neck (23) on fuel tank.
2.
Install bolts (21) and nuts (22) securing filler neck (23) to generator set housing.
3.
Tighten clamps (24 and 25).
4.
Install fitting (18), washer (20), and nut (19) inside of filler neck (23).
5.
Install adapter (17) on fitting (18) and connect hose (16) to adapter (17) with clamp (15).
6.
Install filler neck cap and tube assembly (14).
7.
Close fuel drain valve (29), install cap (27), and service fuel tank. Refer to WP 0006, Table 2 for proper fuel.
8.
Connect negative battery cable. Close battery access door and left side engine access doors.
END OF TASK
END OF WORK PACKAGE
0088-2
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF FUEL SYSTEM, FUEL DRAIN VALVE: REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Gloves & Protective Clothing
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0006, Table 2
WP 0087, Figure 1, Items: 27 & 31
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Operators are to wash exposed skin and change chemical soaked clothing
promptly if exposed to fuel. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Fuels used in the generator set are flammable. Do not smoke or use open flames when
performing maintenance. Failure to comply with this warning can cause injury or death to
personnel, and damage to the generator set.
WARNING
Fuels used in the generator set are flammable. When filling the fuel tank, maintain metal-to-metal
contact between filler nozzle and fuel tank opening to eliminate static electrical discharge. Failure
to comply with this warning can cause injury or death to personnel, and damage to the generator
set.
0089-1
0089
TM 9-6115-644-24
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open left side engine access doors.
3.
Remove cap and chain assembly (WP 0087, Figure 1, Item 27) from adapter (28).
4.
Open drain valve (29) and drain fuel into suitable container.
5.
Remove drain valve (29) and adapter (28) from elbow (30).
6.
Remove adapter (28) from drain valve (29).
7.
If necessary, remove elbow (30) and adapter (31) from fuel tank fitting.
END OF TASK
INSTALLATION
1.
If removed, Install adapter (WP 0087, Figure 1, Item 31) and elbow (30) in fuel tank fitting.
2.
Install fuel drain valve (29) into elbow (30).
3.
Install adapter (28) into drain valve (29), and cap and chain assembly (27) on adapter (28).
4.
Ensure fuel drain valve (29) is closed and service fuel tank. Refer to WP 0006, Table 2 for proper fuel.
5.
Check fuel drain valve and fittings for leakage.
6.
Close left side engine access doors, connect negative battery cable, and close battery access door.
END OF TASK
END OF WORK PACKAGE
0089-2
0089
TM 9-6115-644-24
0090
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF FUEL SYSTEM, FUEL LEVEL SENDER: INSPECTION, REMOVAL, TESTING,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Gloves & Protective Clothing
New Lockwashers
Fuel Level Sender (If indications do not comply with
testing)
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0087, Figure 1, Items: 35 & 36
WP 0159, Item 18
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
INSPECTION
1.
Shut down generator set.
2.
Open left side engine access doors.
3.
Inspect fuel level sender (WP 0087, Figure 1, Item 35) for loose connections/mounting and other damage.
4.
Close left side engine access doors.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
0090-1
TM 9-6115-644-24
0090
WARNING
Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Operators are to wash exposed skin and change chemical soaked clothing
promptly if exposed to fuel. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Fuels used in the generator set are flammable. Do not smoke or use open flames when
performing maintenance. Failure to comply with this warning can cause injury or death to
personnel, and damage to the generator set.
WARNING
Fuels used in the generator set are flammable. When filling the fuel tank, maintain metal-to-metal
contact between filler nozzle and fuel tank opening to eliminate static electrical discharge. Failure
to comply with this warning can cause injury or death to personnel, and damage to the generator
set.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open left side engine access doors.
3.
Disconnect fuel level sender (WP 0087, Figure 1, Item 35) electrical lead.
NOTE
Mark position of float when removing sender. Float must be in same position when installing to
ensure clearance with fuel tank.
4.
Remove screws (32), lockwashers (33), flat washers (34), fuel level sender (35), and gasket (36) from
generator set fuel tank. Discard lockwashers (33) and gasket (36).
5.
Cover opening in fuel tank.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Remove fuel level sender (Removal).
3.
Position fuel level sender in vertical position, similar to position as installed in fuel tank.
4.
Set multimeter for ohms and connect positive lead to fuel level sender terminal and negative lead to sender
ground.
5.
With fuel level sender arm resting freely in what would be an empty position, multimeter should indicate
between 216 and 264 ohms.
6.
Move fuel level sender arm up to what would be a full position and multimeter should indicate between 29.7
and 36.3 ohms.
7.
Replace fuel level sender if indications are not as above.
8.
Install fuel level sender (Installation).
END OF TASK
0090-2
TM 9-6115-644-24
0090
INSTALLATION
1.
Remove cover in fuel tank opening.
2.
Thoroughly clean, make flat and smooth mating surfaces for new gasket (WP 0087, Figure 1, Item 36).
Ensure no foreign material enters fuel tank. Apply sealant (WP 0159, Item 18) to both sides of new gasket
(36).
3.
Insert fuel level sender (35) and gasket (36) into fuel tank. Ensure float is in same position as removed.
4.
Install screws (32), new lockwashers (33), and flat washers (34).
5.
Connect electrical lead and remove tag. Close left side engine access doors.
6.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0090-3/(4 blank)
TM 9-6115-644-24
0091
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF FUEL SYSTEM, LOW FUEL LEVEL/AUXILIARY FUEL PUMP FLOAT SWITCH:
INSPECTION, REMOVAL, TESTING, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Gloves & Protective Clothing
New Lockwashers
Sealant
New Gasket
Low Fuel Level/Auxiliary Fuel Pump Float Switch (If
indications do not comply with testing)
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0087, Figure 1, Items: 40, & 41
WP 0159, Item 18
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
INSPECTION
1.
Shut down generator set.
2.
Open left side engine access doors.
3.
Inspect low fuel level/auxiliary fuel pump float switch (WP 0087, Figure 1, Item 40) for loose
connections/mounting and other damage.
4.
Close left side engine access doors.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
0091-1
TM 9-6115-644-24
0091
WARNING
Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Operators are to wash exposed skin and change chemical soaked clothing
promptly if exposed to fuel. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Fuels used in the generator set are flammable. Do not smoke or use open flames when
performing maintenance. Failure to comply with this warning can cause injury or death to
personnel, and damage to the generator set.
WARNING
Fuels used in the generator set are flammable. When filling the fuel tank, maintain metal-to-metal
contact between filler nozzle and fuel tank opening to eliminate static electrical discharge. Failure
to comply with this warning can cause injury or death to personnel, and damage to the generator
set.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open left side engine access doors.
3.
Tag and disconnect low fuel level/auxiliary fuel pump float switch (WP 0087, Figure 1, Item 40) electrical
connector.
4.
Remove screws (37), lockwashers (38), flat washers (39), float switch (40), and gasket (41) from fuel tank.
Discard lockwashers (38) and gasket (41).
5.
Cover opening in fuel tank.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Remove low fuel level/auxiliary fuel pump float switch (Removal).
3.
Position float switch in vertical position, similar to position as installed in fuel tank.
4.
For the top float, set multimeter for ohms and connect positive lead to pin 2 and negative lead to pin 1 of float
switch electrical connector.
5.
With upper or lower float moving toward the down position, multimeter should indicate continuity 1/4-inch
before float reaches the down position.
6.
Move upper float to full up position. Multimeter should indicate open circuit.
7.
Disconnect multimeter leads from pins 1 and 2. To check lower float, connect positive lead to pin 3 and
negative lead to pin 4 of electrical connector.
8.
Repeat Steps 5 and 6, except with lower float.
9.
Replace low fuel level/auxiliary fuel pump float switch if indications are other than above.
10. Install low fuel level/auxiliary fuel pump float switch (Installation).
END OF TASK
0091-2
TM 9-6115-644-24
0091
INSTALLATION
1.
Loosen float switch plate adjusting nut.
2.
Remove cover in fuel tank opening.
3.
Thoroughly clean, make flat and smooth mating surfaces for new gasket (WP 0087, Figure 1, Item 41).
Ensure no foreign material enters fuel tank. Apply sealant (WP 0159, Item 18) to both sides of new gasket
(41).
4.
Position gasket (41) and float switch (40) in fuel tank.
5.
Install screws (37), new lockwashers (38), and flat washers (39).
6.
Set float switch stem 1/16-inch from bottom of fuel tank. Tighten float switch plate adjusting nut.
7.
Connect electrical connector and remove tag. Close left side engine access doors.
8.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0091-3/(4 blank)
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF FUEL SYSTEM, FUEL PICKUP: REMOVAL, INSPECTION, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Gloves & Protective Clothing
New Lockwashers & New Gasket
Sealant
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0087, Figure 1, Items: 43 & 47
WP 0159, Item 18
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Operators are to wash exposed skin and change chemical soaked clothing
promptly if exposed to fuel. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Fuels used in the generator set are flammable. Do not smoke or use open flames when
performing maintenance. Failure to comply with this warning can cause injury or death to
personnel, and damage to the generator set.
WARNING
Fuels used in the generator set are flammable. When filling the fuel tank, maintain metal-to-metal
contact between filler nozzle and fuel tank opening to eliminate static electrical discharge. Failure
to comply with this warning can cause injury or death to personnel, and damage to the generator
set.
0092-1
0092
TM 9-6115-644-24
0092
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open right side engine access doors.
3.
Disconnect fuel line (WP 0087, Figure 1, Item 42) from fitting (48).
NOTE
Mark position of fuel pickup before removing.
4.
Remove screws (43), lockwashers (44), flat washers (45), fuel pickup (46), and gasket (47) from fuel tank.
Discard lockwashers (44) and gasket (47).
5.
Remove fitting (48) from fuel pickup (46).
6.
Cover opening in fuel tank.
END OF TASK
INSPECTION
1.
Shut down generator set.
2.
Remove fuel pickup (Removal).
3.
Inspect fuel pickup and fitting for clogs, stripped threads, and other damage.
4.
Replace damaged parts.
5.
Install fuel pickup (Installation).
END OF TASK
INSTALLATION
NOTE
Ensure fuel pickup is in same position as marked on removal.
1.
Remove cover in fuel tank opening.
2.
Thoroughly clean, make flat and smooth mating surfaces for new gasket (WP 0087, Figure 1, Item 47).
Ensure no foreign material enters fuel tank. Apply sealant (WP 0159, Item 18) to both sides of new gasket
(47).
3.
Install gasket (47) and fuel pickup (46) in fuel tank with screws (43), new lockwashers (44), and flat washers
(45).
4.
Install fitting (48) in fuel pickup (46).
5.
Connect fuel line (42) to fitting (48). Close right side engine access doors.
6.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0092-2
TM 9-6115-644-24
0093
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF FUEL SYSTEM, FUEL FLOAT MODULE: INSPECTION, TESTING, REMOVAL,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Gloves & Protective Clothing
Fuel Float Module(If operation does not comply with
testing
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0087, Figure 1, Item 51
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
INSPECTION
1.
Shut down generator set.
2.
Open left side engine access doors.
3.
Inspect fuel float module (WP 0087, Figure 1, Item 51) for cracked housing, broken or damaged connectors
and wiring, and other damage.
4.
Close left side engine access doors.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open left side engine access doors.
3.
Disconnect fuel float module (WP 0087, Figure 1, Item 51) electrical connector (J12) from fuel float switch
connector (P12).
4.
Connect pins 1 and 2 of fuel float module electrical connector (J12) together with a jumper wire.
5.
Move MASTER SWITCH to PRIME & RUN AUX FUEL position and auxiliary fuel pump should start
operating. Remove jumper wire and auxiliary fuel pump should stop operating.
6.
Start and operate generator set at rated voltage and frequency.
7.
Using jumper wire, make connection between pins 3 and 4 of fuel float module electrical connector (J12).
Generator set should shut down after approximately 2 seconds and NO FUEL lamp on malfunction indicator
panel should light.
8.
Replace fuel float module if operation is other than above.
9.
Close left side engine access doors.
END OF TASK
REMOVAL
0093-1
TM 9-6115-644-24
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Operators are to wash exposed skin and change chemical soaked clothing
promptly if exposed to fuel. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Fuels used in the generator set are flammable. Do not smoke or use open flames when
performing maintenance. Failure to comply with this warning can cause injury or death to
personnel, and damage to the generator set.
WARNING
Fuels used in the generator set are flammable. When filling the fuel tank, maintain metal-to-metal
contact between filler nozzle and fuel tank opening to eliminate static electrical discharge. Failure
to comply with this warning can cause injury or death to personnel, and damage to the generator
set.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open left side engine access doors.
3.
Tag and disconnect electrical connectors from fuel float module (WP 0087, Figure 1, Item 51).
4.
Remove bolts (49), nuts (50), and fuel float module (51) from generator set.
END OF TASK
INSTALLATION
1.
Install fuel float module (WP 0087, Figure 1, Item 51) in generator set with bolts (49) and nuts (50).
2.
Connect electrical connectors; remove tags. Close left side engine access doors.
3.
Connect negative battery cable and close battery access door.
END OF TASK
0093-2
0093
TM 9-6115-644-24
END OF WORK PACKAGE
0093-3/(4 blank)
0093
TM 9-6115-644-24
0094
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF FUEL SYSTEM, FUEL FILTER/DRAIN VALVE ASSEMBLY: REMOVAL, INSPECTION,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Gloves & Protective Clothing
Washers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0087, Figure 1, Item: 58 & 60
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
NOTE
Maintenance for the fuel filter/water separator is found in the engine TM. Retain fuel filter drain
valve assembly for use with new filters.
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Operators are to wash exposed skin and change chemical soaked clothing
promptly if exposed to fuel. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Fuels used in the generator set are flammable. Do not smoke or use open flames when
performing maintenance. Failure to comply with this warning can cause injury or death to
personnel, and damage to the generator set.
0094-1
TM 9-6115-644-24
WARNING
Fuels used in the generator set are flammable. When filling the fuel tank, maintain metal-to-metal
contact between filler nozzle and fuel tank opening to eliminate static electrical discharge. Failure
to comply with this warning can cause injury or death to personnel, and damage to the generator
set.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open left side engine access doors.
3.
Remove clamp (WP 0087, Figure 1, Item 60) and hose (61) from drain valve (59).
4.
Remove bolt (56), washers (57), and adapter (58). Discard washers (57).
5.
Remove drain valve (59) from adapter (58).
END OF TASK
INSPECTION
Check drain valve assembly for defects and proper operation.
END OF TASK
INSTALLATION
1.
Install adapter (WP 0087, Figure 1, Item 58) on drain valve (59).
2.
Install new washers (57) and bolt (56) to adapter (58) and tighten to bottom of fuel filter/water separator.
3.
Install hose (61) and clamp (60) to drain valve (59). Close left side engine access doors.
4.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0094-2
0094
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF FUEL SYSTEM, ETHER CYLINDER: REMOVAL, INSPECTION, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Gloves & Protective Clothing
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
Equipment Condition
Grounded, Off & Operational
See "One Qualified Technician" Warning
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Fuels used in the generator set are flammable. Do not smoke or use open flames when
performing maintenance. Failure to comply with this warning can cause injury or death to
personnel, and damage to the generator set.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Operators are to wash exposed skin and change chemical soaked clothing
promptly if exposed to fuel. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Fuels used in the generator set are flammable. When filling the fuel tank, maintain metal-to-metal
contact between filler nozzle and fuel tank opening to eliminate static electrical discharge. Failure
to comply with this warning can cause injury or death to personnel, and damage to the generator
set.
0095-1
0095
TM 9-6115-644-24
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open right side engine access doors.
3.
Loosen wing nut (Figure 1, Item 1) and unscrew ether cylinder (2) from ether solenoid valve (14).
4.
Install cap (15) in solenoid valve (14).
5.
Remove nuts (3), lockwashers (4), bolts (5), washers (6), and ether cylinder bracket assembly (7) from
generator set housing. Discard lockwashers (4).
END OF TASK
INSPECTION
1.
Shut down generator set.
2.
Open right side engine access doors.
3.
Inspect ether cylinder bracket assembly (Figure 1, Item 7) for cracks, corrosion, stripped or damaged
threads, or other damage.
4.
Replace defective parts.
5.
Close right side engine access doors.
END OF TASK
INSTALLATION
1.
Install bracket assembly (Figure 1, Item 7) on generator set housing with bolts (5), washers (6), new
lockwashers (4), and nuts (3).
2.
Remove cap (15) from ether solenoid valve (14).
3.
Insert ether cylinder (2) through bracket (7) and screw into ether solenoid valve (14).
4.
Close clamp (7) and tighten wing nut (1).
5.
Close right side engine access doors.
0095-2
0095
TM 9-6115-644-24
Figure 1. Ether Start System.
END OF TASK
END OF WORK PACKAGE
0095-3/(4 blank)
0095
TM 9-6115-644-24
0096
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF FUEL SYSTEM, ETHER SOLENOID VALVE: REMOVAL, INSPECTION, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Gloves & Protective Clothing
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0095, Figure 1, Item 14
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Operators are to wash exposed skin and change chemical soaked clothing
promptly if exposed to fuel. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Fuels used in the generator set are flammable. Do not smoke or use open flames when
performing maintenance. Failure to comply with this warning can cause injury or death to
personnel, and damage to the generator set.
WARNING
Fuels used in the generator set are flammable. When filling the fuel tank, maintain metal-to-metal
contact between filler nozzle and fuel tank opening to eliminate static electrical discharge. Failure
to comply with this warning can cause injury or death to personnel, and damage to the generator
set.
0096-1
TM 9-6115-644-24
0096
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Open right side engine access doors.
4.
Tag and disconnect ether solenoid valve (WP 0095, Figure 1, Item 14) electrical leads.
5.
