Operating instructions

ManualsBrandsMTD ManualsLawn Mower464

ARMY

*TM 9-6115-464-34

AIR FORCE

TO-35C2-3-445-2

NAVY

NAVFAC P-8-624-34

TECHNICAL MANUAL

DIRECT AND GENERAL SUPPORT AND DEPOT LEVEL

MAINTENANCE MANUAL

GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL

Skid MTD., 15 KW, 3 PHASE, 4 WIRE, 120/208 AND

240/416 VOLTS

MEP-004A

MEP-103A

MEP-113A

DOD MODELS

MEP-005AWF

MEP-005AWE

MEP-004ALM

MEP-005AWM

MEP-015ASK

DOD MODELS CLASS

HERTZ

UTILITY

50/60

PRECISE

50/60

PRECISE

INCLUDING OPTIONAL KITS

WINTERIZATION KIT, FUEL BURNING

WINTERIZATION KIT, ELECTRIC

LOAD BANK KIT

WHEEL MOUNTING KIT

APPLICATIONS KIT

ACOUSTIC SUPPRESSION KIT

NSN

6115-00-118-1241

6115-00-118-1245

6115-00-118-1244

NSN

6115-00-463-9083

6115-00-463-9085

6115-00-291-9201

6115-00-463-9094

6115-01-096-9015

6115-01-233-8274

DISTRIBUTION STATEMENT A. Approved for public release, distribution is unlimited.

*This manual supersedes TM 5-6115-464-34/TO 35C2-3-455-2/TM 07523A-34, dated

31 January 1975.

HEADQUARTERS, DEPARTMENTS OF THE ARMY,

AIR FORCE AND NAVY

18 JANUARY 1994

NOMENCLATURE

Summary of content (493 pages)