Remove tube assembly (8) from ether solenoid valve (14) and spray nozzle (9).
6.
Remove ether cylinder (2) from ether solenoid valve (14) (WP 0095, Removal).
7.
Remove nuts (10), lockwashers (11), bolts (12), washers (13), and ether solenoid valve (14) from generator
set housing. Discard lockwashers (11).
8.
Remove spray nozzle (9) from engine intake manifold.
END OF TASK
INSPECTION
1.
Shut down generator set.
2.
Remove ether solenoid valve (WP 0095, Figure 1, Item 14) (Removal).
3.
Inspect ether solenoid valve (14) for cracks, corrosion, damaged threads, evidence of shorting, or other
damage.
4.
Inspect tube assembly (8) for cracks, breaks, pinching, damaged threads, or other damage.
5.
Inspect spray nozzle (9) for cracks, corrosion, clogging, or other damage.
6.
Replace any defective parts.
7.
Install ether solenoid valve (14) (Installation).
END OF TASK
INSTALLATION
1.
Install ether solenoid valve (WP 0095, Figure 1, Item 14) on generator set housing with bolts (12), washers
(13), new lockwashers (11), and nuts (10).
2.
Install ether cylinder (2) into ether solenoid valve (14) (WP 0095, Installation).
3.
Install spray nozzle (9) in engine intake manifold.
4.
Install tube assembly (8) into ether solenoid valve (14) and spray nozzle (9).
5.
Connect electrical leads, remove tags, and close right side engine access doors.
6.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0096-2
TM 9-6115-644-24
0097
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF FUEL SYSTEM, FUEL TANK: INSPECTION, REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Protective Eyewear & Skin Protection
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0006, Table 2
WP 0009, Maintenance & Installation of Major
Components, Engine & Generator Assembly
WP 0089, Maintenance of Fuel System, Fuel Drain
Valve
WP 0090, Maintenance of Fuel System, Fuel Level
Sender
WP 0091, Maintenance of Fuel System, Low Fuel
Level/Auxiliary Fuel Pump Float Switch
WP 0092, Maintenance of Fuel System, Fuel Pickup
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Operators are to wash exposed skin and change chemical soaked clothing
promptly if exposed to fuel. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Fuels used in the generator set are flammable. Do not smoke or use open flames when
performing maintenance. Failure to comply with this warning can cause injury or death to
personnel, and damage to the generator set.
0097-1
TM 9-6115-644-24
0097
WARNING
Fuels used in the generator set are flammable. When filling the fuel tank, maintain metal-to-metal
contact between filler nozzle and fuel tank opening to eliminate static electrical discharge. Failure
to comply with this warning can cause injury or death to personnel, and damage to the generator
set.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
INSPECTION
1.
Shut down generator set.
2.
Remove fuel tank (Removal).
3.
Inspect fuel tank (Figure 1, Item 6) for leaks, cracks, missing hardware, and other damage.
4.
If no damage is found, install fuel tank (Installation).
END OF TASK
REMOVAL
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Drain fuel tank.
4.
Remove engine and generator assembly (WP 0009, Removal).
5.
Remove fuel tank drain valve (WP 0089, Removal).
6.
Remove nuts (Figure 1, Item 1), lockwashers (2), washers (3), bolts (4), and plates (5) securing fuel tank (6)
to skid base. Discard lockwashers (2).
7.
Remove fuel tank (6) from skid base.
8.
Remove low fuel level/auxiliary fuel pump float switch (WP 0091, Removal).
9.
Remove fuel level sender (WP 0090, Removal).
10. Remove fuel pickup (WP 0092, Removal).
11. Remove fittings (7 and 8) from excess fuel studs (10) on right side of tank.
12. Remove fitting (9) from excess fuel stud (10) on left side of tank.
13. Remove studs (10), washers (11), and bushings (12) from fuel tank (6).
14. Cover all openings.
END OF TASK
INSTALLATION
1.
Remove covers placed over openings.
2.
Install bushings (Figure 1, Item 12), washers (11), and studs (10) in fuel tank (6).
3.
Install fitting (9) in excess fuel stud (10) on left side of fuel tank (6).
4.
Install fittings (7 and 8) in excess fuel studs (10) on right side of fuel tank.
5.
Install low fuel level/auxiliary fuel pump float switch (WP 0091, Installation).
6.
Install fuel level sender (WP 0090, Installation).
0097-2
TM 9-6115-644-24
0097
7.
Install fuel pickup (WP 0092, Installation).
8.
Install fuel tank (6) in skid base and secure with plates (5), bolts (4), washers (3), new lockwashers (2), and
nuts (1).
9.
Install engine and generator assembly (WP 0009, Installation).
10. Install fuel tank drain valve (WP 0089, Installation).
11. Service fuel tank; refer to WP 0006, Table 2 for proper fuel.
12. Connect negative battery cable. Close battery access door.
Figure 1. Fuel Tank.
0097-3
TM 9-6115-644-24
END OF TASK
END OF WORK PACKAGE
0097-4
0097
TM 9-6115-644-24
0098
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MEP-805A
GENERATOR SET, SKID MOUNTED, TACTICAL QUIET, 30 kW, 400 Hz
MEP-815A
MAINTENANCE OF OUTPUT BOX ASSEMBLY, OUTPUT BOX ASSEMBLY: REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Heat Resistant Gloves & Protective Clothing
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0016, Maintenance of Housing, Top Housing
Section
WP 0014, Maintenance of Housing, Access Doors
WP 0018, Maintenance of Control Box Assembly,
Rear Housing Section
WP 0019, Maintenance of Control Box Assembly,
Control Box Assembly
WP 0073, Maintenance of Air Intake & Exhaust
System
WP 0099, Maintenance of Output Box Assembly,
Voltage Reconnection Terminal Board
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. Make sure generator set is
completely shut down and free of any power source before attempting any repair or maintenance
on the set, or when connecting or disconnecting load cables. Failure to comply with this warning
can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
0098-1
TM 9-6115-644-24
0098
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
WARNING
High voltage is produced when the generator set is in operation. DO NOT touch live voltage
connections. Never attempt to connect or disconnect load cables or paralleling cables while the
generator set is running. Failure to comply with this warning can cause injury or death to
personnel.
REMOVAL
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box assembly (WP 0019, Removal).
4.
Remove top housing section, (WP 0016, Removal).
5.
Remove air cleaner assembly (WP 0073, Removal).
6.
Remove output box access door (WP 0014, Removal).
7.
Remove rear housing panel (WP 0018, Removal).
8.
Open left side engine access door. Tag and disconnect electrical leads from fuel injection pump, governor
actuator, coolant high temperature switch, DEAD CRANK switch, oil pressure sender, low oil pressure switch,
coolant temperature sender, auxiliary fuel pump, fuel float module, fuel level sender, and magnetic pickup.
9.
Open right side engine access door. Tag and disconnect electrical leads from battery charging alternator,
starter, and ether solenoid valve.
10. Note locations and remove loop clamps securing output box harness to engine.
11. Remove voltage reconnection terminal board (WP 0099, Removal).
12. Remove nuts (Figure 1, Item 1), bolts (2), and output box top panel (3) from output box assembly.
NOTE
Record number and direction of wraps when removing main generator cables from transformers
to aid installation.
13. Unwrap main generator cables from droop current transformer (34) and current transformer (31).
14. Remove screws (4) and cover (5) from AC circuit interrupter relay (40).
15. Tag and disconnect output cables from terminals A2, B2, and C2 of AC circuit interrupter relay (40).
16. Tag and disconnect exciter leads F1 and F2 from terminals 1 and 2 of terminal board (26).
17. Remove nuts (6), bolts (7), and output box assembly from generator set.
END OF TASK
0098-2
TM 9-6115-644-24
0098
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
High voltage is produced when the generator set is in operation. DO NOT touch live voltage
connections. Never attempt to connect or disconnect load cables or paralleling cables while the
generator set is running. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
components have been heated. Wear additional protective clothing as required. Failure to comply
with this warning can cause injury to personnel.
1.
Install output box assembly in generator set with bolts (Figure 1, Item 7) and nuts (6).
2.
Connect exciter leads F1 and F2 to terminals 1 and 2 of terminal board (26). Remove tags.
3.
Connect output cables to terminals A2, B2, and C2 of AC circuit interrupter relay (40). Remove tags.
4.
Install cover (5) on AC circuit interrupter (40) with screws (4).
5.
Install main generator cables onto current transformer (31) and droop current transformer (34) with the same
number of wraps recorded during removal.
6.
Install voltage reconnection terminal board (WP 0099, Installation).
7.
Connect output box harness electrical leads to battery charging alternator, starter, and ether solenoid valve
through right engine access doors and remove tags.
8.
Connect output box harness electrical leads to magnetic pickup, coolant temperature sender, auxiliary fuel
pump, fuel float module, fuel level sender, low oil pressure switch, oil pressure sender, governor actuator,
fuel injection pump, DEAD CRANK switch, and coolant high temperature switch through left engine access
doors and remove tags.
9.
Install loop clamps securing output box harness to engine as noted during removal. Close engine access
doors.
10. Install output box top panel (3) with bolts (2) and nuts (1).
11. Install top housing section (WP 0016, Installation).
12. Install air cleaner assembly (WP 0073, Installation).
13. Install rear housing panel (WP 0018, Installation).
14. Install control box assembly (WP 0019, Installation).
15. Install output box access door (WP 0014, Installation).
16. Connect negative battery cable. Close battery access door.
0098-3
TM 9-6115-644-24
Figure 1. Output Box Assembly.
END OF TASK
END OF WORK PACKAGE
0098-4
0098
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF OUTPUT BOX ASSEMBLY, VOLTAGE RECONNECTION TERMINAL BOARD:
INSPECTION, REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Protective Clothing, Safety Goggles
Chemical Gloves/Heat Resistant Gloves
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0098, Figure 1, Item 21
WP 0100, Figure 1, Item 3
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. Make sure generator set is
completely shut down and free of any power source before attempting any repair or maintenance
on the set, or when connecting or disconnecting load cables. Failure to comply with this warning
can cause injury or death to personnel.
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
0099-1
0099
TM 9-6115-644-24
0099
WARNING
Ensure nuts on ground terminals are properly secured creating a good ground. Failure to comply
with this warning can cause injury or death to personnel.
WARNING
Shut down generator set before performing inspection of wiring. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
WARNING
High voltage is produced when the generator set is in operation. DO NOT touch live voltage
connections. Never attempt to connect or disconnect load cables or paralleling cables while the
generator set is running. Failure to comply with this warning can cause injury or death to
personnel.
INSPECTION
1.
Shut down generator set.
2.
Open output box access door.
3.
Inspect protective cover (WP 0100, Figure 1, Item 3) and moveable terminal board (5) for cracks, breaks,
corrosion, and other damage.
4.
Replace damaged parts.
5.
Close output box access door.
END OF TASK
REMOVAL
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
0099-2
TM 9-6115-644-24
0099
WARNING
Batteries give off a flammable gas. Do not smoke or use open flame when performing
maintenance. Failure to comply with this warning can cause injury or death to personnel, and
damage to the generator set.
WARNING
Battery acid can cause burns to unprotected skin. Wear safety goggles and chemical gloves and
avoid acid splash while working on batteries. Failure to comply with this warning can cause injury
to personnel.
WARNING
When disconnecting or removing batteries, disconnect the negative lead that connects directly to
the grounding stud first; disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply with this warning can
cause injury to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Open output box access door and load terminal board access door.
4.
Remove nuts (WP 0098, Figure 1, Item 8), washers (9), and cover (10) from voltage reconnection board (18).
5.
Unscrew standoffs (11) and remove washers (12), bolts (13), washers (14), and mounts (15).
6.
Remove nuts (16). Tag and disconnect electrical cables (17) and main generator cables from voltage
reconnection board (18).
7.
Remove voltage reconnection board (18) and moveable terminal board (20) from generator set as an
assembly.
8.
Tag position of capacitors (22) on voltage reconnection board (18).
9.
Remove nuts (19), movable terminal board (20), studs (21), and capacitors (22) from voltage reconnection
board (18).
END OF TASK
INSTALLATION
WARNING
When disconnecting or removing batteries, disconnect the negative lead that connects directly to
the grounding stud first; disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply with this warning can
cause injury to personnel.
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
0099-3
TM 9-6115-644-24
0099
WARNING
High voltage is produced when the generator set is in operation. DO NOT touch live voltage
connections. Never attempt to connect or disconnect load cables or paralleling cables while the
generator set is running. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
components have been heated. Wear additional protective clothing as required. Failure to comply
with this warning can cause injury to personnel.
1.
Insert studs (WP 0098, Figure 1, Item 21) in voltage reconnection board (18). Position capacitors (22), as
tagged, align moveable terminal board (20) with voltage reconnection board (18), and install nuts (19).
Remove tags.
2.
Position voltage reconnection board (18) and moveable terminal board (20) in generator set.
3.
Connect electrical cables (17) and main generator cables to voltage reconnection board (18) with nuts (16).
Remove tags.
4.
Secure voltage reconnection board (18) to generator set with bolts (13), washers (14), mounts (15), washers
(12), and standoffs (11).
5.
Install cover (10) with washers (9) and nuts (8). Close output box and load terminal board access doors.
6.
Connect negative battery cable. Close battery access door.
END OF TASK
END OF WORK PACKAGE
0099-4
TM 9-6115-644-24
0100
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF OUTPUT BOX ASSEMBLY, OUTPUT BOX WIRING HARNESS: INSPECTION,
REMOVAL, TESTING, REPAIR, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Heat Resistant Gloves & Protective Clothing
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
FO-2 Wiring Diagram
WP 0019, Maintenance of Control Box Assembly,
Control Box Assembly
WP 0098, Figure 1, Item: 4 & 27
WP 0098, Steps: 10 & 12
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. Make sure generator set is
completely shut down and free of any power source before attempting any repair or maintenance
on the set, or when connecting or disconnecting load cables. Failure to comply with this warning
can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
0100-1
TM 9-6115-644-24
WARNING
High voltage is produced when the generator set is in operation. DO NOT touch live voltage
connections. Never attempt to connect or disconnect load cables or paralleling cables while the
generator set is running. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
INSPECTION
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Ensure nuts on ground terminals are properly secured creating a good ground. Failure to comply
with this warning can cause injury or death to personnel.
WARNING
Shut down generator set before performing inspection of wiring. Failure to comply with this
warning can cause injury or death to personnel.
1.
Shut down generator set.
2.
Remove output box wiring harness (Removal).
3.
Inspect wiring harness (Figure 1, Item 6) for burned, bent, corroded, and broken terminals.
4.
Inspect connectors for cracks, corrosion, stripped threads, bent or broken pins, and obvious damage.
5.
Inspect wire insulation for burns, deterioration, and chafing.
6.
Install output box wiring harness (Installation).
0100-2
0100
TM 9-6115-644-24
Figure 1. Output Box Assembly.
END OF TASK
0100-3
0100
TM 9-6115-644-24
0100
REMOVAL
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box assembly (WP 0019, Removal).
4.
Remove output box top panel (WP 0098, Removal, Step 12).
5.
Open right side engine access doors, tag and disconnect electrical leads from battery charging alternator,
starter solenoid, starter motor, and ether solenoid valve.
6.
Open left side engine access doors, tag and disconnect electrical leads from coolant high temperature
switch, DEAD CRANK switch, low oil pressure switch, oil pressure sender, governor actuator, fuel injection
pump, coolant temperature sender, magnetic pickup, fuel level sender, fuel float module, and auxiliary fuel
pump.
7.
Open output box access door. Remove screws (WP 0098, Figure 1, Item 4) and cover (5) from AC circuit
interrupter relay (40). Tag and disconnect electrical leads from cranking relay (43), current transformer (31),
AC circuit interrupter relay (40), power potential transformer (37), and voltage reconnection board (18).
8.
Tag and disconnect electrical leads for droop current transformer (34) from terminal board (25).
9.
Remove screws (24) and nuts (23) securing terminal boards (25 and 26) in output box.
10. Remove all clamps securing output box harness (27) to generator set.
11. Remove output box harness (27) from output box and generator set.
END OF TASK
TESTING
WARNING
When disconnecting or removing batteries, disconnect the negative lead that connects directly to
the grounding stud first; disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply with this warning can
cause injury to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open output box and engine access doors.
3.
Set multimeter for ohms.
4.
Check individual wires, connectors, and terminal boards for continuity. Refer to Wiring Diagram FO-2 for wire
identification.
5.
Close output box and engine access doors, connect negative battery cable, and close battery access door.
END OF TASK
REPAIR
WARNING
When disconnecting or removing batteries, disconnect the negative lead that connects directly to
the grounding stud first; disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply with this warning can
cause injury to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open applicable access doors.
3.
Replace damaged cable assemblies, terminals, connectors, sockets, and terminal boards.
0100-4
TM 9-6115-644-24
4.
Replace wires with damaged insulation and those that do not indicate continuity.
5.
Connect negative battery cable and close all access doors.
0100
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
High voltage is produced when the generator set is in operation. DO NOT touch live voltage
connections. Never attempt to connect or disconnect load cables or paralleling cables while the
generator set is running. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
components have been heated. Wear additional protective clothing as required. Failure to comply
with this warning can cause injury to personnel.
1.
Position output box wiring harness (WP 0098, Figure 1, Item 27) in output box and generator set.
2.
Install all clamps, as removed, securing output box wiring harness in generator set.
3.
Secure terminal boards (25 and 26) in output box with screws (24) and nuts (23).
4.
Connect electrical leads for droop current transformer (34) to terminal board (25). Remove tags
5.
Connect electrical leads to AC circuit interrupter relay (40), current transformer (31), cranking relay (43),
power potential transformer (37), and voltage reconnection board (18). Install cover (5) with screws (4) on AC
circuit interrupter relay (40). Remove tags and close output box access door.