PAGE 1
*TM 9-6115-464-34 TO-35C2-3-445-2 NAVFAC P-8-624-34 ARMY AIR FORCE NAVY TECHNICAL MANUAL DIRECT AND GENERAL SUPPORT AND DEPOT LEVEL MAINTENANCE MANUAL GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL Skid MTD.
PAGE 2
PAGE 3
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 WARNING All specific cautions and warnings contained in this manual shall be strictly adhered to. Otherwise, severe injury, death and/or damage to the equipment may result. HIGH VOLTAGE is produced when this generator set is in operation. DEATH or severe burns may result if personnel fail to observe safety precautions. Do not operate this generator set until the ground terminal stud has been connected to a suitable ground.
PAGE 4
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 WARNING DRILLING When drilling holes in skid base, do not allow drill bit to enter fuel tank. Death or serious injury may result. HEAT Do not allow personnel to open or close exhaust discharge door when unit is hot. Serious burns or personal injury may result. CAUTION DAMAGE to the equipment may result if personnel fail to observe the cautions contained in this manual.
PAGE 5
* ARMYTM 9-6115 464 34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 C1 CHANGE HEADQUARTERS, DEPARTMENTS OF THE ARMY, THE AIR FORCE, AND THE NAVY WASHINGTON D. C., 31 MARCH 1997 NO 1 DIRECT AND GENERAL SUPPORT AND DEPOT LEVEL MAINTENANCE MANUAL GENERATOR SET, DIESEL ENGINE DRIVEN, TACTICAL SKID MTD.
PAGE 6
PAGE 7
ARMY TM 9-6115 464 34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 TECHNICAL MANUAL HEADQUARTERS, DEPARTMENTS OF THE ARMY, THE AIR FORCE, AND THE NAVY WASHINGTON D.C.
PAGE 8
ARMY TM 9-6115-464-34 NAVY FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 TABLE OF CONTENTS Page LIST OF ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix CHAPTER 1. INTRODUCTION . . . . . . . . . . . . . . . .
PAGE 9
ARMY TM9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 TABLE OF CONTENTS (Cont.) Page Section XVI. MAINTENANCE OF LIFTING FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-315 Section XVll. MAINTENANCE OF SKID BASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-320 CHAPTER 4. GENERATOR SET TESTS AFTER OVERHAUL REPAIR INSTRUCTIONS . . . . . 4-1 Section I. INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 10
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 LIST OF ILLUSTRATIONS Figure 2-1. 2-2. 2-3. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. 3-9. 3-10. 3-11. 3-12. 3-13. 3-14. 3-15. 3-16. 3-17. 3-18. 3-19. 3-20. 3-21. 3-22. 3-23. 3-24. 3-25. 3-26. 3-27. 3-28. 3-29. 3-30. 3-31. 3-32. 3-33. 3-34. 3-35. 3-36. 3-37. 3-38. 3-39. 3-40. 3-41 3-42. iv Title Page Breakout Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 11
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 LIST OF ILLUSTRATIONS (Cont.) Figure 3-43. 3-44. 3-45. 3-46. 3-47. 3-48. 3-49. 3-50. 3-51. 3-52. 3-53. 3-54. 3-55. 3-56. 3-57. 3-58. 3-59. 3-60. 3-61. 3-62. 3-63. 3-64. 3-65. 3-66. 3-67. 3-68. 3-69. 3-70. 3-71. 3-72. 3-73. 3-74. 3-75. 3-76. 3-77. 3-78. 3-79. 3-80. 3-81. 3-82 3-83. 3-84. 3-85. 3-86. 3-87. 3-88. 3-89. 3-90. 3-91. Title Page Checking flywheel concentricity and alignment . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 12
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 LIST OF ILLUSTRATIONS (Cont.) Figure 3-92. 3-93. 3-94. 3-95. 3-96. 3-97. 3-98. 3-99. 3-100. 3-101. 3-102. 3-103. 3-104. 3-105. 3-106. 3-107. 3-108. 3-109. 3-110. 3-111. 3-112. 3-113. 3-114. 3-115. 3-116. 3-117. 3-118. 3-119. 3-120. 3-121. 3-122. 3-123. 3-124. 3-125. 3-126. 3-127. 3-128. 3-129. 3-130. 3-131. 3-132. 3-133. vi Title Page 400 Hz electric governor system wiring harness assembly, Drawing No. 84-704 (sheet 1 of 2) . . . . . .
PAGE 13
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 LIST OF ILLUSTRATIONS (Cont.) Figure 3-134. 3-135. 3-136. 3-137. 3-138. 3-139. 3-140. 3-141. 3-142. 3-143. 3-144. 3-145. 3-146. 3-147. 3-148. 3-149. 3-150. 3-151. 3-152. 4-1. 5-1. 5-2. 5-3. 5-4. 5-5. 5-6. 5-7. 5-8. 5-9. 5-10. 5-11. 5-12. 5-13. 5-14. 5-15. 5-16. 5-17. 5-18. 5-19. 5-20. 5-21. 5-22. 5-23. 5-24. 5-25. 5-26 5-27. 5-28. Title Page Static exciter and voltage regulator assembly sensing circuit bench test . . . . . . . . . .
PAGE 14
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 LIST OF ILLUSTRATIONS (Cont.) Figure 5-29. 5-30. 5-31. 5-32. 5-33. 5-34. 5-35. 5-36. 5-37. Title Page Remote functions assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62 Wiring harness assembly diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63 Relay Socke tAssembly . . . . . . . . . . . . . . . . . . . . . . .
PAGE 15
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 HOW TO USE THIS MANUAL This manual provides information for use in operating and maintaining the generator set. Maintaining the generator set includes observation of symptoms of trouble, troubleshooting procedures, and maintenance procedures to correct a malfunction. You must familiarize yourself with the maintenance procedures before beginning the maintenance tasks.
PAGE 16
ARMY TM 9-6115-464-34 AIR FORCE 35C2-2445-2 NAVY NAVFAC P-8-624-34 h. Wiring diagrams and schematics located in the manual, are valuable aids in troubleshooting. An explanation of their use follows: (1) Some of the wiring diagrams are too large for all the information to be included on a single sheet. These are separated into more than one sheet. The sheets are numbered accordingly. (2) individual wire numbers are shown at each item location. There is also a symbol that indicates where that wire terminates.
PAGE 17
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 CHAPTER 1 INTRODUCTION Section I. GENERAL INFORMATION 1-1. SCOPE. a. This manual contains instructions for the use of (direct and general support) and depot maintenance personnel responsible for maintaining the 15 KW Diesel Engine Generator Sets, Models MEP-004A, MEP-103A, and MEP–113A.
PAGE 18
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 1-5. DESTRUCTION OF MATERIAL TO PREVENT ENEMY USE. Destruction of the generator set to prevent enemy use will be in accordance with the requirements of TM 750-244-3 (Procedures for Destruction of Equipment to Prevent Enemy Use) for U.S. Army. 1-6. SHIPMENT AND STORAGE. a. (F) Preparation for shipment and storage of the generator set for US Air Force will be in accordance with TO 35-1-4. b.
PAGE 19
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 1-10. TABULATED DATA. a. General. This paragraph contains all maintenance data pertinent to (Direct and General Support), and Depot maintenance personnel. For additional tabulated data, refer to the Operator and Unit Maintenance Manual. b. Engine Classification and Rating. Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D198ERX51 .
PAGE 20
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Piston and piston pin: Piston material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heat treated aluminum alloy Pin material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alloy steel Pin type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 21
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 e. Static Exciter and Voltage Regulator Assembly Classification and Rating. Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solid state Voltage regulation: MEP-004A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 percent of rated voltage MEP-103A . . . . . . . . . . . .
PAGE 22
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 1-6
PAGE 23
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 j. Underfrequency Relay Classification and Rating. DOD drawing number: 50/60 Hz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 70-1119 400 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-1141 . Input voltage (nominal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 24
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 1-8
PAGE 25
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 1-9
PAGE 26
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 t. 50/60 Hz Generator Repair and Replacement Standards. Rotor: Number of coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Turns per coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335 Wires per turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 27
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 1-11
PAGE 28
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 1-12
PAGE 29
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 1-13
PAGE 30
ARMY TM 9-6115 464 34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 1-1. FITS AND TOLERANCES Mfg’s Tolerances Desired Clearance Component CYLINDER BLOCK: Cylinder bore dia. Cylinder bore dia.(Bohn) Cylinder bore out of round Cylinder bore taper Main brg. bore - less brgs. Camshaft brg. bore - less brgs. Oil pump bore Valve tappet bore Warpage Milling CRANKSHAFT: Main brg. journal dia. Main brg. journal out of round Main brg. journal taper Main brg. run-out at center Conn. rod journal dia. Conn.
PAGE 31
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 1-1. FITS AND TOLERANCES (CONTINUED) Mfg’s. Tolerances Desired Clearance Component Minimum PISTON RING: Clearance in groove – top Clearance in groove – 2nd & 3rd comp. Clearance in groove – oil control Gap VALVE, INTAKE: Head diameter Stem diameter Stem to guide clearance Stem to rocker arm clearance – hot Seat diameter in head Seat width in head Top of valve recessed below cyl.
PAGE 32
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 1-1. FITS AND TOLERANCES (CONTINUED) Mfg’s. Tolerances Desired Clearance Component Minimum Maximum OIL PUMP BODY: Shaft bore diameter – main Shaft bore diameter - idler Pump gear bore diameter Pump gear bore depth Mounting flange & top of drive flange 0.6255 0.6255 1.5005 1.5640 0.6265 0.6265 1.5015 1.5650 SHAFTS: Length – main Length – idler Diameter - main Diameter – idler Shaft clearance in body 9.2400 2.7450 0.6240 0.
PAGE 33
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 1-1. FITS AND TOLERANCES (CONTINUED) Mfg’s. Tolerances Desired Clearance Component Minimum Maximum FUEL BURNING WINTERIZATION KIT (CONT) Adapter face (parallel with rotor side of adapter) Pump, cam ring to rotor clearance FUEL PUMP: Roller to roller dimension Transfer pump blades (determine wear by measuring length) MAIN BEARING: Clearance Minimum Maximum Maximum Allowable Wear Maximum Allowable Clearance 0.001 0.002 1.
PAGE 34
PAGE 35
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 CHAPTER 2 GENERAL MAINTENANCE INSTRUCTIONS Section I. REPAIR PARTS, SPECIAL TOOLS, AND EQUIPMENT 2-1. TOOLS AND SUPPORT EQUIPMENT. There are no special tools or support equipment required to perform any level of maintenance on generator set Models MEP-004A, MEP-103A, and MEP-113A.
PAGE 36
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 2-1. TOOLS AND SUPPORT EQUIPMENT (CONTINUED) Item FSN or Part No. Reference Figure Para.
PAGE 37
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 2-1. TOOLS AND SUPPORT EQUIPMENT (CONTINUED) Item FSN or Part No. Reference Figure Para.
PAGE 38
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Section II. TROUBLESHOOTING 2-4. GENERAL. This section provides information useful in diagnosing and correcting unsatisfactory operation or failure of the generator sets and their components. Malfunctions which may occur are listed in table 2-2. Each malfunction is followed by test or inspections and corrective actions.
PAGE 39
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 2-2. TROUBLESHOOTING (CONTINUED) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 2. Defective speed switch (figure 3-15). Repair or replace speed switch (para. 3-7). Step 3. Defective fuel injection pump (figure 3-21). Repair or replace fuel injection pump (para. 3-22). Step 4. Governor actuator improperly positioned. Check governor (para.
PAGE 40
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 2-2. TROUBLESHOOTING (CONTINUED) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 5. Improper governor adjustment. Adjust governor (para. 3-64, Electro-hydraulic governor, or 3-65, electric governor equipped precise sets). 5. ENGINE STOPS SUDDENLY. Step 1. Defective fuel injection pump (Figure 3-21). Repair or replace fuel injection pump (para 3-22). Step 2. Defective speed switch (figure 3-15).
PAGE 41
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 2-2. TROUBLESHOOTING (CONTINUED) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 7. Defective hydraulic pump (Electro-hydraulic governor equipped precise sets only) (figure 3-34). Test and repair hydraulic pump (para. 3-41). Step 8. Defective cylinder head gasket (11, figure 3-46). Replace defective cylinder head gasket (para. 3-54). Step 9. Improper governor adjustment. Adjust governor (para.
PAGE 42
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 2-2. TROUBLESHOOTING (CONTINUED) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 4. Oil pump defective. Repair or replace oil pump (para. 3-39). 9. ENGINE KNOCKS. Step 1. Fuel injection nozzle sticking (figure 3-25). Clean, repair or replace fuel injection nozzles (para. 3-23). Step 2. Fuel injection pump timing advanced (figure 3-21). Adjust fuel injection pump timing (para. 3-22). Step 3. Main bearings worn (figure 3-52).
PAGE 43
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 2-2. TROUBLESHOOTING (CONTINUED) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 3. Worn valve guides or seals (figure 3-46). Replace valve guides and seals (para. 3-54). Step 4. Burned valves (figure 3-46). Replace or repair burned valves (para. 3-54). Step 5. Defective head gasket (11, figure 3-46). Replace defective head gasket (para. 3-54). 11. ENGINE OIL CONSUMPTION EXCESSIVE. Step 1. Leaking seals (figure 3-44).
PAGE 44
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 2-2. TROUBLESHOOTING (CONTINUED) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 4. Worn camshaft bearings (figure 3-53). Replace camshaft bearings (para. 3-55). 13. BATTERY CHARGING AMMETER SHOWS NO CHARGE WHEN BATTERIES ARE LOW. Step 1. Battery changing alternator voltage regulator out of adjustment or defective. Adjust or replace battery charging alternator voltage regulator and cover assembly (para.3-6). Step 2.
PAGE 45
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 2-2. TROUBLESHOOTING (CONTINUED) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 2. Defective undervoltage, short circuit (K-13) or overload relay (K-14). Replace defective relay assembly (para. 3-89). NOTE See DC schematic diagram on left engine cover door for location of relays. Step 3. Defective contactor switch S3. Check switch S3. Replace if defective. Step 4. Defective main load contactor (figure 3-100).
PAGE 46
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 2-2. TROUBLESHOOTING (CONTINUED) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 2. Loose electrical connection (figure 3-130). Check and tighten electrical connection. 19. POOR VOLTAGE REGULATION. Step 1. Operations switch set to parallel operation. Place switch to single unit position (para. 3-59). Step 2. Defective voltage regulator (figure 3-130). Repair voltage regulator assembly (para. 3-92). Step 3.
PAGE 47
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 2-2. TROUBLESHOOTING (CONTINUED) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 3. Defective ac ammeter. Replace ac ammeter (para. 3-59). Step 4. Defective current transformer CT1, CT2, OR CT3 (10, figure 3-108). Test and replace defective transformers (para. 3-86). 23. WATT METER FAILS TO REGISTER. Step 1. Defective control cubicle wiring harness assembly (figure 3-59).
PAGE 48
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 2-1.
PAGE 49
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Section Ill. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS 2-5. GENERAL. a. The engine and generator are rigidly bolted together at the engine flywheel housing. This assembly is mounted on the skid base at three points, the front engine trunnion and the two generator feet. Rotation and cooling of the generator is accomplished by a blower and coupling disc assembly which is bolted to the engine flywheel.
PAGE 50
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (i) lf winterization kits are installed, tag and disconnect electrical Ieads to engine sensors and disconnect coolant lines from engine oil pan. CAUTION Do not use a lifting device of less than 1000 lb. capacity. Failure to observe this caution could result in damage to the equipment. (2) Attach a suitable lifting device to engine lifting brackets. (3) Disconnect engine crankcase oil drain tube from fitting in skid base.
PAGE 51
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (9) Install access cover (3), Iockwashers (2), and screw (1). (10) Connect engine crankcase oil drain tube to fitting on skid base. (11) Remove lifting device from hook located on the engine. (12) Refer to the operator and unit maintenance manual TM 9-6115-464-12, sections 8,9 and 10 and accomplish the following: (a) Install winterization kits and connect electrical leads to engine sensors and connect coolant lines to engine oil pan.
PAGE 52
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (9) Remove nuts (14), Iockwashers (15), screws (16) and flat washers (17) to remove right relay table (18). (10) Remove nuts (19), Iockwashers (20), screws (21) and flat washers (22) to remove left relay table (23). (11) Remove screw (24), Iockwasher (25) and access cover (26). (12) Remove screws (27), Iockwashers (28), and air inlet screen (29). (13) Install engine support bracket (30), flat washer (31), Iockwasher (32) and nut (33).
PAGE 53
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (13) Position rear housing support (5), to install screws (4), fltat washers (3), Iockwashers (2), and nuts (1). (14) Install main load contactor and special relay assembly (paragraphs 3-84 and 3-90). (15) Install voltage reconnection board (See the Operator and Unit Maintenance Manual TM 9-6115-464-12, paragraph 4-71). (16) Connect electrical leads between voltage reconnection board and terminal board. Remove tags.
PAGE 54
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 2-2.
PAGE 55
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 CHAPTER 3 ENGINE AND GENERATOR REPAIR INSTRUCTIONS Section I. MAINTENANCE OF ENGINE ELECTRICAL SYSTEM 3-1. GENERAL. The engine electrical system consists of a starting circuit, a battery charging circuit, and protective and monitoring devices. Electrical power for cranking the engine is supplied by two 12 volt, 100 amp-hour lead-acid type batteries connected in series. A slave receptacle facilitates external connection to the batteries.
PAGE 56
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (16) Remove nut (56), flat washer (57), and insulating washer (58). (17) Remove screws (59) to remove pole shoes (60), field coil assembly (61) and insulator (62). (18) Remove and discard o-ring (63) and packing (64). (19) Remove screws (65) and Iockwashers (66) to remove drive housing (67) and gasket (68). Discard gasket. (20) Remove plug (69) and oil wick (70). (21) Do not remove bushing (71) unless inspection reveals defects.
PAGE 57
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3–1.
PAGE 58
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 1 Nut 2 Lockwasher 3 Terminal lead 4 Screw 5 Solenoid assembly 6 Nut 7. Flat washer 8. Insulating washer 9. Nut 10. Lockwasher 11. Nut 12. Flat washer 13. Insulating washer 14. Screw 15. Flat washer 16. Cover 17. Gasket 18. Frame assembly 19. Nuts 20. Lockwasher 21. Nut 22. Flat washer 23. Insulating washer 24. Terminal stud 25. Terminal stud 26. Contact strip 27. Spring 28. Contact assembly 29. Plug 30. Retaining ring 31. Pin 32.
PAGE 59
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 CAUTION Do not allow solvent to contact brushes. Failure to observe this caution could result in equipment damage. (5) Clean brushes with a clean, lint-free cloth. (6) Inspect housings and frames for cracks, corrosion, and distortion. Replace defective parts. (7) Inspect bushings for wear, galling, and scores. Replace defective parts. (8) Test armature for grounding as follows: (a) Connect one lead of a test light to the armature core.
PAGE 60
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (21) Remove minor rough spots, scores, and scratches from bushings using fine crows cloth or a fine stone dipped in cleaning solvent. Wash the bushings thoroughly in cleaning solvent to remove all grit and metal particles. d. Assembly. (1) Assemble starter assembly in reverse order of removal procedures using new gaskets. (2) If brushes were replaced, run in new brushes as follows: (a) Cover armature commutator with a piece of No.