6.
On left side of engine connect electrical leads to auxiliary fuel pump, fuel level sender, fuel float module,
magnetic pickup, coolant temperature sender, governor actuator, fuel injection pump, oil pressure sender,
low oil pressure switch, DEAD CRANK switch, and coolant high temperature switch. Remove tags and close
left side engine access doors.
7.
On right side of engine connect electrical leads to ether solenoid valve, starter motor, starter solenoid, and
battery charging alternator. Remove tags and close right side engine access doors.
8.
Install output box top panel (WP 0098, Installation, Step 10).
9.
Install control box assembly (WP 0019, Installation).
10. Connect negative battery cable. Close battery access door.
END OF TASK
END OF WORK PACKAGE
0100-5/(6 blank)
TM 9-6115-644-24
0101
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF OUTPUT BOX ASSEMBLY, CURRENT TRANSFORMER: INSPECTION, REMOVAL,
TESTING, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Heat Resistant Gloves & Protective Clothing
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0019, Maintenance of Control Box Assembly,
Control Box Assembly
WP 0098, Steps: 10 & 12 & Figure 1, Item 31
WP 0100, Figure 1, Item 7
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. Make sure generator set is
completely shut down and free of any power source before attempting any repair or maintenance
on the set, or when connecting or disconnecting load cables. Failure to comply with this warning
can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
0101-1
TM 9-6115-644-24
0101
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
WARNING
High voltage is produced when the generator set is in operation. DO NOT touch live voltage
connections. Never attempt to connect or disconnect load cables or paralleling cables while the
generator set is running. Failure to comply with this warning can cause injury or death to
personnel.
INSPECTION
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Ensure nuts on ground terminals are properly secured creating a good ground. Failure to comply
with this warning can cause injury or death to personnel.
WARNING
Shut down generator set before performing inspection of wiring. Failure to comply with this
warning can cause injury or death to personnel.
1.
Shut down generator set.
2.
Open output box access door.
3.
Inspect current transformer (WP 0100, Figure 1, Item 7) for security, cracked housing, broken or stripped
terminals, and loose or missing hardware.
4.
Close output box access door.
END OF TASK
REMOVAL
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box assembly (WP 0019, Removal).
4.
Remove output box top panel (WP 0098, Removal, Step 12).
5.
Open output box and right side engine access doors.
6.
Tag and disconnect current transformer (WP 0098, Figure 1, Item 31) electrical leads.
7.
Tag and disconnect main generator cables T2 and T8 from voltage reconnection board (18).
8.
Unwrap main generator cables from droop current transformer (34) and current transformer (31). Note
number and direction of wraps.
9.
Remove screws (29), flat washers (30), nuts (28), and current transformer (31) from output box.
0101-2
TM 9-6115-644-24
0101
END OF TASK
TESTING
WARNING
When disconnecting or removing batteries, disconnect the negative lead that connects directly to
the grounding stud first; disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply with this warning can
cause injury to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open output box access door.
3.
Tag and disconnect electrical leads from current transformer (WP 0100, Figure 1, Item 7) secondary
terminals.
4.
Remove current transformer (Removal).
5.
Set multimeter for ohms and check for continuity between secondary terminals A1 and A2, B1 and B2, and
C1 and C2.
6.
If continuity is present, connect electrical leads to secondary terminals. Remove tags.
7.
If continuity is not present, current transformer is defective and must be replaced.
8.
Set up a test circuit using 10 gauge wire (Figure 1). Make sure to have ten passes with wire through phase A
window.
9.
Turn on power source and load bank. Adjust load bank until 27.7 amps is indicated on ammeter.
10. Set multimeter for amperes and connect to secondary terminals A1 and A2. Multimeter indication must be 0.9
to 1.1 amps.
11. Repeat Steps 8, 9, and 10 above using phase B window and secondary terminals B1 and B2.
12. Repeat Steps 8, 9, and 10 above using phase C window and secondary terminals C1 and C2.
13. Replace current transformer if multimeter indication in any phase is other than stated in Step 10 above.
14. Remove current transformer from test circuit.
15. Install current transformer (Installation).
Figure 1. Testing Current Transformer.
END OF TASK
0101-3
TM 9-6115-644-24
0101
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
High voltage is produced when the generator set is in operation. DO NOT touch live voltage
connections. Never attempt to connect or disconnect load cables or paralleling cables while the
generator set is running. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
components have been heated. Wear additional protective clothing as required. Failure to comply
with this warning can cause injury to personnel.
1.
Install current transformer (WP 0098, Figure 1, Item 31) with screws (29), flat washers (30), and nuts (28).
2.
Wrap main generator cables around current transformer (31) and droop current transformer (34) using same
number of wraps noted during removal.
3.
Connect main generator cables to voltage reconnection board (18). Remove tags.
4.
Connect electrical leads to current transformer (31). Remove tags. Close output box and right side engine
access doors.
5.
Install output box top panel (WP 0098, Installation, Step 10).
6.
Install control box assembly (WP 0019, Installation).
7.
Connect negative battery cable. Close battery access door.
END OF TASK
END OF WORK PACKAGE
0101-4
TM 9-6115-644-24
0102
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF OUTPUT BOX ASSEMBLY, DROOP CURRENT TRANSFORMER: INSPECTION,
REMOVAL, TESTING, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Heat Resistant Gloves & Protective Clothing
Droop Current Transformer (If multimeter indications
do not comply with testing
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0098, Figure 1, Items: 18 & 34
WP 0100, Figure 1, Item 8
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. Make sure generator set is
completely shut down and free of any power source before attempting any repair or maintenance
on the set, or when connecting or disconnecting load cables. Failure to comply with this warning
can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
0102-1
TM 9-6115-644-24
0102
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
WARNING
High voltage is produced when the generator set is in operation. DO NOT touch live voltage
connections. Never attempt to connect or disconnect load cables or paralleling cables while the
generator set is running. Failure to comply with this warning can cause injury or death to
personnel.
INSPECTION
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Ensure nuts on ground terminals are properly secured creating a good ground. Failure to comply
with this warning can cause injury or death to personnel.
WARNING
Shut down generator set before performing inspection of wiring. Failure to comply with this
warning can cause injury or death to personnel.
1.
Shut down generator set.
2.
Open output box access door.
3.
Inspect droop current transformer (WP 0100, Figure 1, Item 8) for cracked housing, security, broken wire
terminals, loose or missing hardware, and other damage.
4.
Close output box access door.
END OF TASK
REMOVAL
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Open output box and right side engine access doors.
4.
Tag and disconnect main generator cables T2 and T8 from voltage reconnection board (WP 0098, Figure 1,
Item 18).
0102-2
TM 9-6115-644-24
0102
5.
Unwrap main generator cables T2 and T8 from droop current transformer (34). Note number and direction of
wraps.
6.
Tag and disconnect droop current transformer (34) electrical leads from terminal board (25).
7.
Remove screws (33), nuts (32), and droop current transformer (34) from output box.
END OF TASK
TESTING
1.
Remove droop current transformer (Removal).
2.
Set multimeter for ohms and check for continuity between secondary leads 1 and 2.
3.
If continuity is present, continue with test. If continuity is not present, droop current transformer is defective
and must be replaced.
4.
Set up a test circuit using 10 gauge wire (Figure 1). Make ten passes with wire through window of droop
current transformer.
5.
Turn on power supply and load bank. Adjust load bank until 20.8 amps is indicated on AC ammeter.
6.
Set multimeter for AC amperes and connect to secondary leads 1 and 2. Multimeter indication must be
between 0.9 and 1.1 amps.
7.
Replace droop current transformer if multimeter indication is other than above.
8.
Remove droop current transformer from test circuit.
9.
Install droop current transformer (Installation).
Figure 1. Testing Droop Current Transformer.
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
0102-3
TM 9-6115-644-24
0102
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
High voltage is produced when the generator set is in operation. DO NOT touch live voltage
connections. Never attempt to connect or disconnect load cables or paralleling cables while the
generator set is running. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
components have been heated. Wear additional protective clothing as required. Failure to comply
with this warning can cause injury to personnel.
1.
Install droop current transformer (WP 0098, Figure 1, Item 34) in output box with screws (33) and nuts (32).
2.
Wrap main generator cables around droop current transformer (34) using same number of wraps noted
during removal.
3.
Connect main generator cables to voltage reconnection board (18). Remove tags.
4.
Connect droop current transformer (34) electrical leads to terminal board (25). Remove tags. Close output
box and engine access doors.
5.
Connect negative battery cable. Close battery access door.
END OF TASK
END OF WORK PACKAGE
0102-4
TM 9-6115-644-24
0103
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF OUTPUT BOX ASSEMBLY, POWER POTENTIAL TRANSFORMER: INSPECTION,
REMOVAL, TESTING, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Heat Resistant Gloves & Protective Clothing
Power Potential Transformer (If readings do not
comply with Testing)
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0019, Maintenance of Control Box Assembly,
Control Box Assembly
WP 0098, Steps: 10 & 12 & Figure 1, Item 37
WP 0100, Figure 1, Item 8
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. Make sure generator set is
completely shut down and free of any power source before attempting any repair or maintenance
on the set, or when connecting or disconnecting load cables. Failure to comply with this warning
can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
0103-1
TM 9-6115-644-24
0103
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
WARNING
High voltage is produced when the generator set is in operation. DO NOT touch live voltage
connections. Never attempt to connect or disconnect load cables or paralleling cables while the
generator set is running. Failure to comply with this warning can cause injury or death to
personnel.
INSPECTION
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Shut down generator set before performing inspection of wiring. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
Ensure nuts on ground terminals are properly secured creating a good ground. Failure to comply
with this warning can cause injury or death to personnel.
1.
Shut down generator set.
2.
Open output box access door.
3.
Inspect power potential transformer (WP 0100, Figure 1, Item 9) for security, cracked housing, broken wire
terminals, loose or missing hardware, and other damage.
4.
Close output box access door.
END OF TASK
REMOVAL
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box assembly (WP 0019, Removal).
4.
Remove output box top panel (WP 0098, Removal, Step 12).
5.
Tag and disconnect power potential transformer (WP 0098, Figure 1, Item 37) electrical leads.
0103-2
TM 9-6115-644-24
6.
Remove screws (36), nuts (35), and power potential transformer (37) from output box.
END OF TASK
TESTING
Power Potential Transformer, P/N 17910
1.
Remove power potential transformer (WP 0098, Figure 1, Item 37) (Removal).
2.
Connect terminals 1 and 2 of power potential transformer (37) to an AC power source (polarity is not
important).
3.
Set power supply for 208 VAC, 60 Hz. Turn on power supply.
4.
Set multimeter for AC volts and take readings between the following terminals and compare to voltages
shown:
Terminals 3 and 7 = 144-176 VAC
Terminals 4 and 6 = 27-33 VAC
5.
Replace power potential transformer (37) if readings are not as voltages above.
6.
Install power potential transformer (37) (Installation).
END OF TASK
Power Potential Transformer, P/N A1497B, for MEP-805A
1.
Remove power potential transformer (WP 0098, Figure 1, Item 37) (Removal).
2.
Connect terminals 1 and 2 of power potential transformer (37) to an AC power source (polarity is not
important).
3.
Set power supply at 208 VAC, 60 Hz. Turn on power supply.
4.
Set multimeter for AC volts and take readings between the following terminals and compare to voltages
shown:
Terminals 5 and 6 = 54-66 VAC
Terminals 5 and 4 = 54-66 VAC
Terminals 5 and 3 = 126-154 VAC
Terminals 5 and 7 = 126-154 VAC
5.
Replace power potential transformer (37) if readings are not as above.
6.
Install power potential transformer (37) (Installation).
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
0103-3
0103
TM 9-6115-644-24
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
High voltage is produced when the generator set is in operation. DO NOT touch live voltage
connections. Never attempt to connect or disconnect load cables or paralleling cables while the
generator set is running. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
components have been heated. Wear additional protective clothing as required. Failure to comply
with this warning can cause injury to personnel.
1.
Install power potential transformer (WP 0098, Figure 1, Item 37) with screws (36) and nuts (35).
2.
Connect electrical leads and remove tags.
3.
Install output box top panel (WP 0098, Installation, Step 10).
4.
Install control box assembly (WP 0019, Installation).
5.
Connect negative battery cable. Close battery access door.
END OF TASK
END OF WORK PACKAGE
0103-4
0103
TM 9-6115-644-24
0104
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF OUTPUT BOX ASSEMBLY, AC CIRCUIT INTERRUPTER RELAY: INSPECTION,
TESTING, REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
References
WP 0100, Figure 1, Items: 10 & 14
Equipment Condition
Grounded, Off & Operational
INSPECTION
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure nuts on ground terminals are properly secured creating a good ground. Failure to comply
with this warning can cause injury or death to personnel.
WARNING
Shut down generator set before performing inspection of wiring. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
0104-1
TM 9-6115-644-24
0104
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open output box access door.
3.
Inspect AC circuit interrupter relay (WP 0100, Figure 1, Item 14) for security, cracked housing, broken wire
terminals, and other damage.
4.
Close output box access door.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open output box access door.
3.
Set multimeter for ohms and check for open circuits between terminals A1 and A2, B1 and B2, C1 and C2,
and 11 and 12.
4.
Connect jumper wire from cranking relay terminal A1 to AC circuit interrupter relay terminal X.
5.
Connect negative battery cable.
6.
Check for closed circuits (continuity) between terminals A1 and A2, B1 and B2, C1 and C2, and 11 and 12.
7.
Disconnect negative battery cable.
8.
Replace AC circuit interrupter relay if indications are other than above.
9.
If replacement is not needed, remove jumper wire and close output box access door.
10. Connect negative battery cable and close battery access door.
END OF TASK
REMOVAL
WARNING
When disconnecting or removing batteries, disconnect the negative lead that connects directly to
the grounding stud first; disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply with this warning can
cause injury to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open output box access door.
3.
Remove screws (WP 0100, Figure 1, Item 10) and cover (11) from AC circuit interrupter relay (14).
4.
Tag and disconnect AC circuit interrupter relay (14) electrical leads.
5.
Remove screws (13), nuts (12), and AC circuit interrupter relay (14) from output box.
END OF TASK
INSTALLATION
1.
Install AC circuit interrupter relay (WP 0100, Figure 1, Item 14) in output box with screws (13) and nuts (12).
2.
Connect AC circuit interrupter relay (14) electrical leads. Remove tags.
3.
Install cover (11) on AC circuit interrupter relay (14) with screws (10).
0104-2
TM 9-6115-644-24
4.
Close output box access door, connect negative battery cable, and close battery access door.
END OF TASK
END OF WORK PACKAGE
0104-3/(4 blank)
0104
TM 9-6115-644-24
0105
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF OUTPUT BOX ASSEMBLY, CRANKING RELAY: INSPECTION, TESTING, REMOVAL,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
References
WP 0100, Figure 1, Items: 17
Equipment Condition
Grounded, Off & Operational
INSPECTION
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure nuts on ground terminals are properly secured creating a good ground. Failure to comply
with this warning can cause injury or death to personnel.
WARNING
Shut down generator set before performing inspection of wiring. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
0105-1
TM 9-6115-644-24
0105
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open output box and right side engine access doors.
3.
Inspect cranking relay (WP 0100, Figure 1, Item 17) for security, cracked housing, broken wire terminals, and
other damage.
4.
Close all access doors.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open output box access door.
3.
Tag and disconnect wires from terminals X1, X2, and A2 of cranking relay (WP 0100, Figure 1, Item 17).
4.
Connect a jumper wire between terminals A1 and X1 of cranking relay (17).
5.
Connect negative battery cable.
6.
Connect X2 wire disconnected in Step 3 above to cranking relay (17) and listen for audible actuation.
7.
Set multimeter for ohms and check for continuity between terminals A1 and A2 of cranking relay (17). If no
continuity is indicated, cranking relay (17) is defective and must be replaced.
8.
If replacement is not needed, disconnect negative battery cable.
9.
Remove jumper wire and connect remaining wires to cranking relay (17) as tagged.
10. Close output box access door, connect negative battery cable, and close battery access door.
END OF TASK
REMOVAL
WARNING
When disconnecting or removing batteries, disconnect the negative lead that connects directly to
the grounding stud first; disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply with this warning can
cause injury to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open output box and right side engine
access doors.
3.
Tag and disconnect cranking relay (WP 0100, Figure 1, Item 17) electrical leads.
4.
Remove screws (16), nuts (15), and cranking relay (17) from output box.
END OF TASK
INSTALLATION
0105-2
TM 9-6115-644-24
WARNING
When disconnecting or removing batteries, disconnect the negative lead that connects directly to
the grounding stud first; disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply with this warning can
cause injury to personnel.
1.
Install cranking relay (WP 0100, Figure 1, Item 17) with screws (16) and nuts (15).
2.
Connect cranking relay (17) electrical leads. Remove tags.
3.
Close output box and right side engine access doors, connect negative battery cable, and close battery
access door.
END OF TASK
END OF WORK PACKAGE
0105-3/(4 blank)
0105
TM 9-6115-644-24
0106
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF OUTPUT BOX ASSEMBLY, LOAD OUTPUT TERMINAL BOARD: REMOVAL,
INSPECTION, REPAIR, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
New Lockwashers
Antiseize Compound
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0018, Maintenance of Control Box Assembly,
Rear Housing Section
WP 0107, Maintenance of Output Box Assembly,
Load Output Terminals
WP 0108, Maintenance of Output Box Assembly,
Varistors
WP 0159, Item 7
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure nuts on ground terminals are properly secured creating a good ground. Failure to comply
with this warning can cause injury or death to personnel.
WARNING
Shut down generator set before performing inspection of wiring. Failure to comply with this
warning can cause injury or death to personnel.