PAGE 61
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (4) Conduct starter assembly stalled torque test as follows: CAUTION Rheostat must have a minimum capacity of 1000 amperes. Failure to observe this caution could result in equipment damage (a) Install starter assembly in test setup shown in figure 3-3. (b) Adjust rheostat until voltmeter indicates 14 Vdc. (c) Ammeter should indicate 540 amperes maximum at a minimum torque of 26 ft-lb indicated on scale.
PAGE 62
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-2.
PAGE 63
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3–3.
PAGE 64
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-4. Starter Assembly, Exploded View (Effective with Serial No.
PAGE 65
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 1. Nut 2. Lockwasher 3. Nut 4. Lockwasher 5. Clamp 6. Screw 7. Solenoid Assembly 8. Boot 9. Nut 10. Lockwasher 11. Nut 12. Flat washer 13. Insulating washer 14. Connector 15. Screw 16. Flat washer 17. Cover 18. Gasket 19. Solenoid frame assy 20. Terminal stud 21. Terminal stud 22. Terminal clip 23. Spring 24. Contact 25. Inspection plug 26. Gasket 27. Adjusting nut 28. Plunger 29. Snap ring 30. O-ring 31. Spring retainer 32. Spring 33.
PAGE 66
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 CAUTION Use care when removing armature to prevent damage to windings. Failure to observe this caution could result in equipment damage. (16) Slide armature (73) from field frame (74). (17) Remove nut (75), washer (76) and insulating washer (77). (18) Remove screws (78) to remove pole shoes (79), field coil (80) and insulator (81). Remove o-ring (82). (19) Inspect field coil insulation (83). Replace if damage is evident. e.
PAGE 67
ARMY TM 9-6115-454-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (6) Inspect housing and frames for cracks, corrosion, and distortion. Replace defective parts. (7) Inspect bushings for wear, galling, and scores. Replace defective parts. (8) Test armature for grounding as follows: (a) Connect one lead of a test light to the armature core. (b) Touch the other test lead to each commutator riser. (c) If test light glows, armature is grounded and must be replaced.
PAGE 68
ARMY TM 9-6115-464-34 AIR FORCE TO 36C2-3-445-2 NAVY NAVFAC P-8-624-34 f. Assembly. (1) Assemble starter and solenoid in reverse order of disassembly procedures using new gaskets and o-rings. Inspect all insulating washers and bushings. Replace if defective. (2) If brushes were replaced, run in new brushes as follows: (a) Cover armature commutator with a piece of No. 00 grit sandpaper. (b) Temporarily install brushes and commutator end frame and run in brushes.
PAGE 69
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (c) Ammeter should indicate 540 amperes maximum at a minimum torque of 26 ft-lb indicated on scale. (d) If both current and torque are low, disassemble the starter and check for poor internal connections or improper brush contact. Both of these conditions would result in high internal resistance. (e) High current and low torque may be caused by defective armature or field coil assembly.
PAGE 70
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (14) Pry woodruff key (47) from keyway in rotor shaft and remove spacer (48). (15) Support head assembly (49) and using a center punch in the indentation in the end of the rotor shaft, drive the rotor assembly (50) out of the head assembly (49). (16) Remove snap ring (51) and bearing (52) and o-ring (55). NOTE It maybe necessary to press or drive the bearing (52) out of the head assembly (49).
PAGE 71
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-5.
PAGE 72
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 1. Screw 2. Regulator and cover assembly 3. Fuse holder 4. Nut 5. Washer 6. Cap 7. Fuse 8. Screw 9. Cover band 10. Thru bolts 11. Head assembly (slip ring end) 12. Nut 13. Nut 14. Lockwasher 15. Brush lead 16. Screw 17. Lockwasher 18. Insulating plate 19. Brushholder 20. Brush and spring assembly 21. Nut 22. Nut 23. Nut 24. Lockwasher 25. Screw 26. Flat washer 27. Capacitor and clamp assembly 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38.
PAGE 73
ARMY TM 9-6115-464-34 AlR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-6.
PAGE 74
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTE The brushes are excessively worn if 3/16 inch or less extends beyond the bottom of the holder. (14) Check brush spring tension. A force of 4 to 6 ounces should move brush against spring. (15) Using an ohmmeter, test brushholder assembly as follows: (a) Attach one test lead to brushholder and touch other lead to each terminal and each brush. There should be no indication of continuity between brushholder and any terminal or brush.
PAGE 75
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (14) Remove wire, inserted in step 3-6d. (11). NOTE Perform steps in paragraph 3-6e(1) before proceeding with assembly. (15) Install capacitor and clamp assembly (27), screw (25), washers (26), Iockwasher (24) and nut (23). Install nuts (22 and 21). (16) Install capacitor and clamp assembly (28) and brush lead (15). (17) Install ventilated cover band (9) with screws (8).
PAGE 76
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-7. Alternator Test Leads Installation (3) Check alternator total circuit voltage as follows: (a) Install alternator in test circuit as shown in figure 3-6. NOTE The test circuit is identical to the alternator installation circuit. If an operational generator set is available, the alternator maybe installed on it for testing. (Refer to the Operator and Unit Maintenance Manual for installation instructions.
PAGE 77
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (b) If voltage is zero, check fuse (11, figure 3-5). (c) If voltage is greater than zero, but below voltage VI in figure 3-8, check for poor circuit conditions between battery positive terminal and alternator positive output terminal. (d) Correct any discrepancies before proceeding with operational tests. (e) If voltage indicated is equal to voltage V1, test alternator negative output circuit as directed in step (5) below.
PAGE 78
ARMY TM 9-6115-464-34 AIR FORCE TO 36C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-8.
PAGE 79
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-9.
PAGE 80
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-10.
PAGE 81
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3–11.
PAGE 82
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 CAUTION Rheostat must be set in maximum resistance position to protect the ammeter in the event the field circuit is short circuited. Failure to observe this caution could result in equipment damage. (a) Install alternator in test circuit as shown in figure 3-13. (b) Slowly reduce field rheostat resistance while observing ammeter and voltmeter. (c) When field rheostat reaches zero ohms, ammeter should indicate 3.0 to 3.
PAGE 83
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-12.
PAGE 84
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-13.
PAGE 85
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 3-7. SPEED SWITCH. a. General. (1) The speed switch provides sequenced control of circuits during engine startup, and protection against engine overspeed during operation. Three sets of contact elements, S9-1, S9-2, and S9-3, contained in the speed switch, are set to open, close, or transfer at certain engine speeds. The speed switch drive gear is designed to drive the speed switch at one-half engine speed.
PAGE 86
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 b. Removal. Refer to Operator and Unit Maintenance Manual for speed switch removal instructions. NOTE Two different types of switch, one electronic, the other mechanical, are used interchangeably in the sets. Determine which type you are removing by referring to figure 3-15 sheets 1 and 2 and proceed accordingly. c. Disassembly (Electronic Type).
PAGE 87
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (2) Refasten with lockwire after readjustment. (h). Assembly (Mechancial Type (1) Position body assembly (8, figure 3-15 sheet 2 ), to install retaining ring (9), packing (7), spacer (6), and counterweight (5). (2) Position cap and cover assembly (10), to install rotor assembly (4), washer (3), and Iockwire (2), and screw (1). (3) Install lockwire on to speed switch. i. Test Equipment (Electronical Type).
PAGE 88
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (12) After Element No. 3 has tripped, connect the VOM between pins F and J to check for continuity. Continuity should exist after Element No. 3 has tripped. (13) Slowly decrease shaft speed while monitoring pin D with the VOM for voltage. There should be 24 volts present, dropping to 0 volts when Element No. 2 resets. “Reset speed” for Element No. 2 should be no more than 100 RPM below the trip speed noted in step (10).
PAGE 89
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-15.
PAGE 90
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-15. Speed Switch, Exploded View (Mechanical Switch) (Sheet 2 of 2) NOTE To obtain the required performance characteristics during tests (3) through (6), adjustments can be made. By loosening screws (1, figure 3-15, sheet 2) and rotating the cap and cover assembly relative to the body assembly, the trip points of all those elements can be raised or lowered.
PAGE 91
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-16.
PAGE 92
ARMY TM 9-6115-464-34 AIR FORCE TO 36C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-16.
PAGE 93
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 3-8. COOLANT TEMPERATURE TRANSMllTER. Refer to the Operator and Unit Maintenance Manual for coolant temperature transmitter maintenance procedures. 3-9. OVERTEMPERATURE SWITCH. Refer to the Operator and Unit Maintenance Manual for overtemperature switch maintenance procedures. 3-10. OIL PRESSURE TRANSMllTER. Refer to the Operator and Unit Maintenance Manual for oil pressure transmitter maintenance procedures. 3-11.
PAGE 94
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-17. Engine Wiring Harness Assembly, Drawing No. 72-2267 (Sheet 1 of 2).
PAGE 95
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-17. Engine Wiring Harness Assembly, Drawing No.
PAGE 96
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 3-16. MAIN FUEL TANK (METAL). a. Removal. (1) Refer to the Operator and Unit Manual and accomplish the following: (a) Drain the main fuel tank assembly. (b) Disconnect fuel lines and fittings from main fuel tank. (c) Disconnect fuel vent system from main fuel tank. (d) Disconnect engine wiring harness from fuel level gauge.
PAGE 97
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 c. Installation. NOTE Install filler neck hose with vent holes to top and outboard. (1) Position metal fuel tank (20, figure 3-18) to install drain valve (19) and cap (18). (2) Install new fuel level switch gasket (17), fuel level switch (16), lockwasher (15), and screws (14). (3) Position strap (13), to install flatwasher (12), and locknut (11). (4) Install gasket (10), adapter (9), Iockwasher (8) and screws (7).
PAGE 98
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-18.
PAGE 99
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (1) Clean exterior surfaces of fuel tank and other nonelectrical parts with dry cleaning solvent (Federal Specification P-D-680). (2) Flush interior of fuel tank with an approved solvent. (3) Inspect fuel tank assembly for cracked or broken welds, dents, leaks, and other damage. (4) Test fuel level sensor in accordance with instructions provided in Operator and Unit Maintenance Manual.
PAGE 100
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-19. Main Fuel Tank (Plastic), Removal and Installation 3-20. DAY TANK ASSEMBLY. a. Removal. Refer to the Operator and Unit Maintenance Manual for day tank assembly removal instructions. b. Cleaning, Inspection, and Repair. WARNING Solvent, Dry Cleaning P-D-880, Type II is flammable and moderately toxic to skin, eyes and respiratory tract. Eye and skin protection required. Good general ventilation is normally adequate.
PAGE 101
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 WARNING Compressed air used for cleaning and drying purposes can create airborne particles that may enter the eyes. Pressure shall not exceed 30 psig and use only with adequate Failure to observe this warning could result in chip guards and chipping goggles. servere personel injury. (1) Clean exterior surfaces with dry cleaning solvent (Federal Specification P-D-680) and dry with filtered compressed air.
PAGE 102
ARMY TM 9-6115-464-34 AIR FORCE TO 36C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-20.
PAGE 103
ARMY TM 9-6115464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-6-624-34 (1) Refer to the Operator and Unit Maintenance Manual and drain the day tank assembly. (2) Disconnect injector return lines (1 and 2, figure 3-20) and remove tee (3). (3) On precise sets, remove self-locking nut (4) and screw (5) to disconnect hydraulic actuator linkage (6). On utility sets disconnect the manual speed control.
PAGE 104
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-6-624-34 Figure 3-21.
PAGE 105
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-6-624-34 Figure 3-21. Fuel Injection Pump, Exploded View (Sheet 2 of 7) Figure 3–21.
PAGE 106
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-6-624-34 Figure 3–21. Fuel Injection Pump, Exploded View (Sheet 4 of 7) Figure 3-21.
PAGE 107
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-6-624-34 Figure 3–21. Fuel Injection Pump, Exploded View (Sheet 6 of 7) Figure 3-21.
PAGE 108
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (10) To disassemble transfer pump, lift out transfer pump seal (68), liner (72), blades (71), and springs (70). (11) Remove the speed droop adjusting cap assembly (73) by pulling it from control rod guide (75). (12) Remove and discard control spring pin (78). (13) Discard seals (74 and 77), control rod guide (75) and washer (76). CAUTION Use care not to bend control rod. Failure to observe this caution could result in equipment damage.
PAGE 109
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (26) Lift off the cam ring (121 ). Check and record the roller-to-roller dimension as instructed in the assembly procedures. This dimension should be 1.9640 ± 0.0005 inches. Remove rollers (125), shoes (126), plungers (127), and leaf springs (124). Discard spring screws (123). CAUTION Do not handle rotor shank. Failure to observe this caution could result in equipment damage.
PAGE 110
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-446-2 NAVY NAVFAC P-8-624-34 (10) Examine the junction points of the metering valve pin hole in the linkage hook, throttle lever, shutoff cam, and shutoff lever for looseness and burrs. (11) Check the metering valve body for wear. Ascertain that the metering valve arm is well seated and there is no radial movement of the arm on the valve. Check the metering valve arm pin for wear or looseness.
PAGE 111
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTE The thrust plate may be reversed if one side appears worn or scratched. A small amount of grease may be used to hold the thrust plate in place, CAUTION Do not use force when inserting rotor. Binding may be caused by the presence of foreign particles. If rotor binds, withdraw it, rinse the rotor and hydraulic head in clean fuel and attempt to assemble again. Failure to observe this caution could result in equipment damage.
PAGE 112
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-22. Adjusting Fuel Injection Pump Roller-to-Roller Dimension (15) Carefully insert the transfer pump blades (71) and springs (70) taking care not to cock them. Rotate the liner several times to check for freedom of movement. Return the liner to the correct position. (16) Install transfer pump seal (68). (17) Slip the head and rotor assembly, drive end up, into the holding fixture.
PAGE 113
ARMY TM 9-6115 464 34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTE Make sure that the assembly is wrung into position past the hydraulic head seal (122). Failure to do this may result in leakage. (21) Rotate the hydraulic head until the head locking screw holes are aligned. Install head locking screws (136 and 137) finger tight. (22) Invert the pump and holding fixture in the vise so that the bottom faces up. (23) Install seals (107) and head locating screw (106).
PAGE 114
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-4452 NAVY NAVFAC P-8-624-34 (38) Slide speed droop guide (75) with seal (77), assembled over end of rod (79) and thread into the housing. Tighten securely. (39) Insert control spring pin (78) into hole at end of rod (79). (40) Assemble seal (74) to groove at end of guide (75) and install speed droop cap assembly (73) over seal. (41) Install end plate (66), making sure that guide pin (69) enters the slot in the transfer pump liner (72).
PAGE 115
ARMY TM 9-6115-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-23. Throttle Linkage Adjustment f. Fuel Inject Pump Bench Test. (1) General. The bench test procedure is based on the following renditions: (a) Injection lines are 3/32 inch ID by 30 inches long. (b) Fuel readings are based on fuel with a viscosity of 34-36 SSU at 100°F. (c) Fuel temperature at 110° to 115°F. (d) Nozzles, part number 12SD12, adjusted to opening pressure of 2500 psi (170 ATS). (2) Test procedure.
PAGE 116
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTE Pump runs at half the engine speed. (c) Start the test stand at lowest speed and check for clockwise rotation. Move throttle to full-load position. When transfer pump picks up suction, allow fuel to bleed for several seconds from loosened connector screws and injection line nuts, then tighten securely. WARNING Compressed air used for cleaning and drying purposes can create airborne particles that may enter the eyes.
PAGE 117
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3–24.
PAGE 118
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 3-1. FUEL DELlVERY PUMP RPM DELlVERY (mm3/stroke) 900 58-59 750 55-58 927 (high idle) 15-20 PRESSURE PSIG MAX VAR BETWEEN CYLINDERS 70-75 3 4 (g) Observe return oil. Return should be at rate of 100-450 cc/minute at 35 psi transfer pump pressure. CAUTION Under no circumstances should 130 psi be exceeded, as the pump will be damaged. Failure to observe this caution could result in equipment damage.
PAGE 119
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (o) At a pump speed of 200 rpm, repeat steps (n) and (o). Delivery shall be 2 mm3 maximum. (p) Check minimum cranking speed delivery as follows: 1. Check transfer pump for 8 psig minimum and close the shutoff valve to gauge. 2. Check for 35 mm3 per stroke, minimum, at 75 rpm. (q) Remove pump from test stand. g. Installation. (1) Remove fuel injector nozzle from No. 1 cylinder.
PAGE 120
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 3-23. FUEL INJECTION NOZZLE HOLDERS AND LINES. a. Removal. Refer to the Operator and Unit Maintenance Manual for fuel injection nozzle holders and lines removal instructions. b. Disassembly. (1) Unscrew spray cap (1, figure 3-25) and remove pintle holder (2) and pintle (3). (2) Remove cap (4) and washer (5). (3) Remove lock nut (6), adjusting screw (7), and washer (8) to remove spring (9) and spindle (10) from body (11). c.
PAGE 121
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-25. Fuel Injection Nozzle Holder, Exploded View (7) Observe fuel spray. Fuel spray shall be even and smooth. Spray cone shall be same thickness at a distance of 5 inches. There shall be no signs of leakage. (8) Remove fuel pressure and remove nozzle holder from testing fixture. (9) Install washer (5, figure 3-25) and cap (4). g. Installation.
PAGE 122
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Section Ill. MAINTENANCE OF ENGINE COOLING SYSTEM 3-26. GENERAL. The engine cooling system is a circulating pressure type system. It consists of a radiator, a belt driven cooling fan and centrifugal water pump, a coolant control thermostat, a thermostatically controlled shutter assembly, and a protective grille.
PAGE 123
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-26.
PAGE 124
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (7) Inspect bushings for scores and excessive wear. (8) Refer to the Operator and Unit Maintenance Manual and test thermostat. (9) Replace any damaged or defective parts. d. Assembly. (1) Position flange (32, figure 3-26) to install manual control are (31), flat washer (30), screw (29), spring (28) and nut (27). (2) Install washers (26, 25, and 24) onto actuator pin, spring (23), and retainer (22).
PAGE 125