0106-1
TM 9-6115-644-24
0106
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open load terminal board access door.
3.
Disconnect load output cables L1, L2, L3, and L0 from load output terminal board.
4.
Remove generator set housing rear panel (WP 0018, Removal).
5.
Remove bolt (Figure 1, Item 1), nut (2), flat washer (3), and lockwasher (4) securing ground strap (15) to skid
base. Discard lockwasher (4).
6.
Remove bolts (5), lockwashers (6), and washers (7) securing terminal board assembly (12) to supports.
Discard lockwashers (6)
7.
Remove nuts (8) and washers (9). Tag and disconnect all main power leads (10) and varistor leads (11) from
load terminals (23).
8.
Remove terminal board assembly (12) from generator set.
9.
Remove load output terminals (WP 0107, Removal).
10. Remove EMI filter (24) positioned between L0 and GND terminals (23).
11. Remove varistor leads (11) from varistors (27). Remove varistors (27) (WP 0108, Removal).
12. Remove EMI filters (28) positioned between load terminals (23) and varistors (27).
13. Remove nuts (13), washers (14), ground strap (15), studs (16), bus bars (17 and 22), and ground plane bar
(29) from terminal board (12).
14. Remove nuts (18) and washers (19) from studs (16).
15. Remove bolts (30), nuts (31), and load output terminal board supports (32 and 33) from generator set.
16. Remove nuts (34), bolts (35), cord (36), wrench (37), and bracket (38) from support (33).
END OF TASK
INSPECTION
1.
Shut down generator set.
2.
Open load terminal board access door.
3.
Inspect load output terminal board for cracks, corrosion, and obvious damage.
4.
Inspect threaded components for stripped threads.
5.
Inspect varistor electrical leads for damaged insulation and loose terminals.
6.
Replace damaged and defective parts.
7.
Close load terminal board access door.
END OF TASK
REPAIR
0106-2
TM 9-6115-644-24
0106
WARNING
When disconnecting or removing batteries, disconnect the negative lead that connects directly to
the grounding stud first; disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply with this warning can
cause injury to personnel.
Repair load output terminal board assembly by replacing damaged or defective wires, load terminals, EMI filters,
and varistors.
END OF TASK
INSTALLATION
1.
Install load output terminal board supports (Figure 1, Items 32 and 33) in generator set with bolts (30) and
nuts (31).
2.
Install ground plane bar (29), bus bars (17 and 22), and ground strap (15) on terminal board (12) with studs
(16), washers (14 and 19), and nuts (13 and 18).
3.
Position EMI filters (28) between varistors (27) and L1, L2, and L3 load terminals (23) mounting holes.
4.
Install varistors (27) (WP 0108, Installation).
5.
Position EMI filter (24) between L0 and GND terminals (23) mounting holes.
6.
Install load terminals (WP 0107, Installation).
7.
Connect leads (11) to varistors (27).
8.
Position load output terminal board assembly in generator set and connect varistor leads (11) and main
power leads (10) to load terminals (23) with washers (9) and nuts (8). Remove tags.
9.
Secure terminal board assembly (12) to supports (32 and 33) with washers (7), new lockwashers (6), and
bolts (5).
10. Apply a thin coat of antiseize compound (WP 0159, Item 7) to skid at ground strap (15) attaching point.
11. Install bolt (1), flat washer (3), new lockwasher (4), and nut (2) securing ground strap (15) to skid base.
12. Install bracket (38), wrench (37), and cord (36) on support (33) with bolts (35) and nuts (34).
13. Install generator set housing rear panel (WP 0018, Installation).
14. Connect load output cables L1, L2, L3, and L0 at load output terminal board and close load terminal access
door.
15. Connect negative battery cable and close battery access door.
0106-3
TM 9-6115-644-24
Figure 1. Load Terminal Board Assembly.
END OF TASK
END OF WORK PACKAGE
0106-4
0106
TM 9-6115-644-24
0107
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF OUTPUT BOX ASSEMBLY, LOAD OUTPUT TERMINALS: REMOVAL, INSPECTION,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
References
WP 0106, Maintenance of Output Box Assembly,
Load Output Terminal Board
Equipment Condition
Grounded, Off & Operational
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure nuts on ground terminals are properly secured creating a good ground. Failure to comply
with this warning can cause injury or death to personnel.
WARNING
Shut down generator set before performing inspection of wiring. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
0107-1
TM 9-6115-644-24
0107
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Open load terminal board access door and disconnect load cables.
4.
Remove load output terminal board assembly from generator set (WP 0106, Removal).
5.
Remove nuts (WP 0106, Figure 1, Item 20), copper washers (21), and load terminals (23) from terminal
board assembly (12).
END OF TASK
INSPECTION
1.
Shut down generator set.
2.
Open load terminal board access door.
3.
Inspect load terminals for stripped threads and other obvious damage.
4.
Replace damaged load terminals, as necessary.
5.
Close load terminal board access door.
END OF TASK
INSTALLATION
1.
Install load output terminals (WP 0106, Figure 1, Item 23) on load output terminal board assembly (12) with
copper washers (21) and nuts (20).
2.
Install load output terminal board assembly in generator set (WP 0106, Installation).
NOTE
Ensure GND load terminal passes through ground plane bracket (29) and L0 load terminal
passes through bus bar (22).
3.
Connect load cables and close load terminal board access door.
4.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0107-2
TM 9-6115-644-24
0108
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF OUTPUT BOX ASSEMBLY, VARISTORS: REMOVAL, TEST AND INSPECTION,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
References
WP 0106, Maintenance of Output Box Assembly,
Load Output Terminal Board
Equipment Condition
Grounded, Off & Operational
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure nuts on ground terminals are properly secured creating a good ground. Failure to comply
with this warning can cause injury or death to personnel.
WARNING
Shut down generator set before performing inspection of wiring. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
0108-1
TM 9-6115-644-24
0108
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove load output terminal board assembly from generator set (WP 0106, Removal).
4.
Tag and disconnect varistor leads (WP 0106, Figure 1, Item 11) from varistors (27).
5.
Remove nuts (26), bolts (25), and varistors (27) from load terminal board assembly (12).
END OF TASK
TEST AND INSPECTION
1.
Shut down generator set.
2.
Remove varistors (Removal).
3.
Inspect varistors (WP 0106, Figure 1, Item 27) for obvious external damage.
4.
Set multimeter for ohms and test each varistor (27) by connecting multimeter to varistor terminals 1 and 2.
Note multimeter indication.
5.
Reverse multimeter leads and note multimeter indication.
6.
Multimeter indications should be infinite ohms in both directions.
7.
Varistors (27) are defective and must be replaced if indications are other than above.
8.
Install varistors (Installation).
END OF TASK
INSTALLATION
1.
Install varistors (WP 0106, Figure 1, Item 27) on load output terminal board assembly (12) with bolts (25) and
nuts (26).
2.
Connect varistor leads (11) to varistors (27). Remove tags.
3.
Install load output terminal board assembly in generator set (WP 0106, Installation).
4.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0108-2
TM 9-6115-644-24
0109
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF OUTPUT BOX ASSEMBLY, OUTPUT BOX PANELS: INSPECTION, REMOVAL, REPAIR,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
CARC Paint
Protective Eyewear, Mask & Gloves/Heat Resistant
Gloves
Fine Grit Abrasive Paper
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
TM 43-0139
WP 0013, Maintenance of DC Electrical System,
NATO Slave Receptacle
WP 0017, Maintenance of Housing, Front Housing
Section
WP 0018, Maintenance of Control Box Assembly,
Rear Housing Sections
WP 0072, Maintenance of Air Intake & Exhaust
System, Air Restriction Indicator
WP 0097, Figure 1, Items: 2, 3, 46, 47, 48, 49, 50 &
51
WP 0098, Maintenance of Output Box Assembly,
Output Box Assembly
WP 0099, Maintenance of Output Box Assembly,
Voltage Reconnection Terminal Board
WP 0100, Maintenance of Output Box Assembly,
Output Box Wiring Harness
WP 0101,Maintenance of Output Box Assembly,
Current Transformer
WP 0102,Maintenance of Output Box Assembly,
Droop Current Transformer
WP 0159, Item 17
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. Make sure generator set is
completely shut down and free of any power source before attempting any repair or maintenance
on the set, or when connecting or disconnecting load cables. Failure to comply with this warning
can cause injury or death to personnel.
0109-1
TM 9-6115-644-24
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
WARNING
High voltage is produced when the generator set is in operation. DO NOT touch live voltage
connections. Never attempt to connect or disconnect load cables or paralleling cables while the
generator set is running. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
INSPECTION
1.
Inspect output box panels (WP 0097, Figure 1, Items 3, 46, 47, and 51) for cracks, dents, loose paint,
corrosion, and other damage.
2.
Inspect grommets (48, 49, and 50); door seal (52); and electromagnetic interference (EMI) seal (53) for
looseness, tears, deterioration, and other damage.
END OF TASK
REMOVAL
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove control box assembly (WP 0018, Removal).
4.
Remove generator housing rear panel (WP 0017, Removal).
5.
Remove output box access door (WP 0013, Removal).
0109-2
0109
TM 9-6115-644-24
6.
Remove air cleaner assembly (WP 0072, Removal).
7.
Remove bolts (WP 0097, Figure 1, Item 2), nuts (1), and output box top panel (3).
8.
Remove voltage reconnection terminal board (WP 0098, Removal).
9.
Remove droop current transformer (WP 0101, Removal).
0109
10. Remove power potential transformer (WP 0102, Removal).
11. Remove current transformer (WP 0100, Removal).
12. Remove output box wiring harness (WP 0099, Removal).
13. Remove nuts (38), screws (39), and AC circuit interrupter relay (40).
14. Remove nuts (41), screws (42), and cranking relay (43).
15. Remove nuts (6), bolts (7), and output box panels from generator set.
16. Remove bolts (45), nuts (44), and output box side panels (46 and 47) from output box bottom panel (51).
17. Remove grommets (48, 49, and 50) from output box panels (3 and 51).
18. Remove door seal (52) and EMI seal (53) from output box top panel (3), if necessary.
END OF TASK
REPAIR
WARNING
CARC paint is a health hazard, and is irritating to eyes, skin, and respiratory system. Wear
protective eyewear, mask, and gloves when applying or removing CARC paint. Failure to comply
with this warning can cause injury to personnel.
1.
Repair all dents and cracks and remove all loose paint.
2.
Remove light corrosion with fine grit abrasive paper (WP 0158, Item 17).
3.
Replace damaged seals and grommets.
4.
Repaint surfaces in accordance with TM 43-0139. (F) Refer to applicable directives.
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
0109-3
TM 9-6115-644-24
0109
WARNING
High voltage is produced when the generator set is in operation. DO NOT touch live voltage
connections. Never attempt to connect or disconnect load cables or paralleling cables while the
generator set is running. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
components have been heated. Wear additional protective clothing as required. Failure to comply
with this warning can cause injury to personnel.
1.
Install grommets (WP 0097, Figure 1, Items 48, 49, and 50) in output box panels (3 and 51).
2.
Install output box side panels (46 and 47) on output box bottom panel (51) with bolts (45) and nuts (44).
3.
Install output box panels in generator set with bolts (7) and nuts (6).
4.
Install cranking relay (43) with screws (42) and nuts (41).
5.
Install AC circuit interrupter relay (40) with screws (39) and nuts (38).
6.
Install current transformer (WP 0100, Installation).
7.
Install power potential transformer (WP 0102, Installation).
8.
Install droop current transformer (WP 0101, Installation).
9.
Install voltage reconnection terminal board (WP 0098, Installation).
10. Install output box wiring harness (WP 0099, Installation).
11. Install air cleaner assembly (WP 0072, Installation).
12. Install output box top panel (3) with bolts (2) and nuts (1).
13. If removed, install self-adhesive door seal (52) and EMI seal (53) with adhesive (WP 0158, Item 2) on output
box top panel (3).
14. Install output box access door (WP 0013, Installation).
15. Install generator housing rear panel (WP 0017, Installation).
16. Install control box assembly (WP 0018, Installation).
17. Connect negative battery cable. Close battery access door.
END OF TASK
END OF WORK PACKAGE
0109-4
TM 9-6115-644-24
0110
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF ENGINE ACCESSORIES, LOW OIL PRESSURE SWITCH: TESTING, REMOVAL,
CLEANING AND INSPECTION, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Heat Resistant Gloves
Eye Protection
Cleaning Cloth
Dry Cleaning Solvent
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0159, Items: 9 & 21
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
TESTING
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Ensure nuts on ground terminals are properly secured creating a good ground. Failure to comply
with this warning can cause injury or death to personnel.
WARNING
Shut down generator set before performing inspection of wiring. Failure to comply with this
warning can cause injury or death to personnel.
0110-1
TM 9-6115-644-24
0110
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open left side engine access doors.
3.
Tag and disconnect electrical leads from low oil pressure switch (Figure 1, Item 1).
4.
Set multimeter for ohms and connect across switch connector pins C and NO. Multimeter shall indicate open
circuit.
5.
Connect multimeter to switch connector pins C and NC. Multimeter shall indicate continuity.
6.
Connect negative battery cable.
7.
Start generator set. Place BATTLE SHORT switch in ON position before releasing MASTER SWITCH from
START position.
8.
Connect multimeter to switch connector pins C and NC. Multimeter shall indicate open circuit.
9.
Connect multimeter to switch connector pins C and NO. Multimeter shall indicate continuity.
10. Shut down generator set. Return BATTLE SHORT switch to OFF position.
11. Disconnect negative battery cable.
12. If switch fails to meet continuity requirements, replace low oil pressure switch (1).
13. If replacement is not needed, connect electrical leads to low oil pressure switch (1). Remove tags and close
left side engine access doors.
14. Connect negative battery cable and close battery access door.
END OF TASK
REMOVAL
WARNING
The high pressure oil system operates at high temperature and pressure. Contact with hot oil can
result in burns and scalding. Shut down generator set, and allow system to cool before
performing checks, services, and maintenance. Wear heat resistant gloves and avoid contacting
hot surfaces. Do not allow hot oil or components to contact skin or hands. Failure to comply with
this warning can cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open left side engine access doors.
3.
Tag and disconnect low oil pressure switch (Figure 1, Item 1) electrical leads.
4.
Unscrew low oil pressure switch (1) from oil sample valve assembly.
END OF TASK
CLEANING AND INSPECTION
1.
Shut down generator set.
0110-2
TM 9-6115-644-24
2.
0110
Remove low oil pressure switch (Figure 1, Item 1) (Removal).
WARNING
Eye protection is required when working with compressed air. Compressed air can propel
particles at high velocity and injure eyes. Do not exceed 15 psi pressure when using compressed
air. Failure to comply with this warning can cause injury to personnel.
WARNING
Cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye
protection are required when working in contact with cleaning solvent. Avoid repeated or
prolonged contact. Work in ventilated area only. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
Solvent used to clean parts is potentially dangerous to personnel and property. Clean parts in a
well-ventilated area. Avoid inhalation of solvent fumes. Wear goggles and rubber gloves to
protect eyes and skin. Wash exposed skin thoroughly. Do not smoke or use near open flame or
excessive heat. Failure to comply with this warning can cause injury to personnel, and damage to
the equipment.
3.
Clean low oil pressure switch (1) with dry, filtered compressed air and wipe with a cleaning cloth (WP 0159,
Item 9) lightly moistened with dry cleaning solvent (WP 0159, Item 21).
4.
Inspect low oil pressure switch (1) for cracked casing, stripped or damaged threads, corrosion, or other
damage.
5.
If no repair is needed, install low oil pressure switch (1) (Installation).
END OF TASK
INSTALLATION
1.
Install low oil pressure switch (Figure 1, Item 1) into oil sample valve assembly.
2.
Connect electrical leads. Remove tags and close left side engine access doors.
3.
Connect negative battery cable and close battery access door.
END OF TASK
0110-3
TM 9-6115-644-24
Figure 1. Engine Switches and Senders.
END OF WORK PACKAGE
0110-4
0110
TM 9-6115-644-24
0111
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF ENGINE ACCESSORIES, OIL PRESSURE SENDER: TESTING, REMOVAL, CLEANING
AND INSPECTION, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Heat Resistant Gloves & Goggles
Cleaning Cloth
Dry Cleaning Solvent
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0110, Figure 1, Item 2)
WP 0159, Item 21)
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
TESTING
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Shut down generator set before performing inspection of wiring. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
0111-1
TM 9-6115-644-24
0111
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open left side engine access doors.
3.
Disconnect electrical lead to oil pressure sender (WP 0110, Figure 1, Item 2).
4.
Set multimeter for ohms and connect between sender terminal and casing.
5.
Multimeter indication shall be between 216 and 264 ohms.
6.
Connect negative battery cable.
7.
Start generator set.
8.
As engine is cranking and accelerates to rated speed, observe multimeter. Indication shall decrease to
between 100 and 33 ohms.
9.
Shut down generator set and disconnect negative battery cable.
10. Replace oil pressure sender (2) if indications are not as above.
11. If replacement is not needed, connect electrical lead to oil pressure sender (2).
12. Close left side engine access doors, connect negative battery cable, and close battery access door.
END OF TASK
REMOVAL
WARNING
The high pressure oil system operates at high temperature and pressure. Contact with hot oil can
result in burns and scalding. Shut down generator set, and allow system to cool before
performing checks, services, and maintenance. Wear heat resistant gloves and avoid contacting
hot surfaces. Do not allow hot oil or components to contact skin or hands. Failure to comply with
this warning can cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open left side engine access doors.
3.
Disconnect oil pressure sender (WP 0110, Figure 1, Item 2) electrical lead.
4.
Unscrew and remove oil pressure sender (2) from engine block.
END OF TASK
CLEANING AND INSPECTION
1.
Shut down generator set.