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (7) Replace radiator if damaged beyond repair. 3-30. SHUTTER ASSEMBLY. a. Removal. Refer to the Operator and Unit Maintenance Manual for shutter removal instructions. b. Disassembly. (1) Remove spring (1, figure 3-27). (2) Remove cotter pin (2) to remove retainer (3) and spring (4). (3) Remove retainer (5) to remove control Iever( 6). (4) Remove any damaged or deteriorated seals (7) from vanes of shutter (8). Figure 3-27.
PAGE 126
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 c. Cleaning, Inspection, and Repair. WARNING Solvent, Dry Cleaning P-D-680, Type II is flammable and moderately toxic to skin, eyes and respiratory tract. Eye and skin protection required. Good general ventilation is normally adequate. Failure to observe this warning could cause servere personal injury. (1) Clean all parts in dry cleaning solvent (Federal Specification P-D-680) and dry thoroughly.
PAGE 127
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-28. Water Pump Assembly, Exploded View c. Cleaning, Inspection and Repair WARNING Solvent, Dry Cleaning P-D-880, Type II is flammable and moderately toxic to skin, eyes and respiratory tract. Eye and skin protection required. Good general ventilation is normally adequate. Failure to observe this warning could cause servere personal injury.
PAGE 128
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 d. Asssembly. CAUTION When installing seal, press on outer flange to avoid damaging the seal. Failure to observe this caution could result in equipment damage. (1) Press replacement seal (11) into pump body (12). CAUTION When installing shaft and bearing assembly, press on outer bearing face and not on end of shaft. Failure to observe this caution could result in equipment damage.
PAGE 129
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 3-33. COOLANT THERMOSTAT AND HOUSING. Refer to the Operator and Unit Maintenance Manual for coolant thermostat and housing maintenance procedures. Section IV. MAINTENANCE OF ENGINE LUBRICATION SYSTEM 3-34. GENERAL. The engine oil pan serves as a reservoir for lubricating oil. It is equipped with a bayonet type gauge for checking the oil level in the pan.
PAGE 130
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (3) Scrape gasket remains from oil pan and cylinder block mating surfaces. (4) Inspect and replace oil level gauge in accordance with instructions provided in the Operator and Unit Maintenance Manual. (5) Inspect oil pan for cracks, dents, broken welds and leaks. (6) Check all threads for crossing, stripping and peening. (7) Repair cracks and broken welds in oil pan by welding.
PAGE 131
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 3-38. OIL PUMP ASSEMBLY. a. Removal. (1) Lower oil pan assembly (paragraph 3-37). (2) Remove screws (1, figure 3-31) and Iockwashers (2) to remove oil pump. b. Disassembly. (1) Remove oil pickup screen (3). (2) Remove pressure relief valve (4), Iockwasher (55) and seal (6). Discard seal. CAUTION Spring is under tension. Use care when removing roll pin. Failure to observe this caution could cause damage to the equipment.
PAGE 132
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3–31.
PAGE 133
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 d. Assembly. (1) Press drive gear (19, figure 3-31) onto shaft (20). (2) Insert shaft into pump body (22) and press gear (12) onto shaft until a dimension of 4.84375 ± 0.010 inches is obtained between the mounting flange and the top of the drive flange (figure 3-32). For type 1 dimensions use 4.220 +/– .010M (3) Press shaft (21, figure 3-31) into pump body and install driven gear (18).
PAGE 134
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-44 Figure 3-32.
PAGE 135
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Section V. MAINTENANCE OF HYDRAULIC SYSTEM (ELECTRO-HYDRAULIC GOVERNOR EQUIPPED PRECISE SETS ONLY) 3-39. GENERAL. The hydraulic system provides a means of precise frequency control on all MEP-103A and some MEP-113A precise generator sets. The system consists of a sump, a replaceable element type filter, a gear type positive displacement pump and a hydraulic actuator unit.
PAGE 136
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 1. 2. 3. 4. 5. 6. 7. Hydraulic line Nut Lockwasher Screw Hydraulic sump Cap and dipstick assy Elbow Figure 3-33.
PAGE 137
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (6) Test hydraulic sump for leaks as follows: (a) Securely install cap and dipstick assembly. (b) Install a plug in outlet connection. (c) install a fitting in inlet opening and connect an air line. (d) Submerge hydraulic sump in a container of water and pressurize at 10 to 15 psig air pressure. (e) Check for air bubble formations which will indicate leaks. (f) Remove hydraulic sump from container. Release air pressure.
PAGE 138
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 c. Cleaning, Inspection, and Repair. WARNING Solvent, Dry Cleaning P-D-680, Type II is flammable and moderately toxic to skin, eyes and respiratory tract. Eye and skin protection required. Good general ventilation is normally adequate. Failure to observe this warning could result in servere personal injury or death. (1) Clean all parts in dry cleaning solvent (Federal Specification P-D-680) and dry thoroughly.
PAGE 139
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (8) Tighten locknut and remove hydraulic pump assembly from test hookup. f. Installation. (1) Install hydraulic pump assembly with gasket (4), flat washers (3), screws (2) and Iockwires (1). (2) Install hydraulic lines and fittings onto hydraulic pump assembly.
PAGE 140
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-34.
PAGE 141
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 3-42. HYDRAULIC SYSTEM FILTER ASSEMBLY. a. Removal. (1) Disconnect hydraulic lines (1, figure 3-35), and drain hydraulic fluid into a suitable container. (2) Remove nuts (2), Iockwashers (3) and screws (4) to remove filter assembly. (3) Do not remove screws (5), Iockwashers (6), nuts (7) and mounting bracket (8) unless inspection reveals damage. b. Disassembly. (1) Remove Iockwire (9) and unscrew housing (10).
PAGE 142
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-62434 Figure 3-35.
PAGE 143
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 3-43 HYDRAULIC ACTUATOR UNIT. a. Removal. (1) Refer to the Operator and Unit Maintenance Manual and drain the hydraulic tank. (2) Disconnect electrical connectors (1 and 2, figure 3-36) and hydraulic lines (3 and 4). (3) Remove nut (5) and bolt (6). (4) Do not remove nut (7), screw (8), rod ends (9), locknut (10), and threaded rod (11) unless inspection reveals damage.
PAGE 144
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-36.
PAGE 145
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-37.
PAGE 146
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.
PAGE 147
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (18) Remove screws (57), lockwashers (58), and nuts (59) to remove mounting plates (60). (19) Remove screws (61), Iockwashers (62), and nuts (63) to remove armature (64). Remove locknuts (65) and setscrews (66) from armature. (20) Remove screws (67) and Iockwashers (68) to remove coils (69). c. Cleaning, Inspection, and Repair.
PAGE 148
ARMY TM 9-6115-464-34 AIR FORCE TO 36C2-3-445-2 NAVY NAVFAC P-8-624-34 d. Assembly. (1) Install coils (69, figure 3-37), Iockwashers (68), and screws (67). (2) Position armature (64), to install setscrews (66), and locknuts (65). Install armature (64), nuts (63), Iockwashers (62) and screws (61). (3) Install mounting plates (60), nuts (59), Iockwashers (58), and screws (57). (4) Install pin springs (56), with attaching parts, position adapters (55), to install Iockwashers (54) and screws (53).
PAGE 149
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (4) Place test stand switch (S2) in the off position to turn off hydraulic fluid pump. (5) Place the actuator unit piston in the full fuel position and check indication on test stand meter (M1). Indication should be less than 3 volts. (6) Place the actuator unit piston in the no fuel position and check indication on test stand meter (M1). Indication should be approximately 48-55 volts.
PAGE 150
ARMY TM 9-6115-464-34 AIR FORCE TO 33C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-39.
PAGE 151
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (c) Move the piston gradually towards the fully closed throttle position. The transducer secondary voltage, indicated by meter M1 shall increase in a linear manner to a maximum of 48 to 55 volts. (d) Repeat these adjustments until the transducer secondary voltage increases linearly from the lowest possible value to a maximum value over the entire 1.0 inch displacement of the piston.
PAGE 152
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-40.
PAGE 153
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 3-2.
PAGE 154
ARMY TM 9-6115-484-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Section VI MAINTENANCE OF INTAKE AND EXHAUST SYSTEMS AND BREATHER 344. GENERAL. a. The intake system consists of a dry type air cleaner assembly with a reusable type filter element. The assembly removes dust and dirt from the engine combustion air. It is equipped with a restriction transducer. The restriction transducer measures vacuum in the air cleaner housing.
PAGE 155
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 h. The connecting rods are heavy alloy steel forgings with precision type bearings for the crankshaft and bronze bushings for the full floating piston pin. The pistons are made of aluminum and are the solid type (no saw slots or splits in the skirt). Each piston is fitted with five rings. The top three rings are compression type and the fourth ring from the top is an oil control ring. The fifth ring is an oil scrapper ring. i.
PAGE 156
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-41. Engine Front Support, Removal and Installation 3-50. FLYWHEEL AND FLYWHEEL HOUSING. a. Removal. (1) Remove oil pan assembly (paragraph 3-37). (2) Remove screws (1, figure 3-42) to remove flywheel (2) and ring gear (3) as an assembly. Do not remove ring gear unless it is badly damaged and replacement is necessary.
PAGE 157
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-42. Flywheel and Flywheel Housing, Exploded View b. Cleaning, Inspection. and Repair. WARNING Solvent, Dry Cleaning P–D–680, Type II is flammable and moderately toxic to skin, eyes and respiratory tract. Eye and skin protection required. Good general ventilation is normally adequate. Failure to observe this warning could result in servere personal injury or death.
PAGE 158
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 WARNING Wear heat resistant gloves when handling heated flywheel to avoid serious burns. Failure to observe this warning could result in servere personal injury or death. (b) Remove flywheel and ring gear and lightly tap ring gear to separate. (c) Heat replacement ring gear as in step (3) (a) above while freezing flywheel. CAUTION Wear heat resistant gloves when handling frozen flywheel and heated ring gear.
PAGE 159
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-43. Checking Flywheel Concentricity and Alignment 3-51. TIMING GEARS AND COVER. a. Removal and Disassembly. (1) Remove the hydraulic pump assembly (paragraph 3-41). (2) Remove the fuel injector nozzle from No. 1 cylinder. (3) Turn the engine over until the 20 degree before top dead center (BDC) mark on the engine flywheel is aligned with the timing mark on the flywheel housing and No. 1 cylinder is on compression stroke.
PAGE 160
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (10) If inspection indicates that idler bearings must be replaced, disassemble idler as follows: (a) Remove bearings (26) and press races (27) from gear (29). NOTE Each bearing and race is a matched set and must be replaced as such. (b) Remove ring (28) from gear. (11) Do not remove idler shaft (30) from cylinder block unless inspection reveals damage. (12) Remove screws (31) and Iockwashers (32) to remove housing (33) and gasket (34).
PAGE 161
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTE: Spacers (35) located top and bottom holes of cover (17). Figure 3-44.
PAGE 162
ARMY TM 9-6115-464-34 AIR FORCE TO 36C2-3-446-2 NAVY NAVFAC P-8-624-34 (8) Install gasket (18) and cover (17) and secure with Iockwashers (8, 10,12,14, and 16), screw (15) and screws (7, 9, 11, and 13). (9) Install spring (6), thrust button (5), gasket (4), and thrust plate (3) and secure with Iockwashers (2) and screws (1). (10) Install hydraulic pump assembly (paragraph 3-41). (11) Install front engine support (paragraph 3-41). (12) Install injector in No.
PAGE 163
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 1. 2. 3. 4. 5. 6. Crankshaft gear Idler assembIy Camshaft gear Fuel pump drive gear Timing gear housing Timing marks Figure 3-45.
PAGE 164
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 3-52. INTAKE MANIFOLD. Refer to the Operator and Unit Maintenance Manual for intake manifold maintenance procedure. 3-53. EXHAUST MANIFOLD. Refer to the Operator and Unit Maintenance Manual for exhaust manifold maintenance procedure. 3-54. CYLINDER HEAD AND ROCKER ARM ASSEMBLY. a. Removal.
PAGE 165
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-46.
PAGE 166
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 c. Cleaning, Inspection, and Repair. WARNING Solvent, Dry Cleaning P-D-680, Type II is flammable and moderately toxic to skin, eyes and respiratory tract. Eye and skin protection required. Good general ventilation is normally adequate. Failure to obsever this warning could cause servere personal injury or death. WARNING Compressed air used for cleaning and drying purposes can create airborne particles that may enter the eyes.
PAGE 167
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (13) Perform magnetic particle inspection in accordance with established procedures. (14) Inspect valve seats of cylinder head. If they are pitted or if new valve guides were installed, the valve seats must be refinished, using a tool with a 3/8 inch pilot. Both intake and exhaust valve seats should be refinished on an angle of 30 degrees for intake valves and 45 degrees for exhaust valves. NOTE Use a vibrating angle grinder type tool.
PAGE 168
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (n) Make ten or twelve pencil marks, equally spaced, across valve seat. (o) Install valve, press firmly, and rotate approximately one quarter of a turn. (P) Remove valve and observe pencil marks. If marks are rubbed out, valve is seating properly. If all pencil marks are not rubbed out, repeat grinding process. CAUTION Mark each valve to insure that it will be installed in the seat into which it was ground.
PAGE 169
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-47. Rocker Arm Mounting Blocks Installation Figure 3-48.
PAGE 170
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-49. Cylinder Head Nut Tightening Sequence 3-55. CAMSHAFT a. Removal. (1) Remove oil pan (paragraph 3-37). (2) Remove oil pump assembly (paragraph 3-38). (3) Remove timing gear cover (paragraph 3-51). (4) Remove rocker arm assembly and push rods (paragraph 3-54). (5) Rotate engine crankshaft until screws (1, figure 3-50) are visible through holes in camshaft drive gear.
PAGE 171
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 b. Disassembly. (1) Remove nut (3, figure 3–50) and support drive gear (4) on arbor press. (2) Press shaft (5) out of gear and remove key (6) and thrust plate (7). c. Cleaning, Inspection, and Repair. WARNING Solvent, Dry Cleaning P-D-680, Type II is flammable and moderately toxic to skin, eyes and respiratory tract. Eye and skin protection required. Good general ventilation is normally adequate.
PAGE 172
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-824-34 Figure 3-50.
PAGE 173
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-51 .Dimensional Inspection of Camshaft (11) If dimension obtained in step (8) indicates excessive wear, replace camshaft bearings as follows: (a) Using a suitable press, remove camshaft bearings from cylinder block. CAUTION Make sure that the replacement bearings are installed so that oil holes match with oil ports in cylinder block. Failure to observe this caution could result in equipment damage.
PAGE 174
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (3) Install camshaft (5, figure 3-50) with Iockwashers (2) and screws (1). (4) Refer to the Operator and Unit Maintenance Manual to install fuel filter assemblies, (5) Install rocker arm assembly and push rods (paragraph 3-54). (6) Install timing gear cover (paragraph 3-51). (7) Install oil pump assembly (paragraph 3-38). (8) Install oil pan (paragraph 3-37).
PAGE 175
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 CAUTION Conspicuously mark each main bearing cap as to position to aid at assembly. Failure to observe this caution could result in equipment damage. b. Disassembly. (1) Do not remove crankshaft gear (13) and woodruff key (14) unless inspection reveals damage and replacement is necessary. (2) Remove retaining ring (15) and piston pin (16) to remove piston assembly (17) from connecting rod (18).
PAGE 176
ARMY TM 9-6115-484-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-52.
PAGE 177
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 c. Cleaning, Inspection, and Repair. WARNING Solvent, Dry Cleaning P-D-680, Type II is flammable and moderately toxic to skin, eyes and respiratory tract. Eye and skin protection required. Good general ventilation is normally adequate. Failure to observe this warning could result in personal injury or death. WARNING Compressed air used for cleaning and drying purposes can create airborne particles that may enter the eyes.
PAGE 178
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (7) If necessary, regrind crankshaft bearing journals to accept undersized bearings in accordance with Table 3–3. (8) inspect crankshaft gear for cracks and chipped, broken or excessive worn teeth. (9) lf replacement of crankshaft gear is necessary, proceed as follows: (a) Support crankshaft gear in arbor press and press crankshaft and woodruff key from gear. (b) Heat replacement gear in an oven at 450°F. (232.2 °C.
PAGE 179
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 d. AssembIy. (1) Using a piston ring expander install oil control ring (23, figure 3-52), scraper ring (22) and compression rings (21 ) onto pistons (24). NOTE If replacement piston rings have dots on the rings, the rings should be installed with the dots toward the piston head. (2) Apply a light coat of engine oil to the bushing (19) and connecting rod (18) and press the bushing into the connecting rod.
PAGE 180
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (11) Apply a liberal coating of engine Iubricating oil to cylinder bores, pistons, piston rings and piston pins. NOTE Proper position of the oil ring gap is with the gap aligned with either piston pin hole. (12) Position piston rings so that no two gaps are aligned.
PAGE 181
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (13) Do not remove plug (15) from cylinder block (16) unless replacement is necessary. b. Cleaning, Inspection, and Repair. (1) Clean sludge and dirt deposits from cylinder block with dry cleaning solvent. If necessary, block should be steam cleaned. (2) Clean all oil and water passages. (3) Scrape carbon deposits from top of block. (4) Remove gasket remains from all mating surfaces.
PAGE 182
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (6) If removed, install stud (4) and oil filler neck and cap assembly (3). (7) Install plugs (2 and 1, figure 3-53). (8) Install crankshaft, connecting rods and pistons (paragraph 3-56). (9) Install timing gear housing (paragraph 3-51). ( l o ) Install camshaft and bearings (paragraph 3-55). (11) Install cylinder head and rocker arm assembly (paragraph 3-54). (12) Install flywheel and flywheel housing (paragraph 3-50).
PAGE 183
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-53.
PAGE 184
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Section Vlll. MAINTENANCE OF GENERATOR SET CONTROLS 3-58. GENERAL. This section contains maintenance instructions for the generator set controls. The control cubicle assembly and sensing monitors contain the controls, instruments and indicators for controlling and monitoring the operation of the generator set.
PAGE 185
ARMY TM 9-115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-54. Frequency Meter and Transducer Test Setup Figure 3-55.
PAGE 186