2.
Remove oil pressure sender (WP 0110, Figure 1, Item 2) (Removal).
3.
Clean oil pressure sender (2) with dry, filtered compressed air and wipe with a cleaning cloth (WP 0159, Item
9) lightly moistened with dry cleaning solvent (WP 0159, Item 21).
WARNING
Cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye
protection are required when working in contact with cleaning solvent. Avoid repeated or
prolonged contact. Work in ventilated area only. Failure to comply with this warning can cause
injury or death to personnel.
0111-2
TM 9-6115-644-24
0111
WARNING
Solvent used to clean parts is potentially dangerous to personnel and property. Clean parts in a
well-ventilated area. Avoid inhalation of solvent fumes. Wear goggles and rubber gloves to
protect eyes and skin. Wash exposed skin thoroughly. Do not smoke or use near open flame or
excessive heat. Failure to comply with this warning can cause injury to personnel, and damage to
the equipment.
WARNING
Eye protection is required when working with compressed air. Compressed air can propel
particles at high velocity and injure eyes. Do not exceed 15 psi pressure when using compressed
air. Failure to comply with this warning can cause injury to personnel.
4.
Inspect oil pressure sender (2) for cracked casing, stripped or damaged threads, corrosion, or other visible
damage.
5.
If no repair is needed, install oil pressure sender (2) into engine block (Installation).
END OF TASK
INSTALLATION
1.
Screw oil pressure sender (WP 0110, Figure 1, Item 2) into engine block.
2.
Connect electrical lead and close left side engine access doors.
3.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0111-3/(4 blank)
TM 9-6115-644-24
0112
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF ENGINE ACCESSORIES, COOLANT TEMPERATURE SENDER: TESTING, REMOVAL,
CLEANING AND INSPECTION, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Gloves, Protective Clothing & Eyewear
Coolant Temperature Sender (If indications do not
comply with testing)
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0076, Figure 1, Item 1
WP 0078, Figure 1, Item 28
WP 0110, Figure 1, Items: 3 & 4
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
TESTING
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Shut down generator set before performing inspection of wiring. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
0112-1
TM 9-6115-644-24
0112
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open left side engine access doors.
3.
Disconnect electrical lead from coolant temperature sender (WP 0110, Figure 1, Item 4).
4.
Set multimeter for ohms and connect positive lead to temperature sender terminal and negative lead to case.
Multimeter indication shall be greater than 300 ohms.
5.
Connect negative battery cable and start generator set.
6.
Allow the engine to operate while observing multimeter.
7.
Ohms indication should decrease as temperature rises.
8.
Shut down generator set and disconnect negative battery cable.
9.
Replace coolant temperature sender (4) if indications are not as above.
10. If replacement is not needed, connect electrical lead to sender.
11. Close left side engine access doors, connect negative battery cable and close battery access door.
END OF TASK
REMOVAL
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
WARNING
Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool
before performing checks, services and maintenance, or wear gloves and additional protective
clothing and goggles as required. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Always remove radiator cap slowly to permit any pressure to escape. Failure to comply with this
warning can cause injury to personnel.
3.
Slowly remove radiator cap (WP 0076, Figure 1, Item 1).
4.
Open left side engine access doors, open engine block drain valve (WP 0110, Figure 1, Item 3), and drain
coolant into suitable container. Close drain valve (3).
5.
Disconnect coolant temperature sender (4) electrical lead and unscrew coolant temperature sender (4) from
engine head.
END OF TASK
CLEANING AND INSPECTION
1.
Shut down generator set.
2.
Remove coolant temperature sender (WP 0110, Figure 1, Item 4) (Removal).
3.
Clean temperature sender with dry, filtered compressed air and cleaning cloth (WP 0159, Item 9) lightly
moistened with dry cleaning solvent (WP 0159, Item 21).
0112-2
TM 9-6115-644-24
WARNING
Cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye
protection are required when working in contact with cleaning solvent. Avoid repeated or
prolonged contact. Work in ventilated area only. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
Solvent used to clean parts is potentially dangerous to personnel and property. Clean parts in a
well-ventilated area. Avoid inhalation of solvent fumes. Wear goggles and rubber gloves to
protect eyes and skin. Wash exposed skin thoroughly. Do not smoke or use near open flame or
excessive heat. Failure to comply with this warning can cause injury to personnel, and damage to
the equipment.
WARNING
Eye protection is required when working with compressed air. Compressed air can propel
particles at high velocity and injure eyes. Do not exceed 15 psi pressure when using compressed
air. Failure to comply with this warning can cause injury to personnel.
4.
Inspect temperature sender for cracked casing, corrosion, and damaged threads and connector.
5.
If no repair is needed, install coolant temperature sender (4) (Installation).
END OF TASK
INSTALLATION
1.
Install coolant temperature sender (WP 0110, Figure 1, Item 4) in engine head. Connect electrical lead.
2.
Add coolant to overflow bottle (WP 0078, Figure 1, Item 28), as necessary, to replace drained coolant.
3.
Close left side engine access doors, connect negative battery cable, and close battery access door.
END OF TASK
END OF WORK PACKAGE
0112-3/(4 blank)
0112
TM 9-6115-644-24
0113
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF ENGINE ACCESSORIES, COOLANT HIGH TEMPERATURE SWITCH: TESTING,
REMOVAL, CLEANING AND INSPECTION, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
foo tools name
foo tools partno (EIC: N/A)
NSN:0000-00-000-0000 (EIC: N/A) (2)
Materials/Parts
Gloves & Protective Clothing
Suitable Container For Coolant
Cleaning Cloth
Dry Cleaning Solvent
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0076, Figure 1, Item 1
WP 0078, Figure 1, Item 28
WP 0110, Figure 1, Items: 3 & 5
WP 0159, Items: 9 & 21
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
TESTING
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
Shut down generator set before performing inspection of wiring. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
0113-1
TM 9-6115-644-24
0113
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Remove coolant high temperature switch (WP 0110, Figure 1, Item 5) (Removal).
3.
Suspend coolant high temperature switch (5) in a container of 50/50 mixture of antifreeze and water so that
sensing element is completely immersed but not touching sides or bottom of container.
4.
Suspend a reliable thermometer in container. Do not allow end of thermometer to rest on bottom of container.
5.
Set multimeter for ohms and check for continuity between switch terminals. Switch operates under open
conditions.
6.
Gradually heat antifreeze/water mixture, stirring so that heat will be evenly distributed and observe
thermometer and multimeter.
7.
At between 220 °F and 230 °F (101 °C and 107 °C), multimeter should indicate continuity.
8.
Replace coolant high temperature switch (5) if it fails to operate as above.
9.
If replacement is not needed, install coolant high temperature switch (5) (Installation).
END OF TASK
REMOVAL
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
WARNING
Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool
before performing checks, services and maintenance, or wear gloves and additional protective
clothing and goggles as required. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Always remove radiator cap slowly to permit any pressure to escape. Failure to comply with this
warning can cause injury to personnel.
3.
Slowly remove radiator cap (WP 0076, Figure 1, Item 1).
4.
Open left side engine access doors, open engine block drain valve (WP 0110, Figure 1, Item 3), and drain
coolant into suitable container. Close drain valve (3).
5.
Tag and disconnect coolant high temperature switch (5) electrical leads.
6.
Unscrew coolant high temperature switch (5) from lower thermostat housing.
END OF TASK
CLEANING AND INSPECTION
1.
Shut down generator set.
2.
Remove coolant high temperature switch (WP 0110, Figure 1, Item 5) (Removal).
0113-2
TM 9-6115-644-24
0113
WARNING
Cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye
protection are required when working in contact with cleaning solvent. Avoid repeated or
prolonged contact. Work in ventilated area only. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
Solvent used to clean parts is potentially dangerous to personnel and property. Clean parts in a
well-ventilated area. Avoid inhalation of solvent fumes. Wear goggles and rubber gloves to
protect eyes and skin. Wash exposed skin thoroughly. Do not smoke or use near open flame or
excessive heat. Failure to comply with this warning can cause injury to personnel, and damage to
the equipment.
WARNING
Eye protection is required when working with compressed air. Compressed air can propel
particles at high velocity and injure eyes. Do not exceed 15 psi pressure when using compressed
air. Failure to comply with this warning can cause injury to personnel.
3.
Clean coolant high temperature switch (5) with dry, filtered compressed air and cleaning cloth (WP 0159,
Item 9) lightly moistened with dry cleaning solvent (WP 0159, Item 21).
4.
Inspect coolant high temperature switch (5) for cracked casing, corrosion, stripped or damaged threads, and
bent or broken connector pins.
5.
If no repair is needed, install coolant high temperature switch (5) (Installation).
END OF TASK
INSTALLATION
1.
Install coolant high temperature switch (WP 0110, Figure 1, Item 5) in lower thermostat housing.
2.
Connect electrical leads; remove tags.
3.
Add coolant to overflow bottle (WP 0078, Figure 1, Item 28), as necessary, to replace drained coolant.
4.
Close left side engine access doors, connect negative battery cable, and close battery access door.
END OF TASK
END OF WORK PACKAGE
0113-3/(4 blank)
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF ENGINE ACCESSORIES, MAGNETIC PICKUP: REMOVAL, CLEANING AND
INSPECTION, INSTALLATION, ADJUSTMENT
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Protective Eyewear, Clothing & Gloves
Cleaning Cloth
Dry Cleaning Solvent
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0043, Figure 1, Item 56
WP 0110, Figure 1, Item: 6, 7 & 11
WP 0159, Items: 9 & 21
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Shut down generator set before performing inspection of wiring. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
0114-1
0114
TM 9-6115-644-24
0114
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open left side engine access doors.
3.
Tag and disconnect magnetic pickup (WP 0110, Figure 1, Item 6) electrical leads.
4.
Loosen locknut (6A) and remove magnetic pickup (6) and reducer bushing (7) from flywheel housing.
END OF TASK
CLEANING AND INSPECTION
1.
Shut down generator set.
2.
Remove magnetic pickup (WP 0110, Figure 1, Item 6) (Removal).
WARNING
Cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye
protection are required when working in contact with cleaning solvent. Avoid repeated or
prolonged contact. Work in ventilated area only. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
Solvent used to clean parts is potentially dangerous to personnel and property. Clean parts in a
well-ventilated area. Avoid inhalation of solvent fumes. Wear goggles and rubber gloves to
protect eyes and skin. Wash exposed skin thoroughly. Do not smoke or use near open flame or
excessive heat. Failure to comply with this warning can cause injury to personnel, and damage to
the equipment.
WARNING
Eye protection is required when working with compressed air. Compressed air can propel
particles at high velocity and injure eyes. Do not exceed 15 psi pressure when using compressed
air. Failure to comply with this warning can cause injury to personnel.
3.
Clean magnetic pickup (6) with dry, filtered compressed air and wipe with a cleaning cloth (WP 0159, Item 9)
lightly moistened with dry cleaning solvent (WP 0159, Item 21).
4.
Inspect magnetic pickup (6) for cracked casing, stripped or damaged threads, corrosion, or other visible
damage.
5.
If no repair is needed, install magnetic pickup (6) (Installation).
END OF TASK
INSTALLATION
1.
Install reducer bushing (WP 0110, Figure 1, Item 7) into flywheel housing. Screw magnetic pickup (6) into
reducer bushing (7) until contact is made with top surface of gear tooth on flywheel. Back magnetic pickup
(6) off one complete revolution and tighten locknut (6A).
2.
Connect electrical leads; remove tags.
3.
Connect negative battery cable and close battery access door.
4.
Adjust magnetic pickup (Adjustment).
5.
Close left side engine access doors.
0114-2
TM 9-6115-644-24
0114
END OF TASK
ADJUSTMENT
1.
Release control panel by turning two fasteners and lower control panel slowly.
2.
Disconnect wire 147C from terminal 16 and wire 148C from terminal 17 of governor control unit (WP 0043,
Figure 1, Item 56).
3.
Set multimeter for ohms and connect to ends of disconnected wires 147C and 148C. Multimeter should
indicate between 800 and 900 ohms.
4.
Leave multimeter connected to wires 147C and 148C and set multimeter for AC volts.
5.
Crank engine with DEAD CRANK switch (WP 0110, Figure 1, Item 11) and observe multimeter. Multimeter
indication should be between 2.0 and 3.0 VAC.
CAUTION
Do not adjust magnetic pickup (6) inward more than one eighth turn each time or damage to
magnetic pickup may result.
6.
To adjust output voltage in Step 5 above, loosen locknut (6A) and turn magnetic pickup (6) in no more than
one-eighth turn at a time to increase or decrease output voltage. Tighten locknut (6A).
7.
Repeat Steps 5 and 6 above until proper output voltage is achieved.
8.
Remove multimeter and connect wires to governor control unit (WP 0043, Figure 1, Item 56).
9.
Raise and secure control panel.
END OF TASK
END OF WORK PACKAGE
0114-3/(4 blank)
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF ENGINE ACCESSORIES, DEAD CRANK SWITCH: TESTING, REMOVAL,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0110, Figure 1, Items: 8 & 11
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
TESTING
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Shut down generator set before performing inspection of wiring. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
0115-1
0115
TM 9-6115-644-24
0115
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open left side engine access doors.
3.
Tag and disconnect electrical leads from DEAD CRANK switch (WP 0110, Figure 1, Item 11).
4.
Set multimeter for ohms and, with switch (11) in NORMAL position, check for continuity between contacts 2
and 3.
5.
Move switch (11) to CRANK position and check for continuity between contacts 1 and 2.
6.
If DEAD CRANK switch (11) fails continuity checks, replace switch.
7.
If replacement is not needed, connect electrical leads to switch (11) and remove tags.
8.
Close left side engine access doors, connect negative battery cable, and close battery access door.
END OF TASK
REMOVAL
WARNING
When disconnecting or removing batteries, disconnect the negative lead that connects directly to
the grounding stud first; disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply with this warning can
cause injury to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Open left side engine access doors and remove nut (WP 0110, Figure 1, Item 8), lockwasher (9), and tab
washer (10). Discard lockwasher (9).
4.
Remove DEAD CRANK switch (11) from governor actuator mounting plate.
5.
Tag and disconnect DEAD CRANK switch (11) electrical leads.
END OF TASK
INSTALLATION
1.
Connect electrical leads to DEAD CRANK switch (WP 0110, Figure 1, Item 11) and remove tags.
2.
Install DEAD CRANK switch (11) in governor actuator mounting plate with tab washer (10), new lockwasher
(9), and nut (8). Close left side engine access doors.
3.
Connect negative battery cable and close battery access door.
END OF TASK
END OF WORK PACKAGE
0115-2
TM 9-6115-644-24
0116
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF ENGINE ACCESSORIES, DIODE ASSEMBLY: REMOVAL, TESTING, REPAIR,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Diode Assembly (If indications do no comply with
testing
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0110, Figure 1, Items: 12 & 13
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
Shut down generator set before performing inspection of wiring. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
0116-1
TM 9-6115-644-24
0116
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open left side engine access doors.
3.
Remove nuts (WP 0110, Figure 1, Item 12) and diode assembly (13) from top of fuel injection pump.
END OF TASK
TESTING
1.
Shut down generator set.
2.
Remove diode assembly (WP 0110, Figure 1, Item 13) (Removal).
3.
Set multimeter for ohms and connect positive lead to terminal on banded side of diode assembly and
negative lead to plain side. Note ohms indication on multimeter.
4.
Reverse multimeter leads on diode assembly. Note ohms indication on multimeter.
5.
Multimeter indication should be high in Step 3 and low in Step 4.
6.
Diode assembly (13) is defective and must be replaced if indications are other than above.
7.
If replacement is not needed, install diode assembly (13) (Installation).
END OF TASK
REPAIR
Repair diode assembly (WP 0110, Figure 1, Item 13) by replacing damaged terminal ends.
END OF TASK
INSTALLATION
1.
Position diode assembly (WP 0110, Figure 1, Item 13) on fuel injection pump with band end toward engine.
2.
Secure diode assembly (13) to fuel injection pump with nuts (12).
3.
Close left side engine access doors, connect negative battery cable, and close battery access door.
END OF TASK
END OF WORK PACKAGE
0116-2
TM 9-6115-644-24
0117
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF ENGINE ACCESSORIES, GOVERNOR ACTUATOR: TESTING, REMOVAL,
INSTALLATION, ADJUSTMENT
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Safety Goggles & Chemical Gloves
Protective Clothing & Heat Resistant Gloves
New Lockwashers
Governor Actuator (If does not comply with Testing
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0115, Maintenance of Engine Accessories,
Dead Crank Switch
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. Make sure generator set is
completely shut down and free of any power source before attempting any repair or maintenance
on the set, or when connecting or disconnecting load cables. Failure to comply with this warning
can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
0117-1
TM 9-6115-644-24
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
WARNING
High voltage is produced when the generator set is in operation. DO NOT touch live voltage
connections. Never attempt to connect or disconnect load cables or paralleling cables while the
generator set is running. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Batteries give off a flammable gas. Do not smoke or use open flame when performing
maintenance. Failure to comply with this warning can cause injury or death to personnel, and
damage to the generator set.
WARNING
Battery acid can cause burns to unprotected skin. Wear safety goggles and chemical gloves and
avoid acid splash while working on batteries. Failure to comply with this warning can cause injury
to personnel.
WARNING
Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Operators are to wash exposed skin and change chemical soaked clothing
promptly if exposed to fuel. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Fuels used in the generator set are flammable. Do not smoke or use open flames when
performing maintenance. Failure to comply with this warning can cause injury or death to
personnel, and damage to the generator set.
WARNING
Fuels used in the generator set are flammable. When filling the fuel tank, maintain metal-to-metal
contact between filler nozzle and fuel tank opening to eliminate static electrical discharge. Failure
to comply with this warning can cause injury or death to personnel, and damage to the generator
set.