ARMY TM 9-6115-46-34 AIR FORCE 35C2—3-445-2 NAVY NAVFAC P-8-624-34 (c) Vary the load while comparing the generator set kilowatt meter reading to that of the calibrated kilowatt meter. (d) If readings vary more than 1.33 percent, install thermal watt converter in a test setup using figure 3-55 as a guide. (e) Adjust all auto transformers to the minimum position. (f) Close switch S-1 and open switches S-2 and S-3.
PAGE 187
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (d) Remove nut (5), Iockwasher (6), flatwasher (7), screw (8), relay (9) k6, and spacer. (e) Remove relay (11) k1. (f) Remove rectifier (CR1). (g) Remove resistor (R10). (h) Remove printed circuit board (14). (3) Cleaning, Inspection, and Repair. (a) Clean relay assembly with filtered compressed air and a soft bristled brush. (b) Visually inspect terminal boards for cracks, burns, and corroded or damaged terminals.
PAGE 188
ARMY TM 9-6115-464-34 AIR FORCE 35C2-344-2 NAVY NAVFAC P-8-624-34 Figure 3-56.
PAGE 189
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3–57.
PAGE 190
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-6-624-34 (5) Testing. (a) Using an ohmmeter or similar device, check relay assembly continuity using figure 3-58 as a guide. CAUTION Make sure that power supply leads are properly connected. Damage to the relay assembly will result if leads are connected to the wrong terminals. Failure to observe this caution could result in damage to the equipment. (b) Connect a 120 Vac, 60 Hz power supply to terminals 4 and 12.
PAGE 191
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-24-34 e. Control Cubicle Terrminal Board. (1) Removal. (a) Tag and disconnect electrical leads to terminal board. (b) Remove nut and captive washer assemblies (3, figure 3-56) and screw (4) to remove terminal board (5). (c) Remove screws (6) and jumpers (7) only if inspection indicates replacement is necessary. (2) Cleaning, Inspection, and Repair.
PAGE 192
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (a) Clean all parts in dry cleaning solvent (Federal Specification P-D-680) and dry with filtered compressed air. (b) Visually inspect housing for cracks, dents, and defective paint. Check hinge for cracks, excessive wear, and cracked or broken welds. (c) Inspect panel for cracks, dents, warping, defective paint and illegible marking. Check fasteners for wear, damaged or deteriorated seals, and damaged pins.
PAGE 193
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 c. Cleaning, Inspection, and Repair. WARNING Solvent, Dry Cleaning P-D-680, Type II is flammable and moderately toxic to skin, eyes and respiratory tract. Eye and skin protection required. Good general ventilation is normally adequate. Failure to observe this warning could result in servere personal injury or death. WARNING Compressed air used for cleaning and drying purposes can create airborne particles that may enter the eyes.
PAGE 194
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 3-4. COMPONENT BOARD TEST VALUES (8) Use an ohmmeter to test resistance of relay K1 (figure 3-61). Resistance shall be 300 ± 30 ohms. Replace relay if defective. (9) Visually inspect fault locating wiring harness connector for cracks, corrosion, and loose or damaged pins. (l0) Check individual wires for corroded or damaged terminals, burned insulation and other damage.
PAGE 195
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 WIRE MARKING NO TO FROM STATION NO LUG FIND NO STATION NO LUG FIND NO WIRE FIND NO. CUT LENGTH IN (REF) MARKING COLOR D20B16 J1-1 A1-L1 8 1 21.5 BLACK D21B16 J2-2 A1-L2 8 1 22 D22B16 J1-3 A1-L3 8 1 22.5 D24A16 M8-(-) 10 S8-41 8 1 8 D24B10 J1-D - M8-(-) 10 1 38 D29A18 A1-(+) 4 M7-(+) 7 2 53.5 D30A18 A1-(-) 4 M7-(-) 7 2 52.5 D68A16 A1-S2 8 S8-33 8 1 48.
PAGE 196
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 WIRE MARKING NO FROM LUG FIND NO STATION NO TO STATION NO LUG FIND NO WIRE FIND CUT NO. LENGTH IN (REF) MARKING COLOR L92A18 S6-2 4 DS4-2 4 2 10 BLACK L93A18 S6-5 4 DS5-2 4 2 8 BLACK L93B18 J1-B DS5-2 4 2 32.5 BLACK P40N16 J1-V - TB1-5 11 1 12 RED P40P16 J1-U - TB1-5 11 1 12 P40R16 TB1-5 11 S2-11 8 1 42.
PAGE 197
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 WIRE MARKING NO FROM STATION NO LUG FIND NO TO STATION NO LUG FIND NO WIRE FIND NO. CUT LENGTH IN (REF) P55DD18 DS1-1 4 DS2-1 4 2 9.5 P55EE18 DS2-1 4 DS3-1 4 2 17 P55FF18 M5-(-) 4 DS3-1 4 2 30 P55GG18 M5-(-) 4 DS6-1 1/4 STRIP 2 14 P55HH18 DS6-1 1/4 STRIP DS7-1 1/4 STRIP 2 16.5 P55KK16 J1-P M1-CASE 9 1 42 P55MM16 A4-2 11 TB1-4 11 1 10.
PAGE 198
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-446-2 NAVY NAVFAC P-8--624-34 WIRE MARKING NO FROM STATION NO LUG FIND NO TO STATION NO LUG FIND NO WIRE FIND CUT NO. LENGTH IN (REF) X12L18 A1-N1 4 A1-N1 4 2 5.5 X14D18 J1-G - DS4-1 4 2 31 X14E18 S8-12 4 DS4-1 4 2 18 X14F18 S8-12 4 S8-24 4 2 4.5 X15D18 J1-H - DS5-1 4 2 33.
PAGE 199
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-59. Control Cubicle Wiring Harness (Sheet 5 of 6) Drawing No.
PAGE 200
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3–59. Control Cubicle Wiring Harness (Sheet 6 of 6) Drawing No.
PAGE 201
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-60.
PAGE 202
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 1. Screw and assembled washer 2. Lockwasher 3. Screw and captive washer assy 4. Cover plate 5. Screw and captive washer assy 6. Indicator panel assembly 7. Nut 8. Indicator light assembly 9. Lens 10. Lamp 11. Base 12. Nut 13. Tooth Iockwasher 14. Test or reset switch 15. Capacitor 16. Nut 17. Positioning washer 18. Nut 19. Tooth Iockwasher 20. Fuse holder assembly 21. Cap 22. Fuse 23. Fuse holder 24. Panel 25.
PAGE 203
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-61.
PAGE 204
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-62.
PAGE 205
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-63. Fault Locating Indicator Wiring Harness Drawing No.
PAGE 206
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 3-63. LOAD MEASURING UNIT. a. Removal. Refer to the Operator and Unit Maintenance Manual for load measuring unit removal instructions. NOTE Disassemble load measuring unit only as is necessary for inspection, testing, and replacement of components. b. Disassembly (1) Remove nut (1, figure 3-64), Iockwashers (2), flatwasher (3) to remove cover(4). (2) Remove screws (5), and Iockwashers (6) to remove connector (7).
PAGE 207
ARMY TM 9-6115-464-34 AIR FORCE TO 35C22 NAVY NAVFAC P-8-624-34 Figure 3-64.
PAGE 208
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-65. Load Measuring Unit Wiring Harness, Drawing No. 69-511.
PAGE 209
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 d. Testing and Repair. NOTE Disconnect leads to components prior to testing to avoid erroneous readings.
PAGE 210
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 LEGEND CR1 — Diode CR2 — Diode CR3 — Diode CR4 — Diode CR5 — Diode CR6 — Diode T1 — Transformer J16— Plug (Mating plug to P16 of wiring harness) R1 — Resistor 1 through 21 are connections and test points for Diodes CR1 through CR6 and Transformer T1 NOTE J16-N is positive 9.9 VDC in reference to J16-S with 100% rated load applied. Figure 3-66.
PAGE 211
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (10) If adjustment does not give the proper relationship or if relationship varies outside of acceptability limits at any point, replace load measuring unit load resistor. (11) Deactivate power source and remove load measuring unit from test circuit. (12) Install load measuring unit cover (figure 3-64). e. Assembly.
PAGE 212
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (1) If the FL-NL or NL - FL transient exceeds 1-1/2 percent of rated speed and/or does not reestablish stable engine operating conditions within one second, realign the control unit in accordance with paragraph 3-64j. Also follow this procedure if the engine speed hunts. If the set cannot be stabilized, check sockets A and B of plug P-21 (figure 3-97) for 24 Vdc (A is positive).
PAGE 213
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 LEGEND: G1 POWER SOURCE, 208 VAC, 3 PHASE, 47-430 HZ M1 VOLTMETER, 0-250 VAC M2 VOLTMETER, 0-10 VDC M3 VOLTMETER, 0-10 VAC R1 LOAD BANK R2 LOAD RESISTOR, 7.5 OHM, 10 WATT R3 LOAD RESISTOR, 7.5 OHM, 10 WATT R4 LOAD RESISTOR, 7.5 OHM, 10 WATT T1 TRANSFORMER T2 TRANSFORMER T3 TRANSFORMER Figure 3-67.
PAGE 214
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 d. Disassembly. (1) Disassemble governor control unit (7 through 58) only as is necessary for inspection, testing, and replacement of parts. NOTE Disassembly and repair of the electric governor control unit at the field level is restricted to removal of the cover, connectors, potentiometers and test jacks. Further disassembly requires unpotting which can be performed by depot maintenance personnel only.
PAGE 215
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-68. Electro-Hydraulic Governor Control Unit.
PAGE 216
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 1. Screw 2. Lockwasher 3. Nut 4. Lockwasher 5. Bracket 6. Threaded rod 7. Screw 8. Lockwasher 9. Nut 10. Nut 11. Tooth Iockwasher 12. Potentiometer (R18) 13. Nut 14. Nut 15. Tooth Iockwasher 16. Potentiometer (R16) 17. Nut 18. Nut 19. Tooth Iockwasher 20. Potentiometer (R15) 21. Nut 22. Nut 23. Tooth Iockwasher 24. Potentiometer (R15) 25. Nut 26. Nut 27. Tooth Iockwasher 28. Potentiometer (R11) 29. Nut 30. Nut 31. 32. 33. 34. 35. 36. 37.
PAGE 217
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (9) Repair wiring harness as follows: If the wiring harness has sustained damage and requires repair or rebuild, refer to figures 3-69 (50/60 Hz) or 3–70 (400 Hz) as required for layout identification and material requirements and Appendix A for detailed soldering and replacement procedures. (10) Test and replace printed circuit board components using figures 3-71, 3–72, 3-73,3-74, and 3-75 as appropriate.
PAGE 218
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (e) Turn R12 to full counterclockwise position. Reading of M2 and M3 shall be 600-1000 milliamperes and be balanced within 50 milliamperes. (f) Adjust R11 and R12 as in step (c) above and Iock for remainder of test. (4) Perform frequency sensing test as follows: (a) Install the governor control unit in test circuit as shown in figure 3-78. (b) Apply 57.5 to 62.5 Hz, 120 ±2 volts ac to P1-A and P1-B (375 to 425 Hz for 400 Hz units).
PAGE 219
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 3-5.
PAGE 220
Figure 3-69. 50/60 Hz Governor Control Unit Wiring Harness, Drawing No.
PAGE 221
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTES: 1. INSTALL CABLE STRAPS, FIND NO. 7, AT 1.5 INTERVALS AND AT EACH CABLE BREAKOUT. 2. CRIMP STYLE TERMINALS, FIND NO. 5, SHALL BE IN ACCORDANCE WITH MIL-STD-454, REQUIREMENT 19. 3. CONDUCTOR ENDS WITHOUT TERMINALS OR CONNECTORS SHALL BE STRIPPED .25 INCH AND TINN– ED IN ACCORDANCE WITH MIL-STD-454, REQUIREMENT NO. 5. 4. SODER ALL CONNECTORS IN ACCORDANCE WITH MIL-STD-454, REQUIREMENT NO. 5 5.
PAGE 222
3-168 Figure 3-70. 400 Hz Electro-Hydraulic Governor Control Unit Wiring Harness, Drawing No.
PAGE 223
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-70. 400 Hz Electro-Hydraulic Governor Control Unit Wiring Harness, Drawing No.
PAGE 224
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 1. Power transformer (T1) 2. Filter reactor (L2) 3. Filter reactor (L1) 4. Fixed capacitor (C7) 5. Resistor R23) 6. Resistor (R5) 7. Power transistor (Q1) 6. Power transistor (Q2) 9. Reactor 10. Transformer (T2) 11. Silicone rectifier (CR5) 12. Silicone rectifier (CR6) 13. Silicone rectifier (CR4) 14. Silicone rectifier (CR3) 15. Fixed capacitor (C9) 16, Resistor (R20) 17. Resistor (R22) 18. Magamp (AR1) 19. Silicone rectifier (CR7) 20.
PAGE 225
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 ELEC REF DESIG AR1 C2 C3, C4 C5 C6 C8 C9 CR2 CR3-CR18 J3 L1 L2 L3 P1 P2 Q1,Q2 A1 A2 DESCRIPTION MAGAMP CAPACITOR, FIXED CAPACITOR, FIXED CAPACITOR, FIXED CAPACITOR, FIXED CAPACITOR, FIXED CAPACITOR, FIXED CAPACITOR, FIXED SELENIUM RECTIFIER RECTIFIER, SILICON CONNECTOR, RECEPTACLE FILTER REACTOR FILTER REACTOR FILTER REACTOR CONNECTOR, RECEPTACLE CONNECTOR, RECEPTACLE CONNECTOR, RECEPTACLE TRANSISTOR, POWER PRINTED WIRING BOARD ASSY PA
PAGE 226
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-73. 400 Hz EIectro-Hydraulic Governor Control Unit Wiring Diagram, DWG No.
PAGE 227
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTES: 1. EXACT VALUES DETERMINED DURING TEST, SEE TEST PROCEDURES DWG 69-737. NOMINAL VALUES: C3=8µF C4=4µF 2. CB SHALL BE 30µF TO 120µF NON- POLARIZED, TANTALUM. EXACT VALUE DEPENDS ON GOVERNOR APPLICATION. 3. THROTTLE CLOSED BY CURRENT INCREASE IN COIL A-B, OPEN THROTTLE DECREASES OUTPUT OF TRANSDUCER. 4. ACTUATOR PISTON ATTACHED TO ENGINE THROTTLE. 5.
PAGE 228
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-74, 50/60 Hz Governor Control Unit Schematic Diagram, Drawing No.
PAGE 229
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTES: 1. EXACT VALUES DETERMINED DURING TEST, SEE TEST PROCEDURES DWG 69-815. NOMINAL VALUES: C3=8µF 2. CB SHALL BE 30µF TO 120µF NON– POLARIZED, TANTALUM. EXACT VALUE DEPENDS ON GOVERNOR APPLICATION. 5. REFERENCES: FOR CONTROL UNIT ASSEMBLY, SEE DWG 69-800 FOR WIRING DIAGRAM, SEE DWG 69-813 FOR WIRING HARNESS, SEE DWG 69-814 3. THROTTLE CLOSED BY CURRENT INCREASE IN COIL A–B, OPEN THROTTLE DECREASES OUTPUT OF TRANSDUCER. 6.
PAGE 230
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-75. 400 Hz Electro-Hydraulic Governor Control Unit Schematic Diagram, Drawing No.
PAGE 231
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3–76. Positioning of Unpotted Electro-Hydraulic Governor Control Unit During Testing Figure 3-77.
PAGE 232
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-78. Electro-Hydraulic Governor Control Unit Frequency Sensing Test Circuit (3) Place the container in a temperature controlled oven. Set the oven temperature at +180 to + 185°F (+82.2°C to +85°C) and allow the container to soak 11 to 12 hours or until potting compound is completely melted.
PAGE 233
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-79.
PAGE 234
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-80. Electro-Hydraulic Governor Control Unit Parallel Winding Test Circuit (2) Position governor control unit to install threaded rod (6, figure 3-68), bracket (5), Iockwashers (4), nuts (3), Iockwashers (2) and nuts (1). (3) Connect electrical connectors to governor control unit and untag.
PAGE 235
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (7) Connect dc voltmeter across test points 1 and 2. Test point 1 is positive. Adjust R11 for zero volts at 60 Hz or 400 Hz at no load. Repeat adjustment until voltage across test points 1 and 2 and 3 and 4 is zero and frequency is 60 Hz or 400 Hz. NOTE If test points 1 and 2 cannot be zeroed, they must be reduced to a minimum, (8) Adjust R12 to give approximately 5 volts across test points A and B.
PAGE 236
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-81.
PAGE 237
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-82. Approximate Position of Controls for Connecting Hydraulic Actuator (Effective with Serial No.
PAGE 238
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-83.
PAGE 239
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTES: 1. ALL SOLDERED CONNECTIONS SHALL BE IN ACCORDANCE WITH MIL-STD454, REQUIREMENT 5. 2. INSTALL STRAPS, FIND NO. 4 AT 3.0 MAX. INTERVALS. 3. WIRE MARKING TO BE IN ACCORDANCE WITH MIL-W-5088 EXCEPT THAT LENGTH BETWEEN GROUPS OF NUMBERS SHALL NOT EXCEED 6 INCHES 4. INSTALL END SEAL PLUGS, FIND NO. 5 ON UNUSED HOLES OF CONNECTORS FIND NO. 1 AND 2. 5. INTERPRET DRAWING PER MIL-STD-100. 6.
PAGE 240
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 3-65. ELECTRIC GOVERNOR CONTROL UNIT (MEP-113A). a. General. (1) The electric governing system is a speed (frequency) sensing system used to maintain constant engine speed and generator output frequency during periods of unchanging load and when load additions or deletions occur. The system consists of a control unit, magnetic pickup and an electric throttle actuating unit.
PAGE 241
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (2) Install nuts (4), Iockwashers (3), 4 hex head screws (2). (3) Connect electrical connector P17 (1). e. Adjustment Procedure (1) Disconnect the actuator linkage rod from the engine fuel shutoff lever. (2) Place the generator set START-RUN- STOP switch (located on the generator set control panel) in the RUN position.
PAGE 242
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-85.
PAGE 243
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-86.
PAGE 244
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 3-7. Electric Governor Malfunction Testing TERMINAL S K L NORMAL PROBABLE CAUSE OF NON-NORMAL READING 1. Defective magnetic pickup. 1.0 volt AC-RMS minimum while cranking. 2. Gap too large between magnetic pickup and gear teeth. 3. Improper or defective wiring to the magnetic pickup. CORRECTIVE ACTION 1. Replace magnetic pickup. 2. Readjust magnetic pickup. 3. Replace wiring harness. 10.1±.20 volts DC while 1.
PAGE 245
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (15) If the engine is unstable as indicated by continuous movement of the actuator lever, turn the control unit gain control counterclockwise until stability is obtained as indicated by a stationary actuator lever. Readjust the control unit frequency adjust screw to the proper engine speed.
PAGE 246
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTE If the actuator bracket has not been removed, proceed with paragraph (3). If the bracket must be installed, proceed as follows: (a) Insert the spacers (9) through the alternator mounting bracket (11).
PAGE 247
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-87.
PAGE 248
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-88.
PAGE 249
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 3-69. TACTICAL RELAY ASSEMBLY TO SPECIAL RELAY ASSEMBLY WIRING HARNESS. a. Refer to the Operator and Unit Maintenance Manual for removal, cleaning, inspection, and repair procedures of tactical relay assembly to special relay assembly wiring harness. b.
PAGE 250
ARMY TM 9-6115-464-34 AIR FORCE 35C2-445-2 NAVY NAVFAC P-8-624-34 3-75. SPECIAL RELAY ASSEMBLY TO FAULT LOCATING INDICATOR WIRING HARNESS. a. Refer to the Operator and Unit Maintenance Manual for special relay assembly to fault locating indicator wiring harness removal, cleaning, inspection, and repair procedures. b.
PAGE 251
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTES: 1. ALL SOLDERED CONNECTIONS SHALL BE IN ACCORDANCE WITH MIL-STD-454, REQUIREMENT 5. 2. INSTALL STRAPS, FIND NO. 5 AT 3.0 MAX. INTERVALS. 3. WIRE MARKING TO BE IN ACCORDANCE WITH MIL-W–5088 EXCEPT THAT LENGTH BETWEEN GROUPS OF NUMBERS SHALL NOT EXCEED 6 INCHES 4. INSTALL END SEAL PLUGS, FIND NO. 4 ON UNUSED HOLES OF CONNECTORS FIND NO. 1 AND 2. 5. INTERPRET DRAWING PER MIL-STD-100. 6.
PAGE 252
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTES: 1. ALL SOLDERED CONNECTIONS SHALL BE IN ACCORDANCE WITH MIL-STD-454, REQUIREMENT 5. 2. INSTALL STRAPS, FIND NO. 3 AT 3.0 MAX. INTERVALS AND AT EACH CABLE BREAK-OUT. 3. WIRE MARKING TO BE IN ACCORDANCE WITH MIL–W–5088 EXCEPT THAT LENGTH BETWEEN GROUPS OF NUMBERS SHALL NOT EXCEED 6 INCHES. 4. INSTALL END SEAL PLUGS, FIND NO. 4 ON UNUSED HOLES OF CONNECTORS FIND NO. 1. 5. INTERPRET DRAWING PER MlL–STD-100. 6.
PAGE 253
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-91. Governor Control Unit to Hydraulic Actuator Unit Wiring Harness, Drawing No.
PAGE 254
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-92. 400 Hz Electric Governor System Wiring Harness Assembly Drawing No.
PAGE 255
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-824-34 NOTES: 1. ALL CONDUCTORS SHALL BE STRIPPED .50+ .12 AND TINNED BEFORE ASSEMBLY USING SOLDER, FIND NO 12. 2. ELECTRICAL CONNECTIONS SHALL BE SOLDERED IN ACCORDANCE WITH MIL-STD-454. REQUIREMENT 5, USING SOLDER, FIND NO. 12. 3. WIRE MARKING SHALL BE IN ACCORDANCE WITH MIL-W-5068 EXCEPT THAT INTERVALS SHALL NOT EXCEED 6.00. 4. TIEDOWN STRAPS. FIND NO. 13, SHALL BE LOCATED APPROXIMATELY 3.00 APART AND ALL BREAKOUTS. 5. CONNECTORS FIND NO.
PAGE 256
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTES: 1. ALL SOLDERED CONNECTIONS SHALL BE IN ACCORDANCE WITH MIL-STD-454, REQUIREMENT 5. 2. INSTALL STRAPS, FIND NO. 9, AT 3.0 MAXIMUM INTERVALS AND AT EACH CABLE BREAK-OUT. 3. WIRE MARKING TO BE IN ACCORDANCE WITH MIL-W-5088 EXCEPT THAT LENGTH BETWEEN GROUPS OF NUMBERS SHALL NOT EXCEED 6 INCHES. 4. CRIMPED TERMINALS SHALL MEET THE PERFORMANCE REQUIREMENTS OF MIL-T-7928. 5. INSTALL END SEAL PLUGS, FIIND NO.
PAGE 257
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-93. AC Power Control Wiring Harness, Drawing No.
PAGE 258