TESTING
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Open left side engine access doors and disconnect connector (Figure 1, Item 1) from engine electrical
harness.
4.
Connect 5 ohm, 25 watt resistor in series with pin 2 of connector (1) and ground.
0117-2
0117
TM 9-6115-644-24
5.
Connect jumper wire from pin 1 of connector (1) to battery positive terminal (24 VDC).
6.
Connect negative battery cable; governor actuator (11) shaft should extend to full fuel position.
7.
Disconnect negative battery cable; governor actuator (11) shaft should retract to no fuel position.
8.
Replace governor actuator (11) if it does not function as above.
9.
Remove resistor and jumper wire from connector (1), ground, and battery.
0117
10. Connect connector (1) to engine electrical harness. Close left side engine access doors.
11. Connect negative battery cable. Close battery access door.
END OF TASK
REMOVAL
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Open left side engine access doors and remove DEAD CRANK switch (WP 0115, Removal).
4.
Tag and disconnect connector (Figure 1, Item 1) from engine electrical harness.
5.
Remove nuts (2 and 3), bolt (4), and rod assembly (5) from fuel injection pump lever and clevis (7).
6.
Loosen nut (6) and unscrew clevis (7) from governor actuator (11) shaft.
NOTE
Count number of turns required to remove clevis (7) for initial adjustment during installation.
7.
Remove nuts (8 and 28), lockwashers (9), bolts (10), and governor actuator (11) from mounting bracket (18).
Discard lockwashers (9).
8.
Remove nut (12), bolt (13), and clamp (14) securing electrical wiring to mounting bracket (18).
9.
Remove nuts (15), lockwashers (16), washers (17), and mounting bracket (18) from front cover mounting
bolts. Discard lockwashers (16).
NOTE
Count number of turns required to separate rod ends for initial adjustment during installation.
10. If necessary, disassemble rod assembly (5) by loosening nuts (19 and 20) and unscrewing rod ends (21 and
22) from rod (23).
11. If necessary, remove nut (24) and bolt (25) from rod end (22).
12. If necessary, drill out rivets (26) and remove identification plate (27) from bracket (18).
0117-3
TM 9-6115-644-24
Figure 1. Governor Actuator Assembly.
END OF TASK
INSTALLATION
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
0117-4
0117
TM 9-6115-644-24
0117
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
High voltage is produced when the generator set is in operation. DO NOT touch live voltage
connections. Never attempt to connect or disconnect load cables or paralleling cables while the
generator set is running. Failure to comply with this warning can cause injury or death to
personnel.
WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
components have been heated. Wear additional protective clothing as required. Failure to comply
with this warning can cause injury to personnel.
1.
If disassembled, screw rod ends (Figure 1, Items 21 and 22) onto rod (23) the same number of turns noted
on disassembly, and tighten nuts (19 and 20) finger tight only.
2.
If removed, install bolt (25) and nut (24) into rod end (22).
3.
If removed, install identification plate (27) on bracket (18) with rivets (26).
4.
Install mounting bracket (18) on front cover mounting bolts with washers (17), new lockwashers (16), and
nuts (15).
5.
Secure electrical wiring to mounting bracket (18) with clamp (14), bolt (13), and nut (12).
6.
Install governor actuator (11) on mounting bracket (18) with bolts (10), new lockwashers (9) and nuts (8 and
28).
7.
Screw clevis (7) on governor actuator (11) shaft the same number of turns noted on disassembly, and tighten
nut (6) finger tight only.
8.
Install rod assembly (5) on injection pump lever and clevis (7) with bolt (4) and nuts (2 and 3).
9.
Install DEAD CRANK switch (WP 0115, Installation).
10. Connect connector (1) to engine harness and remove tag.
11. Connect negative battery cable and close battery access door.
12. Adjust governor actuator (Adjustment).
END OF TASK
ADJUSTMENT
1.
Tag and disconnect connector (Figure 1, Item 1) from engine harness.
2.
Remove nut (2) and disconnect rod assembly (5).
3.
Manually move fuel injection pump lever to full fuel position.
4.
Start generator set while holding fuel injection pump lever in position.
5.
Slowly move fuel injection pump lever toward no fuel position until generator set shuts down.
6.
Mark position of fuel injection pump lever on engine block at exact no fuel (shut down) point. Measure
injection pump lever center line position to mounting surface of actuator. Refer to Figure 2.
7.
Adjust rod assembly (Figure 1, Item 5) and clevis (7) as necessary so that center line of 6uel injection pump
lever when connected and measured as in Step 6, will be positioned past the no fuel point by 0.125 to 0.250
inch (3.17 to 6.35mm). Tighten nuts (6, 19, and 20).
8.
Install rod assembly (5) on fuel injection pump lever with nut (2).
9.
Connect connector (1) to engine harness.
0117-5
TM 9-6115-644-24
10. Start generator set, check generator performance and adjust governor control unit as necessary in
accordance with WP 0061, Adjustment.
Figure 2. Governor Actuator Adjustment.
END OF TASK
END OF WORK PACKAGE
0117-6
0117
TM 9-6115-644-24
0118
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF LUBRICATION SYSTEM, OIL DRAIN LINE: INSPECTION, REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Heat Resistant Gloves
Protective Eyewear
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0006, Service Upon Receipt, Lubricating Oil
See "One Qualified Technician" Warning
Equipment Condition
Grounded, Off & Operational
INSPECTION
WARNING
The high pressure oil system operates at high temperature and pressure. Contact with hot oil can
result in burns and scalding. Shut down generator set, and allow system to cool before
performing checks, services, and maintenance. Wear heat resistant gloves and avoid contacting
hot surfaces. Do not allow hot oil or components to contact skin or hands. Failure to comply with
this warning can cause injury or death to personnel.
WARNING
Oil filter base and housing springs are under tension and can act as projectiles when being
removed. Use eye protection when removing springs. Failure to comply with this warning can
cause injury to personnel.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery and right side engine access doors.
3.
Inspect oil drain line for cracks, holes, loose or missing hardware, and other damage.
4.
Close battery and right side engine access doors.
END OF TASK
REMOVAL
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
0118-1
TM 9-6115-644-24
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply with
this warning can cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door, disconnect negative battery cable, and open right side engine access doors.
3.
Remove plug (Figure 1, Item 1), open drain valve (2), and drain engine oil into suitable container.
4.
Loosen clamp (3) and remove oil drain hose from adapter (4).
5.
Remove drain valve (2) from skid fitting.
6.
Remove adapter (4) and pipe fitting (5) from oil drain valve (2).
Figure 1. Oil Drain Line.
END OF TASK
INSTALLATION
0118-2
0118
TM 9-6115-644-24
1.
Install adapter (Figure 1, Item 4) and pipe fitting (5) in oil drain valve (2).
2.
Install oil drain valve (2) on skid fitting.
3.
Install oil drain hose on adapter (4). Secure with clamp (3).
4.
Ensure oil drain valve (2) is closed. Install plug (1) and service engine oil (WP 0006, Lubricating Oil).
5.
Check engine oil drain line and valve for leakage.
6.
Connect negative battery cable. Close battery and right side engine access doors.
END OF TASK
END OF WORK PACKAGE
0118-3/(4 blank)
0118
TM 9-6115-644-24
0119
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF GENERATOR ASSEMBLY, GENERATOR ASSEMBLY: REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0018, Maintenance of Control Box Assembly,
Rear Housing Section
WP 0098, Maintenance of Output Box Assembly,
Output Box Assembly
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
High voltage is produced when this generator set is in operation. Make sure generator set is
completely shut down and free of any power source before attempting any repair or maintenance
on the set, or when connecting or disconnecting load cables. Failure to comply with this warning
can cause injury or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard. Do not connect any electrical equipment or disconnect any
electrical equipment in an explosive atmosphere. Failure to comply with this warning can cause
injury or death to personnel.
0119-1
TM 9-6115-644-24
0119
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
WARNING
High voltage is produced when the generator set is in operation. DO NOT touch live voltage
connections. Never attempt to connect or disconnect load cables or paralleling cables while the
generator set is running. Failure to comply with this warning can cause injury or death to
personnel.
REMOVAL
WARNING
When disconnecting or removing batteries, disconnect the negative lead that connects directly to
the grounding stud first; disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply with this warning can
cause injury to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove output box assembly (WP 0098, Removal).
4.
Remove generator set rear housing section (WP 0018, Removal).
5.
Loosen bolts (Figure 1, Item 1) and lower engine support brackets (2) to contact skid base. Tighten bolts. If
necessary, place wooden shims under brackets to ensure contact with skid base.
WARNING
Many components require a two-person lift. Lifting heavy components can cause back strain.
Ensure proper lifting techniques are used when lifting heavy components. Failure to comply with
this warning can cause injury to personnel.
WARNING
The generator set, engine, and generator are extremely heavy and require an assistant and a
lifting device (forklift, overhead lifting device) with sufficient capacity. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
Rated capacity of overhead hoist should be at least 1,500 pounds (680 kg). Do not use a hoist
with less capacity. Failure to comply with this warning can cause injury or death to personnel, and
damage to equipment.
WARNING
Keep hands and feet from underside of engine and generator while using lifting device to remove
them from the skid base. Failure to comply with this warning can cause injury or death to
personnel.
6.
Attach lifting harness to overhead hoist and generator lifting eye and take up slack.
7.
Remove nuts (3), lockwashers (4), washers (6), screws (5) and screen/cover (7) from generator case.
Discard lockwashers (4).
8.
Remove bolts (8) and lockwashers (9) securing generator disc drive to engine flywheel. Discard lockwashers
(9).
9.
Remove bolts (11) and lockwashers (13) securing generator to flywheel housing. Discard lockwashers (13).
0119-2
TM 9-6115-644-24
0119
10. Remove nuts (14), washers (15), snubbing washers (16), bolts (18), and Belleville washers (17) securing
generator to skid base.
11. Lift generator slowly from skid base, ensuring that engine flywheel housing and generator separate smoothly
to avoid any undue stress.
NOTE
Mark location of spacers, washers, and bolts to ensure correct positioning during installation.
12. Remove shock mounts (19) from skid base.
13. Remove nuts (20), washers (21), bolts (10), angles (24), and plates (12) from generator.
Figure 1. Generator Assembly Removal.
END OF TASK
INSTALLATION
0119-3
TM 9-6115-644-24
1.
Position generator shock mounts (Figure 1, Item 19) in skid base.
2.
Install angles (24) and plates (12) on generator with bolts (10), washers (21), and nuts (20).
0119
WARNING
Many components require a two-person lift. Lifting heavy components can cause back strain.
Ensure proper lifting techniques are used when lifting heavy components. Failure to comply with
this warning can cause injury to personnel.
WARNING
The generator set, engine, and generator are extremely heavy and require an assistant and a
lifting device (forklift, overhead lifting device) with sufficient capacity. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
Rated capacity of overhead hoist should be at least 1,500 pounds (680 kg). Do not use a hoist
with less capacity. Failure to comply with this warning can cause injury or death to personnel, and
damage to equipment.
WARNING
Keep hands and feet from underside of engine and generator while using lifting device to remove
them from the skid base. Failure to comply with this warning can cause injury or death to
personnel.
3.
Attach lifting harness to overhead hoist and generator lifting eye.
4.
Position generator on skid base aligning mounting holes with mounts and engine flywheel housing.
5.
Install bolts (11) and new lockwashers (13), tightening bolts (11) slowly to ensure even and proper seating of
generator housing lip to flywheel housing.
6.
Install bolts (18), Belleville washers (17), snubbing washers (16), washers (15), and nuts (14) securing
generator assembly to skid base. Torque nuts (14) to 210 ft•lbs (285 N•m).
7.
Align scribe mark on generator drive disc and engine flywheel, and install bolts (8) and new lockwashers (9)
securing generator drive disc to engine flywheel.
8.
Install screen/cover (7) on generator case with screws (5), washers (6), new lockwashers (4), and nuts (3).
9.
Adjust nuts (20) on generator mount to obtain 0.5 inch (12.7 mm) minimum clearance between ends of bolts
(10) and skid base.
10. Install generator set rear housing section (WP 0018, Installation).
11. Install output box assembly (WP 0098, Installation).
12. Connect negative battery cable. Close battery access door.
13. Start generator set and check for proper operation.
END OF TASK
END OF WORK PACKAGE
0119-4
TM 9-6115-644-24
0120
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF GENERATOR ASSEMBLY, ROTATING RECTIFIER DIODES: TESTING, REMOVAL,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
TM 9-2815-255-24
WP 0018, Maintenance of Control Box Assembly,
Rear Housing Section
WP 0121, Maintenance of Generator Assembly, End
Bell and Main Bearing
WP 0159, Item 10
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
TESTING
1.
Shut down generator set. Allow generator to cool to ambient temperature.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove generator set housing rear panel (WP 0018, Removal).
0120-1
TM 9-6115-644-24
4.
0120
Remove generator end bell cover plates (WP 0121, Removal, Step 4).
NOTE
It will be necessary to bar (turn) engine in order to position a specific area of the rotating rectifier
at one of the end bell access holes. Use center bolt on harmonic balancer to turn engine; refer to
TM 9-2815-255-24.
5.
Remove nuts (Figure 1, Item 1) and lockwashers (2) from rotating rectifier terminals. Discard lockwashers (2).
6.
Tag and remove main rotor and diode leads from rotating rectifier terminals.
Figure 1. Rectifier Assembly.
7.
Tag exciter rotor leads and remove bolts (3), washers (4), and exciter rotor leads from rectifier mounting plate
(5).
8.
Set multimeter for ohms and connect positive lead to one side and negative lead to other side of each diode
(6). Record multimeter reading for each diode.
9.
Repeat Step 8 above with multimeter leads reversed.
10. Resistance (ohms) readings should be low in one direction and high in reversed direction. If readings are
high or low in both directions, diode (6) is defective and must be replaced.
0120-2
TM 9-6115-644-24
0120
11. Install diode (6) and main rotor leads to rotating rectifier terminals with nuts (1) and new lockwashers (2).
Remove tags.
12. Install exciter rotor leads to rectifier mounting plate (5) with washers (4) and bolts (3). Remove tags.
13. Install generator end bell cover plates (WP 0121, Installation, Step 6).
14. Install generator set housing rear panel (WP 0018, Installation).
15. Connect negative battery cable. Close battery access door.
END OF TASK
REMOVAL
WARNING
Many components require a two-person lift. Lifting heavy components can cause back strain.
Ensure proper lifting techniques are used when lifting heavy components. Failure to comply with
this warning can cause injury to personnel.
WARNING
The generator set, engine, and generator are extremely heavy and require an assistant and a
lifting device (forklift, overhead lifting device) with sufficient capacity. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove generator set housing rear panel (WP 0018, Removal).
4.
Remove generator end bell top cover and louvered covers (WP 0121, Removal, Step 4).
NOTE
It will be necessary to bar (turn) engine in order to position a specific area of the rotating rectifier
at one of the end bell access holes. Use center bolt on harmonic balancer to turn engine; refer to
TM 9-2815-255-24.
5.
Unsolder electrical lead from diode (Figure 1, Item 6) being removed.
6.
Remove nut (7), lockwasher (8), and diode (6) from rectifier mounting plate (5) through access hole in end
bell. Discard lockwasher (8).
END OF TASK
INSTALLATION
1.
Run bead of thermal-electric compound (WP 0159, Item 10) around base of diode (Figure 1, Item 6) prior to
installing. Do not coat threads.
2.
Insert diode (6) through generator end bell access hole, and install on rectifier mounting plate (5) with new
lockwasher (8) and nut (7). Torque nut (7) 28 to 30 in•lbs. (3.16 to 3.38 N•m).
0120-3
TM 9-6115-644-24
3.
Using solder (WP 0159, 20) and soldering iron, solder electrical lead to diode (6).
4.
Install generator end bell top cover and louvered covers (WP 0121, Installation, Step 6).
5.
Install generator set housing rear panel (WP 0018, Installation).
6.
Connect negative battery cable. Close battery access door.
END OF TASK
END OF WORK PACKAGE
0120-4
0120
TM 9-6115-644-24
0121
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF GENERATOR ASSEMBLY, END BELL AND MAIN BEARING: REMOVAL,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
New Lockwashers
New Bearing (If removing bearing for any reason)
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
TM 9-2815-255-24
WP 0018, Maintenance of Control Box Assembly,
Rear Housing Section
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
REMOVAL
0121-1
TM 9-6115-644-24
0121
WARNING
Many components require a two-person lift. Lifting heavy components can cause back strain.
Ensure proper lifting techniques are used when lifting heavy components. Failure to comply with
this warning can cause injury to personnel.
WARNING
The generator set, engine, and generator are extremely heavy and require an assistant and a
lifting device (forklift, overhead lifting device) with sufficient capacity. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove generator set housing rear panel (WP 0018, Removal).
4.
Remove bolts (Figure 2, Item 1), lockwashers (2), top cover (3), and louvered covers (4) from end bell (5).
Discard lockwashers (2).
CAUTION
The end bell supports the main rotor, thus the rotor will drop on the stator once the end bell is
removed. Prior to proceeding, bar engine by using center bolt on harmonic balancer (refer to TM
9-2815-255-24) until two main rotor poles are vertical in generator stator. Having the rotor in this
position will limit the amount of drop, otherwise, damage to rotor and/or stator could occur.
5.
Remove bolts (6) and lockwashers (7) from end bell (5). Discard lockwashers (7).
6.
Install two bolts (6) in “backout” holes in end bell (5) flange; refer to Figure 1.
7.
Loosen lead clamp assembly (Figure 2, Item 33) clamping generator leads at side of generator housing.
Ensure that wires F1 and F2 are free to slide in and out of generator housing.
8.