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTES: 1. SOLDERING SHALL BE IN ACCORDANCE WITH MIL-STD-454, REQUIREMENT 5. 2. INSTALL STRAP, FIND NO. 8, AT 3.00 MAXIMUM INTERVALS AND AT EACH CABLE BREAK-OUT. 3. WIRE MARKING TO BE IN ACCORDANCE WITH MIL-W-5088 EXCEPT THAT LENGTH BETWEEN GROUPS OF NUMBERS SHALL EXCEED 6,00 INCHES. 4. CRIMPED TERMINAL SHALL MEET THE PERFORMANCE REQUIREMENTS OF MIL-T-7928. 5. INSTALL END SEAL PLUGS, FIND NO. 2, IN UNUSED HOLES OF CONNECTOR, FIND NO. 1. 6.
PAGE 259
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTES: 1. ALL SOLDERED CONNECTIONS SHALL BE IN ACCORDANCE WITH MIL-STD-454, REQUIREMENT 5. 2. INSTALL STRAPS, FIND NO. 4, AT 3.0 MAX INTERVALS. 3. WIRE MARKING TO BE IN ACCORDANCE WITH MIL-W-5088 EXCEPT THAT LENGTH BETWEEN GROUPS OF NUMBERS SHALL NOT EXCEED 6 INCHES. 4. INSTALL END SEAL PLUGS, FIND NO. 5 IN UNUSED HOLES OF CONNECTOR FIND NO. 1 AND 2. 5. INTERPRET DRAWING PER MIL-STD-100. 6.
PAGE 260
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-96. Special Relay Assembly to Control Cubicle Wiring Harness, Drawing No.
PAGE 261
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-97. Precise Relay Assebly to Governor Control Unit Wiring Harness, Drawing No.
PAGE 262
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-824-34 Figure 3-98. Special Relay Assembly to Precise Relay Assembly, Drawing No.
PAGE 263
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Section X. MAINTENANCE OF CONVENIENCE AND PARALLELING RECEPTACLES AND WIRING HARNESS 3-79. GENERAL. a. All models of the generator set are equipped with a 125 volt, 15 amp convenience receptacle. The receptacle is equipped with a spring loaded weather cover and protected by a 15 amp circuit breaker. b.
PAGE 264
ARMY TM 9-6115-464-34 AIR FORCE 35C2-445-2 NAVY NAVFAC P-8-624-34 Figure 3-99. Convenience and Paralleling Receptacles Wiring Harness, Drawing No.
PAGE 265
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 e. There is a bypass capacitor connected from each of the output terminals to ground in order to prevent electromagnetic interference. The capacitors are mounted on a bracket just below the load terminal board. 3-83. VOLTAGE RECONNECTION BOARD ASSEMBLY. Refer to the Operator and Unit Maintenance Manual for voltage reconnection board assembly removal, maintenance, and installation procedures. 3-84. MAIN LOAD CONTACTOR.
PAGE 266
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (5) Remove nut (21) Iockwasher (22), and main contactor assemblies (23), (6) Remove retaining ring (24), main contactor operator (31), shim (26), locating bushing (27), contact spring (28), shim (29) and shim (30) from bridge assembly (25). (7) Remove nut (39), Iockwasher (40), terminal washer (41). (8) Remove screw (42), Iockwasher (43), adjusting bushing (44), and actuator& connector assembly (45).
PAGE 267
ARMY TM 9-6115-464—34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (9) Remove connector (19) and gasket (20). (10) Remove locking spacer (21), Iockwasher (22), flatwasher (23), Chamber (24), and gasket (25). (11) Remove nut (26), lockwasher (27), flatwasher (28), and base assembly (29). (12) Remove flatwasher (32 and 33), nut (34), insert (36) from base (37). (13) Remove nut (39), Iockwasher (40), flatwasher (41), spacer (42), bushings (43 and 44) and bridge assembly (45).
PAGE 268
ARMY TM 9-6115-464—34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 e. Cleaning Inspection and Repair (Type A and B.) (1) Clean all components with cloth dampened in cleaning solvent, Federal Specification P-D-680. (2) Inspect all components for insecure mounting, loose electrical connections, cracks, corrosion and evidence of shorting or other damage. (3) Replace any parts found defective or damaged beyond repair. f. Assembly (Type A). (1) Assemble core and frame (83), coil washer (84), and coil (85).
PAGE 269
ARMY TM 9-6115-454-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-100.
PAGE 270
ARMY TM 9-6115-464-34 AIR FORCE 35C2—34-445-2 NAVY NAVFAC P-8-624-34 Figure 3-100.
PAGE 271
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-100.
PAGE 272
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-101.
PAGE 273
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-101.
PAGE 274
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-101.
PAGE 275
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-102.
PAGE 276
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-103. Main Contact Preload Check Points (Type A) (16) Check preload of each contact as follows: (See figure 3-103.) NOTE Preload is checked by the initial breakaway of retaining ring (point (B)). (a) Using a force gauge, check each individual contact at its edge (point (A)). Preload should be 1.5 to 2.5 pounds. (b) If preload is not as specified, add or subtract shims (26, 29, and 30, figure 3-100).
PAGE 277
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (a) Move loosely installed bracket (3) to transfer switch. (b) Check that the switch button is fully depressed, and allow 0.0l inch clearance between the switch button and the top operator (point (C)). (c) lnsert a 0.010 inch feeler gauge into the core gap (point (A)). (d) Apply 24 Vdc to connector pins A and B (See figure 3-105). (e) Bend the tab (point D, figure 3-104) of bracket toward the switch until the switch actuates.
PAGE 278
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-104.
PAGE 279
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-105. Main Load Contactor Schematic Diagram, Contactor to Load Terminals Wiring Harness, Dwg. No. 72-2290, and Contactor to Reconnection Board Wiring Harness, Dwg. No.
PAGE 280
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3–105. Main Load Contactor Schematic Diagram, Contactor to Load Terminals Wiring Harness, Dwg. No. 72–2290, and Contactor to Reconnection Board wiring Harness, Dwg. No.
PAGE 281
ARMY TM 9-6115-46444 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-6-624-34 NOTES: INTERPRET DRAWING PER MlL-STD–100. 1. ALL SOLDERED CONNECTIONS SHALL BE IN ACCORDANCE WITH MIL-STD-454, REQUIREMENT 5. 3. 4. 5. 6. INSTALL STRAPS, FIND NO. 5, AT 3.0 MAXIMUM INTERVALS AND AT EACH CABLE BREAKOUT. WIRE MARKING TO BE IN ACCORDANCE WITH MIL-W-5088 EXCEPT THAT LENGTH BETWEEN GROUPS OF NUMBERS SHALL NOT EXCEED 6 INCHES. CRIMPED TERMINAL SHALL MEET THE PERFORMANCE REQUIREMENTS OF MIL–T–7928. REFERENCES: a.
PAGE 282
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (2) Economizing Switch. (a) Apply 24 Vdc to connector pins A and B (See figure 3-105). (b) Adjust placement of switch (88, figure 3-101) on bracket (89) so that green button of switch is actuated by operator (57). (c) Check that the switch button is fully depressed, and allow 0.010 inch clearance between the switch button and the operator. (d) Remove 24 Vdc. White button of switch should be actuated by Iower tab of operator.
PAGE 283
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (b) If preload is not as specified, replace spring (48) with a known good spring. h. Installation. (Type A and Type B). Install main load contactor in reverse order of Removal procedures given in paragraph a.
PAGE 284
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-106.
PAGE 285
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 3-85. LOAD TERMINAL BOARD ASSEMBLY. a. Removal. WARNING Lethal voltages are present at the load terminal board when the generator set is in operation. Do not attempt to perform maintenance on the load terminal board while the generator set is in operation. Serious electrical shock or death may result from failure to observe this warning. (1) Tag and disconnect electrical leads to load terminal board assembly.
PAGE 286
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-107.
PAGE 287
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3–108. Transformer assemblies, Removal and Installation b. Cleaning. Inspection. and Testing. (1) Clean transformer assemblies with a clean, lint-free cloth moistened with an approved solvent and dry thoroughly. (2) Inspect transformer assemblies for cracks, corroded terminals, and evidence of shorting.
PAGE 288
ARMY TM 9-6115-454-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (1) If removed, install mounting brackets (17, figure 3–108) flat washers (16), screw and washer assemblies (15). (2) Install cross-current compensation transformer (14), Iockwashers (13), screws (12), and nuts (11). (3) Install instrumentation transformer (10), flat washers (9) screw and washer assemblies (8). (4) If removed, install mounting bracket (7), flat washers (6) screw and washer assemblies (5).
PAGE 289
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3–110. Electromagnetic Interference Capacitors 3-87. ELECTROMAGNETIC INTERFERENCE CAPACITORS a. Removal (1) Disconnect capacitor leads from terminal. (2) Loosen and remove two capacitor bracket bolts (1, figure 3-110), and two lockwashers (2) from chassis. (3) Remove capacitor bracket (3). (4) Loosen and remove two capacitor bolts (4), nuts (5), and four washers (6) and remove four capacitors (7). b.
PAGE 290
ARMY TM 9-6116-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-6-624-34 c. Installation. (1) Install four capacitors (7, figure 3-110), four washers (6), nuts (5) and two capacitors bolts (4) and tighten. (2) Install capacitor bracket (3). (3) Position chassis to install two Iockwashers (2), two capacitor bracket bolts (1) and tighten. Section X11. MAINTENANCE OF RELAY TABLE COMPONENTS 3-88. GENERAL.
PAGE 291
ARMY TM 9-6115-484-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (7) Remove nut & captive washer assembly (18), flatwashers (19), ground screw (20), nut (21), screw& captive washer assembly (22), nut (23), screw & captive washer assembly (24), and wiring harness assembly (25), from Chassis (26). c. Cleaning, lnspection, and Repair. WARNING Compressed air used for cleaning and drying purposes can create airborne particles that may enter the eyes.
PAGE 292
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-111.
PAGE 293
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 2) Inspect cover and chassis for cracks, corrosion, warping, dents, and defective paint. (3) Inspect relays for cracked casing, corroded terminals and evidence of shorting or overheating. (4) Inspect overload protective device for cracked casing, corroded terminals, and evidence of shorting or overheating. (5) Inspect tactical relay resistor assembly for burns, cracked or damaged components, and evidence of shorting.
PAGE 294
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTES: 1. ALL SOLDERED CONNECTIONS SHALL BE IN ACCORDANCE WITH MIL-STD-454. REQUIREMENT 5. 2. CUT INSULATION SLEEVING, FIND NO. 8, INTO 32 PIECES .750 INCHES LONG AND INSTALL OVER WIRES AND PINS, AFTER SOLDERING, TO THE CONNECTORS, FIND NOS. 2 AND 3. THEN APPLY HEAT OF 400°F FOR 2-3 SEC. FOR PROPER SHRINKAGE. 3. INSTALL STRAPS, FIND NO. 7, AT 3.0 MAX INTERVALS AND AT EACH CABLE BREAK-OUT. 4.
PAGE 295
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-112. Tactical Relay Assembly Wiring Harness, Drawing No.
PAGE 296
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-113.
PAGE 297
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-114. Overvoltage Relay Test Circuit (h) Set output frequency of power source G1 to 50 Hz. Slowly increase output voltage to 156 volts. DS1 shall extinguish and DS2 shall illuminate. Momentarily open switch S1 and allow relay to reset. (i) Repeat step (h) for frequencies of 60,70 and 100 Hz. (j) Set output frequency of power source G1 to 350 Hz. Increase output voltage to 151 volts ac.
PAGE 298
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-115. Short Circuit Relay Test Circuit (g) Place switch S2 in B position and dose switch S1. (h) Repeat steps (d) through (f). (i) Place switch S2 in C position and dose switch S1. (j) Repeat steps (d) through (f). (k) The voltage at which relay trips in step (e), (h) and (j) shall be within 1 volt.
PAGE 299
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-445-2 NAVY NAVFAC P-8-624-34 Figure 3-116.
PAGE 300
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3–117. Tactical Relay Resistor Assembly Schematic Diagram (b) Touch other lead to terminals 3,2, and 1. (c) Ohmmeter should indicate 7.5 ohms in each case. (15) Replace defective components of tactical relay resistor assembly using figure 3-118 as a guide.
PAGE 301
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 3-90. SPECIAL RELAY ASSEMBLY. WARNING Do not attempt to perform maintenance on the special relay assembly while the generator set is operating. Severe electrical shock or death may result from failure to observe this warning. a.Removal. (1) Tag and disconnect electrical connectors to special relay assembly, (2) Remove screws (1, figure 3-119) and Iockwashers (2) to remove special relay assembly.
PAGE 302
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 WARNING Solvent, Dry Cleaning P-D-680, Type II is flammable and moderately toxic to skin, eyes and respiratory tract. Eye and skin protection required. Good general ventilation is normally adequate. Failure to observe this warning could result in servere personal injury or death. (1) Clean special relay components with filtered compressed air and a soft bristle brush.
PAGE 303
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-4 Figure 3-118. Tactical Relay Resistor Assembly, Exploded View (16) Test dc relay assembly as follows: (a) Apply 24 Vdc to terminals 6 and 15 (figure 3-121). (b) Use an ohmmeter to check for continuity across terminals 5 and 17. (c) Check for open circuit across terminals 4 and 16. (d) Install a jumper between terminals 9 and 6. (e) Apply 24 Vdc to terminals 12 and 15 with 12 positive.
PAGE 304
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-119.
PAGE 305
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 1. Screw 2. Lockwasher 3. Screw & captive washer assy 4. Cover 5. Locking nut 6. Nut 7. Tooth Iockwasher 8. Potentiometer 9. Nut 10. Screw & captive washer assy 11. Nut 12. Screw & captive washer assy 13. Wiring harness assy 14. Nut 15. Screw & captive washer assy 16. Shorting plug 17. Nut 18. Screw & captive washer assy 19. Protective cap assy 20. Nut & captive washer assy 21. Flat washer 22. Screw 23. Nut and captive washer assy 24.
PAGE 306
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (13) Install screw & captive washer assembly (10), and nut (9). (14) Install potentiometer (8), tooth Iockwasher (7), nut (6) and locking nut (5). (15) Position chassis (46) to install cover (4), and screw & captive washer assembly (3) e. Installation. (1) Position special relay assembly to install Iockwashers (2, figure 3-119) and screws (l). (2) Connect electrical connectors to special relay assembly. 3-91. PRECISE RELAY ASSEMBLY.
PAGE 307
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-120. Special Relay Assembly Wiring Harness, Drawing No.
PAGE 308
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-120. Special Relay Assembly Wiring Harness, Drawing No.
PAGE 309
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-120. Special Relay Assembly Wiring Harness, Drawing No.
PAGE 310
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P8-624-34 Figure 3-120. Special Relay Assembly Wiring Harness, Drawing No.
PAGE 311
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-121. DC Relay Assembly Schematic Diagram c. Cleaning, Inspection, and Repair. WARNING Compressed air used for cleaning and drying purposes can create airborne particles that may enter the eyes. Pressure shall not exceed 30 psig and use only the adequate chip guards and chipping goggles. Failure to observe this warning could result in servere personal injury or death.
PAGE 312
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (6) Inspect resistors and capacitors of electronic components assembly for insecure mounting and burns or other evidence of shorting. (7) Inspect terminal board assembly for cracks, corroded terminals, damaged terminal jumpers and evidence of shorting. (8) Test under voltage relay as follows: (a) Install relay in test circuit shown in figure 3-124. (b) Activate power source G1 and adjust output voltage to 120 Vac at 50 HZ.
PAGE 313
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3–122.
PAGE 314
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-123.
PAGE 315
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445--2 NAVY NAVFAC P-8-624-34 Figure 3-124. Under Voltage Relay Test Circuit Figure 3-125.
PAGE 316
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (e) Slowly raise output frequency of power source GI until test lamps transfer. Test lamps shall transfer at 46 ± 1 Hz (375 Hz for 400 Hz units). (f) Adjust output voltage of power source G1 to 132 Vac. Check for test lamp transfer points. Transfer points shall be within 1 Hz of those of steps (d) and (e). (g) Adjust output voltage of power source G1 to 108 Vac. Check for test lamp transfer points.
PAGE 317
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3–1 26. Permissive Paralleling Relay Test Circuit (15) Check individual wires for continuity. Replace defective wires using wire conforming to Military Specification MIL-W–5086, Type Il. Use figures 3-128 or 3-129 as a guide. d. Assembly.. (1) Position chassis (33, figure 3-123) to install permissive paralleling relay (32) and screw & captive washer assembly (31).
PAGE 318
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 3-92. STATIC EXCITER AND VOLTAGE REGULATOR ASSEMBLY. a. General. The static exciter and voltage regulator assembly provide excitation and voltage regulation for the generator output voltage and compares it to a reference voltage which is established by the voltage adjust rheostat on the generator set control cubicle. If difference exists, an error signal is sent to the static exciter.
PAGE 319
ARMY TM 9-5115-454-34 AIR FORCE TO 35C2—3-445-2 NAVY NAVFAC P-8-62-434 (15) Remove nut & captive washer assembly (55), screw (56), resistor bracket (57) and resistor R3 (58). (16) Remove nut & captive washer assembly (59), screw (60), and cable clamp (61). (17) Remove nut & captive washer assembly (62), screw (63), and cable clamp (64). (18) Remove nut & captive washer assembly (65), screw (66), and wiring harness (67).
PAGE 320
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-127.
PAGE 321
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTES: 1. ALL SOLDERED CONNECTIONS SHALL BE IN ACCORDANCE WITH MIL-STD-454, REQUIREMENT 5. 2. CUT INSULATION SLEEVING (FIND #9) INTO 38 PIECES, .750 INCHES LONG AND INSTALL OVER WIRES AND PINS, AFTER SOLDERING, TO THE CONNECTORS (FIND #2 AND #3). THEN APPLY HEAT OF 400°FOR 3-5 SEC. FOR PROPER SHRINKAGE. 3. INSTALL STRAPS, FIND NO. 7 AT 3.0 MAX INTERVALS AND AT EACH CABLE BREAK-OUT. 4.
PAGE 322
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-128. 50/60 Hz Precise Relay Assembly Wiring Harness, Drawing No.
PAGE 323
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTES: 1. ALL SOLDERED CONNECTIONS SHALL BE IN ACCORDANCE WITH MIL-STD-454, REQUIREMENT 5. 2. AFTER SOLDERING, INSTALL INSULATION SLEEVING, FIND NO. 9, .5 LONG, OVER EACH CONTACT OF CONNECTOR FIND NO. 2 AND 3. 3. INSTALL STRAPS, FIND NO. 7 AT3.0 MAX INTERVALS AND AT EACH CABLE BREAK-OUT. 4. WIRE MARKING TO BE IN ACCORDANCE WITH MIL–W-5088 EXCEPT THAT LENGTH BETWEEN GROUPS OF NUMBERS SHALL NOT EXCEED 6 INCHES. 5.
PAGE 324
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-129. 400Hz Precise Relay Assembly Wiring Harness, Drawing No.
PAGE 325
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3–130.
PAGE 326
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-130.
PAGE 327
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 1. Screw 2. Lockwasher 3. Screw 4. Chassis cover 5. Nut & captive washer assy 6. Flat washer 7. Screw 8. Heat sink assy 9. Nut & captive washer assy 10. Screw 11. Wire 12. Terminal lug 13. Semiconductor 14. Semiconductor 15. Nut & captive washer assy 16. Screw 17. Heat sink 18. Heat sink support 19. Nut & captive washer assy 20. Screw 21. Terminal board 22. Nut & captive washer assy 23. Screw 24. Transformer 25. Nut 26. Nut 27. Screw 28.
PAGE 328
ARMY TM 9-6115-464-34 AIR FORCE 36C2-3-445-2 NAW NAVFAC P-8-624-34 Figure 3-131. 50/60 Hz Static Exciter and Voltage Regulator Schematic Diagram, Drawing No.
PAGE 329
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (b) One direction shall give an indication of less than 100 ohms. The other direction shall give an indication of one megohm or more. There shall be no indication of discontinuity in either direction. (c) Replace defective semiconductors. (5) Inspect terminal board assembly for cracks, burns, and corroded terminals. Replace defective terminal board assembly.
PAGE 330