Remove end bell (5), with exciter stator (16) attached, from generator housing (11) by tightening bolts (6)
evenly into “back-out” holes.
9.
Remove preformed packing (9) from end bell (5).
CAUTION
If bearing needs to be removed for any reason, always install new bearing. Main bearing is easily
damaged when removed from rotor shaft. Damage to equipment could result.
10. Using bearing puller, remove bearing (8) from main rotor shaft (10).
0121-2
TM 9-6115-644-24
0121
Figure 1. End Bell Removal.
END OF TASK
INSTALLATION
1.
Install bearing (Figure 2, Item 8). Ensure that bearing is seated squarely against main rotor shaft (10)
shoulder by applying pressure to inner race only.
CAUTION
If bearing needs to be removed for any reason, always install new bearing. Main bearing is easily
damaged when removed from rotor shaft. Damage to equipment could result.
2.
Install preformed packing (9) in end bell (5).
3.
Position bearing (8) in end bell (5).
NOTE
It may be necessary to use a lifting device to raise and align end bell (5) with generator housing
(11).
4.
Position end ball (5), with exciter stator (16) attached, on generator housing (11) while pulling slack of wires
F1 and F2 through side of generator housing. Secure end bell (5) with bolts (6) and new lockwashers (7).
Torque bolts (6) 59 to 61 in•lbs (6.7 to 7.0 N•m).
5.
Tighten lead clamp assembly (33) at side of generator housing ensuring that generator leads are clamped
securely.
6.
Install top cover (3) and louvered covers (4) on end bell (5) with bolts (1) and new lockwashers (2).
7.
Install generator set housing rear panel (WP 0018, Installation).
8.
Connect negative battery cable. Close battery access door.
0121-3
TM 9-6115-644-24
Figure 2. Generator Assembly.
END OF TASK
END OF WORK PACKAGE
0121-4
0121
TM 9-6115-644-24
0122
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF GENERATOR ASSEMBLY, ROTATING RECTIFIER: REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0018, Maintenance of Control Box Assembly,
Rear Housing Section
WP 0120, Figure 1, Items: 2 & 3
WP 0121, Figure 2, Items: 12 & 14
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
REMOVAL
WARNING
Many components require a two-person lift. Lifting heavy components can cause back strain.
Ensure proper lifting techniques are used when lifting heavy components. Failure to comply with
this warning can cause injury to personnel.
0122-1
TM 9-6115-644-24
0122
WARNING
The generator set, engine, and generator are extremely heavy and require an assistant and a
lifting device (forklift, overhead lifting device) with sufficient capacity. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove generator set housing rear panel (WP 0018, Removal).
4.
Remove generator end bell and main bearing (WP 0121, Removal).
5.
Remove bolts (WP 0120, Figure 1, Item 3) and lockwashers (4) securing exciter rotor leads (3 places) to
rotating rectifier. Tag and remove exciter rotor leads. Discard lockwashers (4).
6.
Remove nuts (1) and lockwashers (2); tag and remove two main rotor leads and rotating rectifier diode leads.
Discard lockwashers (2).
7.
Remove bolts (WP 0121, Figure 2, Item 12), lockwashers (13), and rotating rectifier (14) from rotor assembly
(28).
END OF TASK
INSTALLATION
1.
Install rotating rectifier (WP 0121, Figure 2, Item 14) on rotor assembly (28) with bolts (12) and new
lockwashers (13).
2.
Connect two main rotor leads and rotating rectifier diode leads with new lockwashers (WP 0120, Figure 1,
Item 2) and nuts (1).
3.
Connect three exciter rotor leads to rotating rectifier with bolts (3) and new lockwashers (4).
4.
Install main bearing and generator end bell (WP 0121, Installation).
5.
Install generator set housing rear panel (WP 0018, Installation).
6.
Connect negative battery cable. Close battery access door.
END OF TASK
END OF WORK PACKAGE
0122-2
TM 9-6115-644-24
0123
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF GENERATOR ASSEMBLY, EXCITER STATOR: TESTING, REMOVAL, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Exciter Stator (If multimeter reading doesn't comply
with Table 1 in this work package
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0018, Maintenance of Control Box Assembly,
Rear Housing Section
WP 0121, Figure 2, Items 15 & 16
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
TESTING
1.
Shut down generator set. Allow generator to cool to ambient temperature.
2.
Open battery access door and disconnect negative battery cable.
3.
Open output box access door and disconnect exciter field leads F1 and F2 from terminals 1 and 2 of TB8.
4.
Set multimeter for ohms and connect between disconnected exciter field leads. Multimeter reading should be
0123-1
TM 9-6115-644-24
0123
as shown in Table 1.
5.
A multimeter reading other than shown in Table 1 indicates open or shorted windings an exciter stator must
be replaced.
Table 1. Generator Resistance Values at 25 °C (77 °F).
Resistance
Component
MEP-805A
MEP-815A
Exciter Stator
Between 24.85 and 33.61 ohms
Between 24.9693 and 33.7819 ohms
Exciter Rotor
Between 0.202 and 0.274 ohms
Between 0.2061 and 0.2787 ohms
Generator Rotor
Between 1.03 and 1.51 ohms
Between 1.9874 and 2.6888 ohms
Generator Stator
Between 0.0736 and 0.0994 ohms
Between 0.0306 and 0.0412 ohms
NOTE
Ambient temperature must be expressed in °C. To convert °F to °C, use °F = °Cx9/5+32.
a.
To determine the resistance values at current ambient temperature, use the following formula:
R1
= R25[1 + 0.00385 (T-25)]
R1
= Unknown resistance
Where:
R25 = Known resistance at 25 °C (77 °F)
T
b.
= Current ambient temperature
Example for exciter stator leads at 5 °C (41 °F):
R1 = 33.714 [1 +0.00385 (5-25)]
R1 = 33.714 [1 +0.00385 (-20)]
R1 = 33.714 [1±0.077)]
R1 = 33.714 [0.923]
R1 = 31.118±15% ohms
6.
Connect multimeter between each exciter field lead and generator frame in turn.
7.
A multimeter reading of less than infinity indicates defective ground insulation and exciter stator must be
replaced.
8.
Connect exciter field leads to terminals 1 and 2 of TB8. Close output box access door.
9.
Connect negative battery cable. Close battery access door.
END OF TASK
REMOVAL
WARNING
Many components require a two-person lift. Lifting heavy components can cause back strain.
Ensure proper lifting techniques are used when lifting heavy components. Failure to comply with
this warning can cause injury to personnel.
0123-2
TM 9-6115-644-24
0123
WARNING
The generator set, engine, and generator are extremely heavy and require an assistant and a
lifting device (forklift, overhead lifting device) with sufficient capacity. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
1.
Shut down generator set.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove generator set housing rear panel (WP 0018, Removal).
4.
Open output box access door and disconnect exciter field leads F1 and F2 from terminals TB8-1 and TB8-2.
5.
Attach “fish wires” to disconnected F1 and F2 leads to aid in installation process.
6.
Remove generator end bell (WP 0121, Removal).
7.
Remove setscrews (WP 0121, Figure 2, Item 15) and exciter stator (16) from end bell (5).
8.
Detach “fish wires” once F1 and F2 leads clear generator housing (11).
END OF TASK
INSTALLATION
1.
Attach “fish wires” to F1 and F2 leads of exciter stator (WP 0121, Figure 2, Item 16).
2.
Gently pull on “fish wires” to pull F1 and F2 leads back through generator housing (11). Disconnect “fish
wires” and position F1 and F2 leads in output box.
3.
Position exciter stator (16) in end bell (5) and secure in place with setscrews (15).
4.
Install generator end bell (WP 0121, Installation).
5.
Install generator set housing rear panel (WP 0018, Installation).
6.
Connect exciter field leads F1 and F2 to terminals TB8-1 and TB8-2. Close output box access door.
7.
Connect negative battery cable. Close battery access door.
END OF TASK
END OF WORK PACKAGE
0123-3/(4 blank)
TM 9-6115-644-24
0124
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF GENERATOR ASSEMBLY, EXCITER ROTOR: TESTING
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Excitor Rotator (If multimeter readings do not comply
with testing)
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
TM 9-2815-255-24
WP 0018, Maintenance of Control Box Assembly,
Rear Housing Section
WP 0120, Figure 1, Items: 3 & 4
WP 0121, Removal, Steps: 4 & Installation, Step 6
WP 0123, Table 1
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
TESTING
1.
Shut down generator set. Allow generator to cool to ambient temperature.
2.
Open battery access door and disconnect negative battery cable.
0124-1
TM 9-6115-644-24
0124
3.
Remove generator set housing rear panel (WP 0018, Removal).
4.
Remove generator end bell top cover and louvered covers (WP 0121, Removal, Step 4).
5.
Tag and disconnect exciter rotor leads (3 places) from rotating rectifier by removing bolts (WP 0120, Figure
1, Item 3) and lockwashers (4). Discard lockwashers.
NOTE
It will be necessary to bar (turn) engine in order to position a specific area of the rotating rectifier
at one of the end bell access holes. Use center bolt on harmonic balancer to turn engine; refer to
TM 9-2815-255-24.
6.
Connect resistance bridge between two exciter rotor leads and note resistance reading. Continue this
procedure until readings are noted for each combination of leads (i.e., 1 and 2, 1 and 3, and 2 and 3).
7.
Resistance readings should be as shown in WP 0123, Table 1 for each combination of leads. A reading other
than shown in WP 0123, Table 1 indicates open or shorted windings and exciter rotor must be replaced.
8.
Set multimeter for ohms and connect between each exciter rotor lead and end bell in turn.
9.
A multimeter reading of less than infinity indicates defective ground insulation and the exciter rotor must be
replaced.
10. Connect exciter rotor leads to rotating rectifier with new lockwashers (WP 0120, Figure 1, Item 4) and bolts
(3). Remove tags.
11. Install end bell top cover and louvered covers (WP 0121, Installation, Step 6).
12. Install generator set housing rear panel (WP 0018, Installation).
13. Connect negative battery cable. Close battery access door.
END OF TASK
END OF WORK PACKAGE
0124-2
TM 9-6115-644-24
0125
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF GENERATOR ASSEMBLY, MAIN ROTOR ASSEMBLY: TESTING, REMOVAL,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
TM 9-2815-255-24
WP 0018, Maintenance of Control Box Assembly,
Rear Housing Section
WP 0119, Maintenance of Generator Assembly,
Generator Assembly
WP 0120, Figure 1, Item 1
WP 0121, Removal, Steps: 4, Installation, Step 6 &
Figure 2, Items: 19, 27 & 28
WP 0122, Maintenance of Generator Assembly,
Rotating Rectifier
WP 0123, Table 1
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
TESTING
0125-1
TM 9-6115-644-24
0125
1.
Shut down generator set. Allow generator to cool to ambient temperature.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove generator set housing rear panel (WP 0018, Removal).
4.
Remove generator end bell cover plates (WP 0121, Removal, Step 4).
5.
Tag and disconnect main rotor leads (2 places) from rotating rectifier by removing nuts (WP 0120, Figure 1,
Item 1) and lockwashers (2). Discard lockwashers (2).
NOTE
It will be necessary to bar (turn) engine in order to position a specific area of the rotating rectifier
at one of the end bell access holes. Use center bolt on harmonic balancer to turn engine; refer to
TM 9-2815-255-24.
6.
Set multimeter for ohms and connect between disconnected main rotor leads. Multimeter reading should be
as shown in WP 0123, Table 1.
7.
A reading other than shown in WP 0123, Table 1 indicates shorted or open windings and main rotor must be
replaced.
8.
Connect multimeter between each main rotor lead and end bell in turn.
9.
A reading of less than infinity indicates defective ground insulation and main rotor must be replaced.
10. Connect main rotor leads to rotating rectifier with nuts (WP 0120, Figure 1, Item 1) and new lockwashers (2).
Remove tags.
11. Install generator end bell top cover and louvered covers (WP 0121, Installation, Step 6).
12. Install generator set housing rear panel (WP 0018, Installation).
13. Connect negative battery cable. Close battery access door.
END OF TASK
REMOVAL
WARNING
Many components require a two-person lift. Lifting heavy components can cause back strain.
Ensure proper lifting techniques are used when lifting heavy components. Failure to comply with
this warning can cause injury to personnel.
WARNING
The generator set, engine, and generator are extremely heavy and require an assistant and a
lifting device (forklift, overhead lifting device) with sufficient capacity. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
1.
Shut down generator set.
2.
Remove generator assembly from generator set (WP 0119, Removal).
0125-2
TM 9-6115-644-24
0125
NOTE
Mark location of spacers (WP 0121, Figure 2, Item 19), washers (18), and bolts (17) to ensure
correct positioning during installation.
3.
Remove bolts (17 and 20), washers (18 and 21), spacers (19), and drive discs (22) from drive hub (26).
4.
Remove bolts (23), lockwashers (24), and fan (25) from drive hub (26). Discard lockwashers (24).
5.
Attach a suitable rotor lifting device to drive hub (26) and overhead hoist (Figure 1).
6.
Remove generator end bell (WP 0121, Removal).
CAUTION
Special care should be taken when removing rotor assembly. Winding damage could result if
rotor is allowed to hit main stator.
7.
Carefully remove rotor assembly (WP 0121, Figure 2, Item 28) and attached components from main stator
and generator housing (11).
8.
Remove main bearing (WP 0121, Removal)
9.
Remove rotating rectifier (WP 0122, Removal).
10. Using bearing puller, remove drive hub (26) and key (27) from rotor assembly (28).
Figure 1. Rotor Assembly Lifting Device (Typical).
END OF TASK
INSTALLATION
1.
Place key (WP 0121, Figure 2, Item 27) on rotor assembly (28) and install drive hub (26) over key (27) and
onto main rotor assembly (28).
NOTE
Ensure gap between fan halves are equal from side to side.
2.
Install rotating rectifier (WP 0122, Installation).
3.
Install main bearing (WP 0121, Installation).
CAUTION
Special care must be taken when installing rotor assembly. Winding damage could result if rotor
is allowed to hit main stator.
4.
Attach a suitable rotor lifting device to drive hub (26) and overhead hoist (Figure 1).
0125-3
TM 9-6115-644-24
0125
5.
Carefully install rotor assembly (28) and attached components into main stator and generator housing (11).
6.
Install generator end bell (WP 0121, Installation) and remove rotor lifting device.
7.
Install fan (25) on drive hub (26) with new lockwashers (24) and bolts (23).
NOTE
Make sure all disc mounting holes at the inner and outer diameters are properly aligned.
NOTE
Ensure correct positioning of spacers, washers, and bolts as marked on removal.
8.
Install drive discs (22) on drive hub (26) with spacers (19), washers (18 and 21), and bolts (17 and 20).
Torque bolts (20) to 28 ft•lbs (38 N•m) and bolts (17) to 35 ft•lbs (47 N•m).
9.
Install generator assembly in generator set (WP 0119, Installation).
END OF TASK
END OF WORK PACKAGE
0125-4
TM 9-6115-644-24
0126
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF GENERATOR ASSEMBLY, MAIN STATOR AND HOUSING: TESTING, REMOVAL,
INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0119, Maintenance of Generator Assembly,
Generator Assembly
WP 0098, Figure 1, Item 37
WP 0099, Maintenance of Output Box Assembly,
Voltage Reconnection Terminal
WP 0106, Figure 1, Item 17
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
ENGINE CONTROL SWITCH OFF/RESET
Battery Disconnect Switch OFF
DEAD CRANK SWITCH OFF
WARNING
High voltage is produced when the generator set is in operation. Never attempt to start the
generator set unless it is properly grounded. Failure to comply with this warning can cause injury
or death to personnel.
WARNING
Dangerous voltage exists on live circuits. Always observe precautions and never work alone.
Failure to comply with this warning can cause injury or death to personnel.
WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET; Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF). Failure to comply with this warning can cause injury or death to personnel.
WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply with this warning can
cause injury to personnel, and damage to equipment.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
TESTING
1.
Shut down generator set. Allow generator to cool to ambient temperature.
2.
Open battery access door and disconnect negative battery cable.
3.
Remove protective cover and moveable terminal board from voltage reconnection terminal board (WP 0099,
0126-1
TM 9-6115-644-24
0126
Removal).
4.
Disconnect two electrical connectors from bottom of control box assembly.
5.
Tag and disconnect wires 107C and 109J from terminals 1 and 2 of power potential transformer (WP 0098,
Figure 1, Item 37).
6.
Connect resistance bridge and note readings between terminals T1 and T4, T2 and T5, T3 and T6, T7 and
T0, T8 and T0, and T9 and T0 of AC voltage reconnection terminal board.
7.
All resistance readings should be as shown in WP 0123, Table 1.
8.
If resistance is low, there are shorted windings; if resistance is high, stator windings are open. In either case,
stator must be replaced.
9.
Disconnect removable grounding link (WP 0106, Figure 1, Item 17) on load output terminal board.
10. Set multimeter for ohms and connect between each coil lead and ground in turn.
11. If multimeter indicates resistance on any connection, stator windings are grounded and stator must be
replaced.
12. Connect removable grounding link (17) on load output terminal board.
13. Connect wires 107C and 109J to terminals 1 and 2 of power potential transformer (WP 0098, Figure 1, Item
37). Remove tags.
14. Connect two electrical connectors to bottom of control box assembly.
15. Install moveable terminal board and protective cover on voltage reconnection terminal board (WP 0099,
Installation).
16. Connect negative battery cable. Close battery access door.
END OF TASK
REMOVAL
WARNING
Many components require a two-person lift. Lifting heavy components can cause back strain.
Ensure proper lifting techniques are used when lifting heavy components. Failure to comply with
this warning can cause injury to personnel.
WARNING
The generator set, engine, and generator are extremely heavy and require an assistant and a
lifting device (forklift, overhead lifting device) with sufficient capacity. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
1.
Shut down generator set.
2.
Remove generator assembly from generator set (WP 0119, Removal).
3.
Remove generator rotor assembly (WP 0125, Removal).
4.
Remove lifting eye (WP 0121, Figure 2, Item 29) and nut (30) from generator housing (11).
5.
Remove bolts (31), lockwashers (32), lead clamp assembly (33), and gasket (34) from generator housing
(11). Discard lockwashers (32).
0126-2
TM 9-6115-644-24
6.
0126
Remove nuts (35), lockwashers (36), screws (37), washers (38), and cover/screen (39) from generator
housing (11). Discard lockwashers (36).
END OF TASK
INSTALLATION
1.
Install generator rotor assembly (WP 0125, Installation).
2.
Install cover/screen (WP 0121, Figure 2, Item 39) on generator housing (11) with screws (37), washers (38),
new lockwashers (36), and nuts (35).
3.
Install gasket (34) and lead clamp assembly (33) on generator housing (11) with bolts (31) and new
lockwashers (32).
4.
Install lifting eye (29) in generator housing (11) and tighten nut (30).
5.
Install generator assembly in generator set (WP 0119, Installation).
END OF TASK
END OF WORK PACKAGE
0126-3/(4 blank)
TM 9-6115-644-24
0127
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
MAINTENANCE OF SKID BASE: REMOVAL, REPAIR, INSTALLATION
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
CARC Paint
Protective Eyewear, Mask & Gloves
New Lockwashers
Personnel Required
Two: (1) Power Generation Mechanic (52D) & (1)
Assistant/Operator
References
WP 0009, Removal & Installation of Major
Components, engine and Generator Assembly
WP 0097, Maintenance of Fuel System, Fuel Tank
See "One Qualified Technician" Warning
See "Never Work Alone" Warning
Equipment Condition
Grounded, Off & Operational
REMOVAL
WARNING
Many components require a two-person lift. Lifting heavy components can cause back strain.
Ensure proper lifting techniques are used when lifting heavy components. Failure to comply with
this warning can cause injury to personnel.
WARNING
The generator set, engine, and generator are extremely heavy and require an assistant and a
lifting device (forklift, overhead lifting device) with sufficient capacity. Failure to comply with this
warning can cause injury or death to personnel.
WARNING
All metal jewelry can conduct electricity and become entangled in generator set components.
Remove all jewelry when working on generator set. Failure to comply with this warning can cause
injury or death to personnel.
WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply with this warning can cause injury or death to personnel.
WARNING
Support components when removing attaching hardware or component may fall. Failure to
comply with this warning can cause injury to personnel, and damage to equipment.
WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
cause injury or death to personnel.
1.
Shut down generator set.
2.
Remove engine and generator assembly (WP 0009, Removal).
0127-1
TM 9-6115-644-24
0127
3.
Remove fuel tank (WP 0097, Removal).
4.
Remove nuts (Figure 1, Item 1), lockwashers (2), bolts (3), washers (4), and forklift guides (5) from skid base.
Discard lockwashers (2).
5.
Remove cable grommets (6 and 7) from skid base.
END OF TASK
REPAIR
Repair of skid base will be limited to corrosion control and spot welding minor cracks. If major structural damage
to skid base has occurred, replace skid base.
WARNING
CARC paint is a health hazard, and is irritating to eyes, skin, and respiratory system. Wear
protective eyewear, mask, and gloves when applying or removing CARC paint. Failure to comply
with this warning can cause injury to personnel.
WARNING
Solvent used to clean parts is potentially dangerous to personnel and property. Clean parts in a
well-ventilated area. Avoid inhalation of solvent fumes. Wear goggles and rubber gloves to
protect eyes and skin. Wash exposed skin thoroughly. Do not smoke or use near open flame or
excessive heat. Failure to comply with this warning can cause injury to personnel, and damage to
the equipment.
WARNING
Eye protection is required when working with compressed air. Compressed air can propel
particles at high velocity and injure eyes. Do not exceed 15 psi pressure when using compressed
air. Failure to comply with this warning can cause injury to personnel.
WARNING
Avoid breathing fumes generated by soldering. Eye protection is required. Good general
ventilation is normally adequate. Failure to comply with this warning can cause injury to
personnel.
END OF TASK
INSTALLATION
1.
Install forklift guides (Figure 1, Item 5) in skid base with bolts (3), washers (4), new lockwasher (2), and nuts
(1).
2.
Install cable grommets (6 and 7) in skid base.
3.
Install fuel tank (WP 0097, Installation).
4.
Install engine and generator assembly (WP 0009, Installation).
0127-2
TM 9-6115-644-24
Figure 1. Skid Base.
END OF TASK
END OF WORK PACKAGE
0127-3/(4 blank)
0127
TM 9-6115-644-24
0128
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
PREPARATION FOR STORAGE OR SHIPMENT
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
One
References
MIL-STD-129P(4)
TB 740-97-2
TO 38-1-5
Equipment Condition
Grounded, Off & Operational
PREPARATION FOR STORAGE OR SHIPMENT
Preservation
Preserve generator sets in accordance with levels A/A, A/B, C/B or C/C of PPP-G-2919.
Preserve generator set cooling systems in accordance with method II of PPP-G-2919 or the antifreeze and water
procedure of ATPD 2232.
Packing
Pack generator sets in accordance with levels A/A, A/B, C/B or C/C of PPP-G-2919.
Marking
Mark for shipment or storage in accordance with MIL-STD-129P(4).
Use of Corrosion-Preventive Compounds, Moisture Barriers, and Desiccant Materials
(A) Refer to Corrosion and Corrosion Prevention/Metal, MIL-HDBK-729 NOT 1.
Storage
(A) For storage information, refer to TB 740-97-2. (F) Refer to TO 38-1-5.
END OF TASK
END OF WORK PACKAGE
0128-1/(2 blank)
TM 9-6115-644-24
0129
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
ILLUSTRATED LIST OF MANUFACTURED ITEMS INTRODUCTION
ILLUSTRATED LIST OF MANUFACTURED ITEMS INTRODUCTION
Scope
WP 0130 through WP 0154 includes complete instructions for making items authorized to be manufactured or
fabricated at the field maintenance level.
How to Use the Index of Manufactured Items
A part number index in alphanumeric order is provided for cross-referencing the part number of the item to be
manufactured to the information which covers fabrication criteria.
Explanation of the Illustrations of Manufactured Items
All instructions needed by maintenance personnel to manufacture the item are included on the illustrations. All
bulk materials needed for manufacture of an item are listed by part number or specification number in a tabular
list on the illustration.
INDEX OF MANUFACTURED ITEMS
P/N AND/OR DWG NO
PART DESCRIPTION
REFERENCE
88-22126-1 through 88-22126-7
Cable Assembly, AC Power (P/N
88-22126-1 through 88-22126-7)
WP 0130
88-22178
Cable Assembly, Battery (P/N
88-22178)
WP 0131
88-22127
Cable Assembly, Battery (P/N
88-22127)
WP 0132
88-22181
Cable Assembly, Battery (P/N
88-22181)
WP 0133
88-22179
Cable Assembly, Battery (P/N
88-22179)
WP 0134
88-22207
Cable Assembly, Battery (P/N
88-22207)
WP 0135
88-22120
Holder, Control Panel (P/N
88-22120)
WP 0136
88-20191-6
Hose Assembly (P/N 88-20191-6)
WP 0137
88-22582
Insulation, Panel, Top (P/N
88-22582)
WP 0138
88-22592
Insulation, Baffle (P/N 88-22592)
WP 0139
88-22593
Insulation, Baffle (P/N 88-22593)
WP 0140
88-22584
Insulation, Top, Center (P/N
88-22584)
WP 0141
88-22585
Insulation, Top, Rear (P/N
88-22585)
WP 0142
88-22591
Insulation, Front Housing (P/N
WP 0143
0129-1
TM 9-6115-644-24
0129
INDEX OF MANUFACTURED ITEMS - Continued
P/N AND/OR DWG NO
PART DESCRIPTION
REFERENCE
88-22591)
88-22586
Insulation, Top, Front (P/N
88-22586)
WP 0144
88-22587
Insulation, Top, Center (P/N
88-22587)
WP 0145
88-22588
Insulation, Top, Center (P/N
88-22588)
WP 0146
88-22583
Insulation, Top, Front (P/N
88-22583)
WP 0147
122-3066-1 and 29879
Resistor Assembly (P/N
122-3066-1 and 29879)
WP 0148
88-22631
Resistor Assembly, Volt (P/N
88-22631)
WP 0149
88-22632
Resistor-Diode Assembly (P/N
88-22632)
WP 0150
88-22106
Resistor-Diode Assembly (P/N
88-22106)
WP 0151
88-22553
Solenoid Assembly (P/N 88-22553)
WP 0152
88-22548
Switch Assembly, Fuel Level (P/N
88-22548)
WP 0153
88-20305-1 through 88-20305-3
and 88-20305-5
Wire, Varistor (P/N 88-20305-1
through 88-20305-3 and
88-20305-5)
WP 0154
END OF WORK PACKAGE
0129-2
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
CABLE ASSEMBLY, AC POWER (P/N 88-22126-1 THROUGH 88-22126-7)
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
One
References
TM 9-6115-644-24P
Equipment Condition
Grounded, Off & Operational
P/N 88-22126-1 THROUGH 88-22126-7
Figure 1. Cable Assembly, AC Power (P/N 88-22126-1 through 88-22126-7).
END OF TASK
END OF WORK PACKAGE
0130-1/(2 blank)
0130
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
CABLE ASSEMBLY, BATTERY (P/N 88-22178)
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
One
References
TM 9-6115-644-24P
Equipment Condition
Grounded, Off & Operational
P/N 88-22178
Figure 1. Cable Assembly, Battery (P/N 88-22178).
END OF TASK
END OF WORK PACKAGE
0131-1/(2 blank)
0131
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
CABLE ASSEMBLY, BATTERY (P/N 88-22127)
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
One
References
TM 9-6115-644-24P
Equipment Condition
Grounded, Off & Operational
P/N 88-22127
Figure 1. Cable Assembly, Battery (P/N 88-22127).
END OF TASK
END OF WORK PACKAGE
0132-1/(2 blank)
0132
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
CABLE ASSEMBLY, BATTERY (P/N 88-22181)
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
One
References
TM 9-6115-644-24P
Equipment Condition
Grounded, Off & Operational
P/N 88-22181
Figure 1. Cable Assembly, Battery (P/N 88-22181).
END OF TASK
0133-1
0133
TM 9-6115-644-24
END OF WORK PACKAGE
0133-2
0133
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
CABLE ASSEMBLY, BATTERY (P/N 88-22179)
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
One
References
TM 9-6115-644-24P
Equipment Condition
Grounded, Off & Operational
P/N 88-22179
Figure 1. Cable Assembly, Battery (P/N 88-22179).
END OF TASK
END OF WORK PACKAGE
0134-1/(2 blank)
0134
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
CABLE ASSEMBLY, BATTERY (P/N 88-22207)
INITIAL SETUP:
Tools and Special Tools
Grounded, Off & Operational
Personnel Required
One
References
TM 9-6115-644-24P
Equipment Condition
Grounded, Off & Operational
P/N 88-22207
Figure 1. Cable Assembly, Battery (P/N 88-22207).
END OF TASK
END OF WORK PACKAGE
0135-1/(2 blank)
0135
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
HOLDER, CONTROL PANEL (P/N 88-22120)
INITIAL SETUP:
Tools and Special Tools
Grounded, Off & Operational
Personnel Required
One
References
TM 9-6115-644-24P
Equipment Condition
Grounded, Off & Operational
P/N 88-22120
Figure 1. Holder, Control Panel (P/N 88-22120).
END OF TASK
END OF WORK PACKAGE
0136-1/(2 blank)
0136
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
HOSE ASSEMBLY (P/N 88-20191-6)
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
One
References
TM 9-6115-644-24P
Equipment Condition
Grounded, Off & Operational
P/N 88-20191-6
Figure 1. Hose Assembly (P/N 88-20191-6).
END OF TASK
END OF WORK PACKAGE
0137-1/(2 blank)
0137
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
INSULATION, PANEL, TOP (P/N 88-22582)
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
One
Equipment Condition
Grounded, Off & Operational
P/N 88-22582
Figure 1. Insulation, Panel, Top (P/N 88-22582).
END OF TASK
END OF WORK PACKAGE
0138-1/(2 blank)
0138
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
INSULATION, BAFFLE (P/N 88-22592)
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Sealing Compound
Personnel Required
One
References
WP 0159, Item 19
Equipment Condition
Grounded, Off & Operational
P/N 88-22592
0139-1
0139
TM 9-6115-644-24
Figure 1. Insulation, Baffle (P/N 88-22592).
END OF TASK
END OF WORK PACKAGE
0139-2
0139
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
INSULATION, BAFFLE (P/N 88-22593)
INITIAL SETUP:
P/N 88-22593
0140-1
0140
TM 9-6115-644-24
Figure 1. Insulation, Baffle (P/N 88-22593).
END OF TASK
END OF WORK PACKAGE
0140-2
0140
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
INSULATION, TOP, CENTER (P/N 88-22584)
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
One
Equipment Condition
Grounded, Off & Operational
P/N 88-22584
0141-1
0141
TM 9-6115-644-24
Figure 1. Insulation, Top, Center (P/N 88-22584).
END OF TASK
END OF WORK PACKAGE
0141-2
0141
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
INSULATION, TOP, REAR (P/N 88-22585)
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Sealing Compound
Personnel Required
One
References
WP 0159, Item 19
Equipment Condition
Grounded, Off & Operational
P/N 88-22585
Figure 1. Insulation, Top, Rear (P/N 88-22585).
END OF TASK
0142-1
0142
TM 9-6115-644-24
END OF WORK PACKAGE
0142-2
0142
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
INSULATION, FRONT HOUSING (P/N 88-22591)
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
One
Equipment Condition
Grounded, Off & Operational
P/N 88-22591
0143-1
0143
TM 9-6115-644-24
Figure 1. Insulation, Front Housing (P/N 88-22591).
END OF TASK
END OF WORK PACKAGE
0143-2
0143
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
INSULATION, TOP, FRONT (P/N 88-22586)
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
One
Equipment Condition
Grounded, Off & Operational
P/N 88-22586
0144-1
0144
TM 9-6115-644-24
Figure 1. Insulation, Top, Front (P/N 88-22586).
END OF TASK
END OF WORK PACKAGE
0144-2
0144
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
INSULATION, TOP, CENTER (P/N 88-22587)
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Sealing Compound
Personnel Required
One
References
WP 0159, Item 19
Equipment Condition
Grounded, Off & Operational
P/N 88-22587
0145-1
0145
TM 9-6115-644-24
Figure 1. Insulation, Top, Center (P/N 88-22587).
END OF TASK
END OF WORK PACKAGE
0145-2
0145
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
INSULATION, TOP, CENTER (P/N 88-22588)
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Materials/Parts
Sealing Compound
Personnel Required
One
References
WP 0159, Item 19
Equipment Condition
Grounded, Off & Operational
P/N 88-22588
0146-1
0146
TM 9-6115-644-24
Figure 1. Insulation, Top, Center (P/N 88-22588).
END OF TASK
END OF WORK PACKAGE
0146-2
0146
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
INSULATION, TOP, FRONT (P/N 88-22583)
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
One
Equipment Condition
Grounded, Off & Operational
P/N 88-22583
0147-1
0147
TM 9-6115-644-24
Figure 1. Insulation, Top, Front (P/N 88-22583).
END OF TASK
END OF WORK PACKAGE
0147-2
0147
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
RESISTOR ASSEMBLY (P/N 122-3066-1 AND 29879)
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
One
References
TM 9-6115-644-24P
Equipment Condition
Grounded, Off & Operational
P/N 122-3066-1 AND 29879
Figure 1. Resistor Assembly (P/N 122-3066-1 and 29879).
END OF TASK
END OF WORK PACKAGE
0148-1/(2 blank)
0148
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
RESISTOR ASSEMBLY, VOLT (P/N 88-22631)
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
One
References
TM 9-6115-644-24P
Equipment Condition
Grounded, Off & Operational
P/N 88-22631
Figure 1. Resistor Assembly, Volt (P/N 88-22631).
END OF TASK
END OF WORK PACKAGE
0149-1/(2 blank)
0149
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
RESISTOR-DIODE ASSEMBLY (P/N 88-22632)
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
One
References
TM 9-6115-644-24P
Equipment Condition
Grounded, Off & Operational
P/N 88-22632
Figure 1. Resistor-Diode Assembly (P/N 88-22632).
END OF TASK
0150-1
0150
TM 9-6115-644-24
END OF WORK PACKAGE
0150-2
0150
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
RESISTOR-DIODE ASSEMBLY (P/N 88-22106)
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
One
References
TM 9-6115-644-24P
Equipment Condition
Grounded, Off & Operational
P/N 88-22106
Figure 1. Resistor-Diode Assembly (P/N 88-22106).
END OF TASK
0151-1
0151
TM 9-6115-644-24
END OF WORK PACKAGE
0151-2
0151
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
SOLENOID ASSEMBLY (P/N 88-22553)
INITIAL SETUP:
Tools and Special Tools
Generator Mechanical Tool Kit
Personnel Required
One
References
TM 9-6155-644-24P
Equipment Condition
Grounded, Off & Operational
P/N 88-22553
Figure 1. Solenoid Assembly (P/N 88-22553).
END OF TASK
0152-1
0152
TM 9-6115-644-24
END OF WORK PACKAGE
0152-2
0152
TM 9-6115-644-24
FIELD MAINTENANCE
30 kW 50/60 AND 400 Hz SKID MOUNTED TACTICAL QUIET GENERATOR SETS
SWITCH ASSEMBLY, F