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (11) Install cable clamp (61), screw (60), and nut and captive washer assembly (59). (12) Install resistor R3 (58), mounting bracket (57), screw (56), and nut and captive washer assembly (55). (13) Install resistor R2 and R1 (54 and 53), mounting bracket (52), mica washer (51), screw (50), washers (49), nut and captive washer assembly (48), screw (47), nut and captive washer assembly (46).
PAGE 331
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (a) With chassis cover (4, figure 3-130) removed, connect positive lead of voltmeter to heat sink where CR1-CR3 are mounted. Connect negative lead to heat sink where CR4-CR6 are mounted. (See item 17, figure 3–130). (b) Apply 12 Vac (any frequency between 50 and 400 Hz) to pins A and B of connector J13. (c) Voltmeter connected across heat sinks should indicate 9.3 Vdc.
PAGE 332
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 3-8.
PAGE 333
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3–132. 400 Hz Static Exciter and Voltage Schematic Diagram, Drawing No.
PAGE 334
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTES: 1. ALL SOLDERED CONNECTIONS SHALL BE IN ACCORDANCE WITH MIL-STD-454, REQUIREMENT 5. 2. CUT INSULATION SLEEVING, FIND NO. 7, INTO 24 PIECES, .750 INCHES LONG AND INSTALL OVER WIRES AND PINS, AFTER SOLDERING, TO THE CONNECTORS, FIND NOS. 3,2, AND 1. THEN APPLY HEAT OF 400° F FOR 3-5 SEC. FOR PROPER SHRINKAGE. 3. INSTALL STRAPS, FIND NO. 9, AT APPROXIMATELY 2.5 INTERVALS AND AT EACH WIRE BREAKOUT. 4.
PAGE 335
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 B. Static Exciter Wiring (Sheet 2 of 2) Figure 3-133. Static Exciter Wiring Harness, Dwg. No. 72-2628, Voltage Regulator Wiring Harness, Dwg. No. 72-2627, and Static Exciter Connection Wiring Diagram, Dwg. No.
PAGE 336
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTES: 1. 2. 3. 4. 5. 6. ALL SOLDERED CONNECTIONS SHALL BE IN ACCORDANCE WITH MIL-STD-454, REQUIREMENT 5. CUT INSULATION SLEEVING, FIND NO. 5, INTO 9 PIECES, .750 INCHES LONG AND INSTALL OVER WIRES AND PINS. AFTER SOLDERING, TO THE CONNECTOR, FIND NO. 1. THEN APPLY HEAT OF 400°F FOR 3-5 SEC. FOR PROPER SHRINKAGE. INSTALL STRAPS, FIND NO. 4, AT 3.00 MAX INTERVALS AND AT EACH CABLE BREAK-OUT.
PAGE 337
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3–133. Static Exciter Wiring Harness, Dwg. No. 72–2628, Voltage Regulator Wiring Harness, Dwg. No. 72-2627, and Static Exciter Connection Wiring Diagram, Dwg, No.
PAGE 338
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3–134. Static Exciter and Voltage Regulator Assembly Sensing Circuit Bench Test Figure 3–135.
PAGE 339
ARMYTM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Section XIII. MAINTENANCE OF GENERATOR ASSEMBLIES 3-94. GENERAL. This section contains maintenance procedures for the generator assemblies. There are two types of generators used in the generator set. The 50/60 Hz generator is used in both the 50/60 Hz utility, and 50/60 Hz precise generator sets. The 400 Hz generator is used only in the 400 Hz precise generator set.
PAGE 340
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-136.
PAGE 341
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 1. Screw 2. Lockwasher 3. Drip cover 4. Screw 5. Lockwasher 6. Screen guard 7. Screw 8. Lockwasher 9. Lead block assy 10. Gasket 11. Screw 12. Lockwasher 13. Screen Guard 14. Screw 15. Lockwasher 16. Cover plate 17. Plug 18. Screw 19.
PAGE 342
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (23) Remove Iifting eye bolt and steel bar. NOTE If a steel bar is not available, carefully stand generator on end and remove rotor. (24) Remove screws (27) to remove lock plate (28), pressure plate (29), coupling disc (30), blower wheel (31) from rotor and balance assembly (25). (25) Remove screws (32) and Iockwashers (33) to remove end bell assembly (34) from stator (26). NOTE Feed leads to stator through end bell as it is removed.
PAGE 343
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-137.
PAGE 344
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-138.
PAGE 345
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-139.
PAGE 346
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-139.
PAGE 347
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3–140. Lead Block Assembly, Exploded View (30) If inspection reveals damage to the lead block assembly, disassemble as follows: (a) Remove nuts (1, figure 3-140), Iockwashers (2) and screws (3). (b) Separate pressure plates (4) and blocks (5, 6, and 7). (31) If inspection reveals damage to stator assembly, disassemble as follows: (a) Remove screws (1, figure 3–141) and Iockwashers (2) to remove ring (3).
PAGE 348
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-141.
PAGE 349
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (2) Ultra sonic cleaning may be used if available. Consult manufacturer’s recommendations for cleaning solutions and procedures to be used. (3) After cleaning, dry rotor and balance assembly, stator assembly, and exciter stator by baking in an oven at 200°F (93°C) for approximately 3 hours.
PAGE 350
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (19) Install blower and coupling disc assembly on a dymetric balance machine and check both static and dynamic balance. Unbalance shall not exceed 0.5 inch-ounce in either plane. Balance blower and coupling disc assembly as outlined in step (26) below. (20) Use a double bridge to measure resistance of each phase of exciter rotor. Resistance of each phase shall be 0.1473 to 0.1627 ohm at 77°F (25°C).
PAGE 351
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (30) Impregnate the wound rotor as follows: (a) Mark all fit surfaces to prevent the resin from adhering. (b) Preheat the wound core for 2 hours (minimum) at 302°F (150°C) (minimum). (c) Allow the core to cool in ambient surroundings to 104°F (40°C) (maximum). (d) Place the core in the vacuum tank and evacuate to 1 to 5 mm Hg and hold for 15 minutes.
PAGE 352
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3–142.
PAGE 353
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-142.
PAGE 354
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-143.
PAGE 355
ARMY TM 9-6115-4-34 AIR FORCE TO 35C2—3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-143.
PAGE 356
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-143.
PAGE 357
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 1. 2. INTERPRET DRAWING PER MlL-STD-100. STACK LAMINATIONS, FIND NOS. 1 AND 2, ON I.D. UNDER 2.5 ± 10% TONS. 3. BRAZE CAGE ROD, FIND NO. 3, TO LAMINATIONS, FIND NO. 1, IN ACCORDANCE WITH MIL–B-7883. TYPE 1, GRADE B, BRAZING FLUX SHALL BE IN ACCORDANCE WITH AWS TYPE 3A. 4. ONE COIL SPACER SHALL BE USED AT EACH OF EIGHT PLACES. 5. APPLY 4 LAYERS OF TAPE, FIND NO. 8, TO SECURE CABLE STUDS. 6. APPLY 2 1/2 LAYERS OF TAPE, FIND NO.
PAGE 358
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTES: 1. 2. 3. 4. 5. 6. LOCATE HEAD STUD AS SHOWN, 45° ± 5° FROM ROTOR RETWIST. SOLDERING SHALL BE IN ACCORDANCE WITH MIL-STD-454, REQUIREMENT 5. BAND COIL EXTENSIONS AT EACH BEND WITH TAPE, FIND NO. 4. BAND OUTSIDE CIRCUMFERENCE OF WINDING WITH 9 LAYERS OF TAPE, FIND NO. 16, AS SHOWN, UNDER 33 LBS ± 10°. VACUUM-PRESSURE IMPREGNATE IN ACCORDANCE WITH 72-2487. INTERPRET DRAWING PER MlL-STD-100. Figure 3-145.
PAGE 359
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 CAUTION Do not use press which contacts core windings. Press only on core laminations. Failure to observe this caution could result in damage to the equipment. (c) Remove heated rotor core from oven and press onto rotor shaft until firmly seated against shoulder. Do not allow key to project more than 0.12 inch on either side of rotor.
PAGE 360
ARMY TM 9-6115-464—34 AIR FORCE 35C2-3-44-2 NAVY NAVFAC P-8-624-34 NOTES: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. INTERPRET DRAWING PER MIL-STD-100. SOLDERING SHALL BE IN ACCORDANCE WITH MIL-STD-454. REQUIREMENTS. STACK LAMINATIONS, FIND NO .5, UNDER 3 TONS ± 10%. TORQUE CAP SCREWS, FIND NO. 6, TO 16+1 FT-LBS, WHILE LAMINATIONS ARE UNDER PRESSURE. AFTER ASSEMBLY, SPRAY WITH ONE COAT OF VARNISH IN ACCORDANCE WITH MIL-V-173. SLEEVING, FIND NO.
PAGE 361
ARMY TM 9-6115-464—34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-146.
PAGE 362
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-147.
PAGE 363
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-147.
PAGE 364
ARMY TM 9-6115 464 34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (c) Pull all slack from the leads and tighten the clamping screws of lead block. (d) Secure lead block and gasket to end bell assembly using lockwashers (8) and (e) Using a suitable lifting device stand the stator assembly on the end bell NOTE Use blocking as necessary to maintain stator in the vertical position. (f) Remove the lifting eye bolt from the stator and install it in the coupling disc end.
PAGE 365
ARMY TM 9-6115 464 34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 a. Testing Exciter Stator (On Equipment Test). Locate and disconnect exciter stator winding resistance using ohmmeter. On the 15 kW and 30 kW generator sets, leads F1 and F2 are located on the terminal board near the static exciter/voltage regulator control box. Check across leads F1 and F2 for resistance. A normal resistance reading of 1 to 4 ohms should be found.
PAGE 366
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-824-34 3-97. REPLACEMENT OF INTERFERENCE SUPPRESSION COMPONENTS. a. Refer to the Operator and Unit Maintenance Manual to replace fuel transfer pumps. b. To replace capacitors at load terminal: (1) Remove screws (1, figure 3–148) and disconnect and tag electrical leads. (2) Remove nuts (2), screws (3), capacitors (4) and Iockwashers (5) from bracket (6). (3) Reassemble in reverse order using new capacitors, c.
PAGE 367
ARMY TM 9-6115 464 34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 c. Cleaning. Inspection. and Repair WARNING Solvent, Dry Cleaning P-D-680, Type II is flammable and moderately toxic to skin, eyes and respiratory tract. Eye and skin protection required. Good general ventilation is normally adequate. Failure to observer this warning could cause severe personal injury or death. WARNING Compressed air used for cleaning and drying purposes can create airborne particles that may enter the eyes.
PAGE 368
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 c. Cleaning, Inspection, and Repair. WARNING Solvent, Dry Cleaning P-D-680, Type II is flammable and moderately toxic to skin, eyes and respiratory tract. Eye and skin protection required. Good general ventilation is normally adequate. Failure to observe this warning could result in servere personal injury or death. (1) Clean relay table parts in dry cleaning solvent (Federal specification P-D-680) and dry thoroughly.
PAGE 369
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-824-34 (7) Install flatwasher (10), Iockwasher (9), and screw (8). (8) Install terminal block (7), screw (6) and screw (5). (9) Install nut (4), clamp (3), Iockwasher (2) and screw (1). Section XVI. MAINTENANCE OF LIFTING FRAME 3-100. GENERAL The lifting frame is securely attached to the skid base. It is equipped with lifting clevises at the top of each side for lifting equipment attachment.
PAGE 370
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (4) Check all threads for crossing, stripping, and other damage. (5) Repair cracks and breaks in supports by welding. (6) Remove corrosion and defective paint. Treat and paint in accordance with service requirements. (7) Replace all parts worn or damaged beyond repair. c. Installation.
PAGE 371
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-149.
PAGE 372
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-150.
PAGE 373
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-151.
PAGE 374
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Section XVII. MAINTENANCE OF SKID BASE ASSEMBLY 3-102. GENERAL The skid base assembly provides the mounting points for the engine assembly, the generator assembly, and the enclosure assembly. It contains the main fuel tank and the tool box. The generator set ground point is also contained in the skid base assembly. The skid base is also drilled to accept attachment of the wheel mounting kit.
PAGE 375
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 d. Assembly. (1) Position skid base (12, figure 3-152) to install panel blank (11), Iockwasher (10) and screw (9). (2) Install tool box (8), screw (7), Iockwasher (6), and nut (5). (3) Install ground terminal stud (4), nut (3), flatwasher (2) and self-locking nut (1). e. Installation. (1) Install the lifting frame (paragraph 3-101). (2) Install main fuel tank (paragraph 3-16). (3) Install generator assembly (paragraph 2-7).
PAGE 376
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 3-152.
PAGE 377
PAGE 378
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-445-2 NAVY NAVFAC P-8-624-34 CHAPTER 4 GENERATOR SET TESTS AFTER OVERHAUL REPAIR INSTRUCTIONS Section I. INSPECTION 4-1. GENERAL. a. The activity performing the repair or overhaul is responsible for the performance of all applicable tests and inspections specified herein. Activities performing maintenance on any portion of the generator set must perform those tests and inspections required by the applicable component or system repair instruction. b.
PAGE 379
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Section Il. OPERATING TESTS 4-6. GENERAL. a. The tests described in this section require generator set operation and provide verification of generator set performance characteristics. NOTE All tests shall be conducted with the 240/416 volt connections, unless otherwise specified. All tests that are applicable, will be conducted on both Mode I and Mode II generator sets.
PAGE 380
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-445-2 NAVY NAVFAC P-8-624-34 4-9. LOW FUEL PROTECTIVE DEVICE. a. Disconnect cable to the day tank fuel solenoid valve. b. Operate generator set at full load. c. The low fuel protective device must operate when the fuel in the day tank falls to a point at which there is only enough to operate the set at rated load for one minute. 4-10. PARALLEL OPERATION PROVISIONS. a. For Class 1 (Precise) Sets (REAL POWER): (1) Remove the shorting plug.
PAGE 381
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 4-1. OPERATING TESTS CAUTION Prior to performing any of the operating tests listed in table 4-1, insure that the generator set is serviced with the correct fuel, oil, and coolant as listed on the data plate. Failure to observe this caution could result in damage to the equipment.
PAGE 382
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-445-2 NAVY NAVFAC P-8-624-34 Table 4-2.
PAGE 383
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 4-3. ELECTRICAL PERFORMANCE CHARACTERISTIC PARAMETERS AC PRECISE (CLASS 1) CHARACTERISTIC PARAMETER a. Voltage characteristics 1. Regulation (%) 2. Steady-state-stability (variation) (bandwidth %) (a) Short term (30 seconds) (b) Long term (4 hours) 3. Transient performance (a) Application of rated load (1) Dip (%) a. 60 HZ b. 400 HZ (2) Recovery (seconds) (b) Rejection of rated load (1) Rise (%) a. 60 Hz b.
PAGE 384
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-445--2 NAVY NAVFAC P-8-624-34 Table 4-3. ELECTRICAL PERFORMANCE CHARACTERISTIC PARAMETERS AC PRECISE (CLASS 1) (CONTINUED) CHARACTERISTIC PARAMETER b. Frequency characteristics 1. Regulation (%) 2. Steady–state-stability (variation (bandwidth %) (a) Short term (30 seconds) (b) Long term (4 hours) 3. Transient performance (a) Application of rated load (1) Undershoot (%) (2) Recovery (seconds) (b) Rejection of rated load (1) Overshoot (%) (2) Recovery (seconds) 4.
PAGE 385
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 c. Generator With Separate Excitation. (1) Preparation for test. (a) Completely isolate the generator windings (armature coils and field windings). (b) Connect the frequency meter to one of the armature coils of the generator. (c) Provide separate excitation for the exciter field. (2) Test. (a) Start and operate the generatorat rated frequency and at no load.
PAGE 386
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-445-2 NAVY NAVFAC P-8-624-34 (2) Test. (a) Start and operate the generator set and allow the set to stabilize at rated load, rated voltage and rated frequency. During this period record all instrument readings including thermal instrumentation at minimum intervals of 10 minutes. If necessary, adjustments to the load, voltage and frequency may be made to maintain rated load at rated voltage and frequency.
PAGE 387
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (r) Adjust voltage to the minimum attainable value or a value just prior to activation of the undervoltage protection device. (s) Record all instrument readings (after transients have subsided). (t) Repeat steps (a) through (s) above for all other voltage connection(s). d. Sample Calculations.
PAGE 388
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-445-2 NAVY NAVFAC P-8-624-34 c. Procedure. (1) Preparation for test. (a) Connect the load and field instrumentation in accordance with the applicable figure of MIL-HDBK-705, Method 205.1, paragraphs 205.1.10, for one voltage and frequency. Connect the signal input of the recording meter(s) to the convenience receptacle of the set or to the generator coil which is used as the voltage sensing input to the voltage regulator.
PAGE 389
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (c) The recording meter chart speed(s) shall be 12 inches per minute throughout the remainder of this test. At each of the following load conditions (one step) operate the set for a minimum of 40 seconds (or the short-term stability period plus the allowable recovery time as specified in the procurement document).
PAGE 390
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-445-2 NAVY NAVFAC P-8-624-34 (3) To determine the maximum voltage variation at constant load: (a) One-half the observed voltage bandwidth (B) is the plus or minus value of voltage deviation at constant load. (b) Divide each of the values obtained in (a) by the rated voltage of the generator and multiply by 100 to convert to percentage.
PAGE 391
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Trace and definitions apply to either voltage or frequency. NOTE Chart marked at start of test. A Actual instrument trace of function. B Observed steady–state band (two lines parallel to the axis of chart movement one each passing through the center points of maximum and minimum trace excursion respectively during the shortterm stability sample period, TS). C Mean of observed band.
PAGE 392
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-445-2 NAVY NAVFAC P-8-624-34 (b) Convert each of the values obtained in (a) above to a percentage of rated voltage by dividing by the rated voltage and multiplying by 100. This is the voltage regulation expressed in percent. (c) Repeat paragraph 4-15d. (1) above substituting frequency for voltage. (d) Compare the results tabulated in paragraphs 4-15d. (1) and 4-15d. (6) (c) with the requirements of Table 4-1. 4-15. FREQUENCY ADJUST RANGE TEST a. General.
PAGE 393
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTE This step is not applicable to generator sets having governors that utilize a threaded shaft and lock nut(s) or other mechanical means as a method of operator speed adjustment. (h) Adjust the generator set frequency for the minimum attainable frequency. Read and record all instrument readings.
PAGE 394
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-445-2 NAVY NAVFAC P-8-624-34 4-17. CIRCUIT INTERRUPTER TEST (SHORT CIRCUIT). a. General. A circuit interrupter is connected between the generator voltage reconnection system and the generator set output terminals to disconnect the generator output from the load and also to protect the generator from a short circuit. The circuit interrupter is operated from a current sensor external to the interrupter. b. Apparatus.
PAGE 395
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (2) Calculate the short-circuit current using the peak-to-peak amplitudes of the current trace and the steady state ammeter reading prior to application of the short circuit. See figure 512.1-11. (3) Tabulate the above results and the malfunction indicator indication for each line connection at each voltage connection and compare the results with the requirement in table 4-1. 4-18. CIRCUIT INTERRUPTER TEST (OVERLOAD CURRENT) a. General.
PAGE 396
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-445-2 NAVY NAVFAC P-8-624-34 (e) The generator set contains an overload malfunction indicator. Check and record its indication. (f) Allow the generator set to cool at rated load for a minimum of 15 minutes. (9) Repeat steps (c) thru (f) except that the load current is increased to the overload current value in Phase A only. Phases B and C remain at the rated load current value.
PAGE 397
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (f) Read and record both voltmeter readings. (g) With the oscillograph recording and the circuit interrupter closed, close the switch. (See figure 512.3-I. (h) Reactivate the shutdown provision if used. (i) The generator set contains an ovewoltage malfunction indicator; check and record its indication. (j) Record whether or not the set shuts down.
PAGE 398
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-445-2 NAVY NAVFAC P-8-624-34 e. Results. (1) From the oscillograms made in 4-20c, determine and tabulate the time between the application of the overvoltage and operation of the circuit interrupter for each application of overvoltage. (2) From the oscillograms made in 4-20d. determine and tabulate the time between the application of the undervoltage and the operation of the circuit interrupter for each application of undervoltage.
PAGE 399
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 c. Procedure. (1) Preparation for test. (a) Connect the load instrumentation in accordance with the applicable figure of MIL-HDBK-705, Method 205.1, Paragraph 205.1.10. (b) Install a thermocouple to measure the same temperature as seen by the protective device sensor. (2) Test. (a) Start ando perate the generator set at rated voitage, rated frequency (speed), and rated load.
PAGE 400
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-445-2 NAVY NAVFAC P-8-624-34 4-23. MAXIMUM POWER TEST. a. General. The maximum power of a generator set is a function of the ambient conditions (temperature and altitude) and the mechanical condition of the engine at any particular time. b. Apparatus. Instrumentation for measuring load conditions, field voltage and current, pressure and temperatures shall be as described and illustrated in MIL-HDBK-705.
PAGE 401
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (2) Test. (a) Start and operate the generator set and allow it to stabilize at rated load, rated voltage and rated frequency (speed). During this period, readings of all instruments including thermal instrumentation shall be recorded at minimum intervals of 10 minutes. If necessary, adjustments to the load, voltage and rated frequency.
PAGE 402
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-445-2 NAVY NAVFAC P-8-624-34 (e) Results. 1. Average the three valid power readings. This average is the observed maximum power value. 2. Correct the observed maximum power value to standard conditions using the procedure in MIL–HDBK-705, Method 220.2, paragraph 220.2.3. This is the corrected maximum power value. 3. Compare these results with the requirements of table 4-1. 4-24. UNDER FREQUENCY PROTECTIVE DEVICE TEST a. General.
PAGE 403
PAGE 404
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 CHAPTER 5 REPAIR INSTRUCTIONS FOR MATERIAL USED IN CONJUNCTION WITH THE GENERATOR SET Section 1. FUEL BURNING WINTERIZATION KIT 5-1. GENERAL. The fuel burning winterization kit is used to preheat engine coolant and lubricating oil to facilitate starting at ambient temperatures between –25°F (-31. 7° C) and -65° F (-53. 9° C).
PAGE 405
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 5-1. FUEL BURNING WINTERIZATION KIT TROUBLESHOOTING CHART (Continued) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 3. SWITCH ON, HEATER WILL NOT IGNITE; BLOWER OPERATES Step 1. Defective igniter. Replace igniter (para. 5-4). Step 2. Metering orifice clogged. Clean orifice (para. 5-4). Step 3. Pressure regulator solenoid closed. Check regulator valve. Replace if defective (para. 5-4). 4. FAN RUNS WITH SWITCH OFF Step 1.
PAGE 406
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 5-1. FUEL BURNING WINTERIZATION KIT TROUBLESHOOTING CHART (Continued) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 8. SURGING COMBUSTION Fuel regulator operating erratically. Check fuel rate and replace valve if necessary (para. 5-4). 9. COOLANT PUMP FAILS TO RECIRCULATE LIQUID Step 1. Faulty coolant pump. Repair or replace pump (para. 5-4). Step 2. Clogged coolant line. Unclog or replace coolant line (para. 5-4). 10.
PAGE 407
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 5-1. FUEL BURNING WINTERIZATION KIT TROUBLESHOOTING CHART (Continued) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 12. LEAKAGE Step 1. Face of steel cage scored or damaged seal O-ring. Disassemble and inspect seal cage face and O-ring. Refinish or replace as required (para. 5-4). Step 2. Seal face of adapter scored. Disassemble and inspect seal face. Refinish or replace the adapter (para 5-4). 13. MOTOR FAILURE Step 1.
PAGE 408
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 5-3. HEATER CONTROL ASSEMBLY. a. Removal. Refer to the Operator and Unit Maintenance Manual for heater control assembly removal instructions. b Disassembly. (1) Tag all electrical leads before disconnecting. (2) Remove screws (1, figure 5-1), and remove panel assembly (9), from housing (21). (3) Remove nut (2), tooth lockwasher (3), on-off switch (15), and key washer (11). (4) Remove nut (4), Iockwasher (5), and circuit breaker (16).
PAGE 409
ARMY TM 9-6116-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (11) Replace damaged connectors and terminals by unsoldering and removing electrical leads. Install replacement part, make mechanical connection and solder in accordance with established procedure. (12) Replace defective wires using wire conforming to Military Specification MIL-W-5086, Type Il. (13) Inspect housing for cracks, warping, and corrosion. (14) Inspect all threads for crossing, stripping, and other damage.
PAGE 410
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-1.
PAGE 411
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-2.
PAGE 412
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 5-4. HEATER ASSEMBLY. a. Removal. Refer to the Operator and Unit Maintenance Manual for heater assembly removal instructions. NOTE It is not necessary to completely disassemble the heater assembly to replace a single part. Only those parts requiring repair or replacement need be removed. b. Disassembly (1) Tag or otherwise identify electrical leads as they are disconnected to facilitate installation. (2) Remove cover (1, figure 5-3).
PAGE 413
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-6-624-34 c. Cleaning, lnspection, and Repair. (1) Clean all electrical parts with filtered compressed air and a soft bristle brush. If necessary, remove caked deposits with an approved cleaning solvent. Do not dip electrical parts in cleaning water. (2) Clean all non-electrical parts with dry cleaning solvent (Federal Specification P-D-680) and dry thoroughly.
PAGE 414
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-3.
PAGE 415
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-3.
PAGE 416
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 d. Assembly. Assemble the fuel burning heater assembly in reverse order of disassembly procedures while observing the following: (1) Exercise care in replacing quartz rod (13, figure 5-3) as it is easily broken if dropped. After installation, gently move rod up and down to make sure it moves freely in its stainless steel tube. Also make sure at least 1/32 inch extends out of tube when rod is resting on bottom.
PAGE 417
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 e. Testing and Adjustment. (1) Flame Switch Adjustment. Refer to the Operator and Unit Maintenance Manual for flame switch adjustment procedures. (2) Fuel Regulator Valve Adjustment. Refer to the Operator and Unit Maintenance Manual for fuel regulator valve adjustment procedures. (3) Coolant Pump Testing.
PAGE 418
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-4 Coolant Pump Test Diagram 5-15
PAGE 419
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-5. Fuel Burning Winterization Kit Wiring Harness, Drawing No.
PAGE 420
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-6. Fuel Burning Winterization Heater Control Assembly to Special Relay Assembly Wiring Harness Drawing No.
PAGE 421
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Section Il. ELECTRIC WINTERIZATION KIT 5-7. GENERAL. The electric winterization kit is used to maintain the engine coolant and lubricating oil at normal operating temperature in situations which require immediate starting of the generator set. It will function effectively down to an ambient temperature of -65°F (–53. 9°C).
PAGE 422
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Table 5-2. ELECTRIC WINTERIZATION KIT TROUBLESHOOTING CHART (Continued) MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 2. POWER ON INDICATOR LIGHT DOES NOT ILLUMINATE WITH SWITCH IN ON POSITION. Step 1. See Malfunction 1 of this table. Step 2. Defective thermostat. Replace thermostat (para. 5-10). 3. HEATER ELEMENT DOES NOT HEAT UP Step 1. Defective wiring harness. Replace wiring harness (para. 5-13). Step 2. Defective heater element.
PAGE 423
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 5-9. HEATER CONTROL ASSEMBLY. a. Removal. Refer to the Operator and Unit Maintenance Manual for heater control assembly removal instructions. b.Disassembly. NOTE Disassemble heater control assembly only as required to clean, inspect, test and replace components. (1) Tag all electrical leads before disconnecting.
PAGE 424
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (1) Clean all electrical parts with filtered compressed air and a soft bristle brush. If necessary, caked deposits may be removed with a clean, lint-free cloth moistened with solvent P-D-680 Type Il. Do not dip electrical parts in cleaning solvent. (2) Clean non-electrical parts with a clean, lint–free cloth moistened with dry cleaning solvent (P-D-680) and dry thoroughly.
PAGE 425
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-7.
PAGE 426
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-7.
PAGE 427
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 d. Assembly. (1) Install transformer (59, figure 5-7), screw and captive washer assembly (58) and nut (57), on chassis (60). (2) Install relay insulator (56), power relay (55), screw (54), shoulder washer (53) and nut (52). (3) Position wiring harness (51), and install attaching screw and cpative washer assemblies (46 and 49) and nuts 48 and 50). Install protective cap chain (47).
PAGE 428
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 WIRE NO. X9EA12C X1OEA16C X1OEB16C X11EA16C X12EA12N X13EB16N X14EB16C X14EA16C X301A16 X302A16 P90A16 P90C16 P90D16 P91A16 P91C16 P91D16 P91E16 P91F16 P99B16 P99A16 V64F16 V65F16 V65G16 X13EA16N X12EB16N X15EA16N X16EA16C SIZE REF. 12 16 16 12 16 16 16 16 16 16 16 16 LENGTH REF. 21.00 20.50 7.50 10.00 14.50 13.50 18.50 8.50 12.50 14.50 13.50 24.50 18.50 12.50 13.00 25.50 25.50 19.50 20.50 12.00 13.50 10.00 20.50 17.50 21.50 11.
PAGE 429
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-9. Electric Winterization Kit Heater Control Assembly, Wiring Harness (Sheet 2 of 2) Drawing No.
PAGE 430
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 5-10. HEATER ASSEMBLY. Refer to the Operator and Unit Maintenance Manual for electric winterization kit heater assembly maintenance instructions. 5-11. COOLANT PUMP AND MOTOR ASSEMBLY. a. Removal. Refer to the Operator and Unit Maintenance Manual for coolant pump and motor assembly removal procedures. b.Disassembly. (1) Remove plug (1, figure 5-10), spring (2), and ball (3).
PAGE 431
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (6) Place o-ring (6) into groove of port plate (5), then position port plate against cam ring (7). Align scribe marks and secure with screws (4). (7) Install ball (3), spring (2), and plug (1). e. Testing. Test coolant pump and motor assembly as directed in paragraph 5-4(e) (3). 5-12. COOLANT LINES AND FlTTINGS.
PAGE 432
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-11. Electric Winterization Kit Wiring Harness, Drawing No.
PAGE 433
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Section Ill. WHEEL MOUNTING KIT 5-14. GENERAL. The wheel mounting kit provides added mobility for the generator set. It consists of a front and a rear axle assembly. The front axle assembly is equipped with a tow bar, pintle and safety chains. A lock holds the tow bar in the vertical position when not in use. A mechanical parking brake locks the wheels of the rear axle assembly against rotation.
PAGE 434
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-12. Wheel Mounting Kit Installation 5-18. AXLE ASSEMBLIES. a. Removal. Refer to paragraph 5-15 for axle assembly removal instructions. b. Disassembly. NOTE Disassemble wheel mounting kit only as necessary to replace defective parts. (1) Refer to the Operator and Unit Maintenance Manual and remove the wheels, tires brakes, and wheel bearings.
PAGE 435
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (10) Remove cotter pin (46), nut (47), bolt (48), and tie rod end (49), nuts (44 and 45), tube (43) and grease fitting (50). (11) Remove grease fitting (51), roll pin (52), king pin (53), spindle & knuckle (54). (12) Remove tie rod end (55), and grease fitting (56). (13) Remove cotter pin (57), pin (58), spacer washer (59), tow bar assembly (60) and center arm (61).
PAGE 436
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 d.Assembly. (1) Position ID plate (102, figure 5-13) and secure with rivets (101). (2) Install beveled washer (100), capscrew (99), flatwasher (98), Iockwasher (97) and nut (96).
PAGE 437
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-13.
PAGE 438
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-13.
PAGE 439
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Section IV. LOAD BANK 5-19. GENERAL. The load bank is used to apply up to 50 percent of the generator rated load to prevent carbon buildup in the engine due to light loads. It is a balanced three phase, air cooled, resistive load which maybe operated at either 120/208 or 240/416 volts. Generator load is selected through the load selector switch in increments of 12.5 percent rated generator load. 5-20. CONTROL BOX ASSEMBLY. a. Removal.
PAGE 440
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (4) Inspect mode selector switch for cracks, corrosion and other damage. Check switch continuity using an ohmmeter. (5) Inspect transformer for cracks, corrosion and burns or other evidence of shorting. Using an ohmmeter, check transformer coils for continuity. (6) Refer to the Operator and Unit Maintenance Manual for wiring harness cleaning, inspection, and repair procedures.
PAGE 441
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-14.
PAGE 442
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 5-21. LOAD BANK HOUSING. a. Removal. Refer to the Operator and Unit Maintenance Manual for load bank housing removal instructions. b. Disassembly. (1) Remove control box assembly (paragraph 5-20), (2) Remove heater strips, thermostat and terminal board as outlined in the Operator and Unit Maintenance Manual. (3) Remove nut (1, figure 5-17), screw and captive washer assembly (2), and protective cap (3).
PAGE 443
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-15. Control Box Assembly Wiring Harness, Drawing No.
PAGE 444
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-16. Control Box Assembly Branched Wiring Harness (Sheet 1 of 2), Drawing No.
PAGE 445
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-16.
PAGE 446
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-17.
PAGE 447
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-18. Load Bank Wiring Harness (Sheet 1 of 2), Drawing No.
PAGE 448
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-18. Load Bank Wiring Harness (Sheet 2 of 2), Drawing No.
PAGE 449
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-19. Top Load Bank Wiring Harness (Sheet 1 of 2), Drawing No.
PAGE 450
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-19. Top Load Bank Wiring Harness (Sheet 2 of 2) Drawing No.
PAGE 451
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-20. Bottom Load Bank Wiring Harness (Sheet 1 of 2), Drawing No.
PAGE 452
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-20. Bottom Load Bank Wiring Harness (Sheet 2 of 2), Drawing No.
PAGE 453
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-21. Load Bank Power Wiring Harness, Drawing No.
PAGE 454
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-22. Load Bank Signal Wiring Harness, Drawing No.
PAGE 455
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Section V. APPLICATIONS KIT 5-23. GENERAL. The applications kit provides the MEP–113A generator set with remote control of the emergency stop and battle short capabilities, and remote low fuel monitoring. The kit consists of a connector plate, remote housing assembly, cable harness assembly, and electrical tiedown straps. NOTE Remove the application kit before generator set is forwarded for depot maintenance.
PAGE 456
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445--2 NAVY NAVFAC P-8-624-34 Table 5-3. APPLICATIONS KIT TROUBLESHOOTING CHART MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 1. REMOTE LOW FUEL MONITOR NOT FUNCTIONING Step 1. Defective printed circuit band (PCB) inside remote housing (11, figure 5-29). Replace remote functions assembly (para 5-27). Step 2. Defective cable assembly (figure 5-27). Repair cable assembly (para 5-26) Step 3. Defective K3 relay on remote housing (figure 5-31).
PAGE 457
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTES Insure the dust rover retaining chain (figure 5-25) on connector J1 is mounted on the lower right hand mounting screw of connector. A third lockwasher is added between the mounting nut and ground lug on connector mounting screw. (e) Mount connector plate using six capscrews (3) and Iockwashers (4) removed from plate and sleeve assembly. Figure 5-23.
PAGE 458
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34
PAGE 459
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (c) 5-56 (1) Tag load cables for identification purposes. (2) Using a small crescent wrench remove six hex terminal studs and retainers. (3) Beginning from L1 load terminal, install one flat washer, terminal lug, the other flat washer, lock washer and hex nut onto load terminal. Insure the terminal lug is oriented as in figure 5-26. (4) Tighten the hex nut securely.
PAGE 460
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-25.
PAGE 461
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-26. Load Terminal Board Stud Assembly b. Test. (1) Remote Battle Short Function. NOTE Refer to the Operator and Unit Maintenance Manual for generator set controls and switches. (a) Close DC circuit breaker. (b) Place START–RUN-STOP switch in RUN position. (c) Place BATTLE SHORT switch in ON position. NOTE The electric fuel pumps should immediately start to run making a steady clicking sound.
PAGE 462
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 1. Fuel Level Sensor 2. Connector P10 3. Connector P11 4. Connector J9 5. Connector P9 6. Connector P5 7. Fuel Level Sensor Wire (from P2) 8. Connector J8 9. Connector J10 Figure 5-27.
PAGE 463
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 1. Cable Harness Assembly 2. Remote Function Assembly 3. Tiedown Strap (8 ea.) 4. Capscrew (4 ea.) 5. Lockwasher (4 ea.) 6. Spacer (4 ea.) Figure 5-28.
PAGE 464
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (9) Place BATTLE SHORT switch in OFF position. NOTE The AC circuit breaker indicator light should stay lit and the electric fuel pumps should continue to run, indicating that the REMOTE BATTLE SHORT is operational. (2) Remote stop function. NOTE This test should be conducted immediately after testing the remote battIe short function. Test leads and generator set controls and switches should not be changed.
PAGE 465
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-29.
PAGE 466
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-30.
PAGE 467
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 5-26. CABLE HARNESS ASSEMBLY. a. Test (1) Set multimeter on ohms scale. (2) Test each point on cable assembly. NOTE Use Table 5-4 and figures 5-32 and 5-33 as guides. b. Repair. Replace wires, terminals, and connectors by unsoldering connections, installing replacement parts, and soldering connections. 5-27. REMOVAL/INSTALLATION REMOTE FUNCTIONS ASSEMBLY. a. Removal (figure 5-31) (1) Open left rear access cover.
PAGE 468
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-31.
PAGE 469
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAYFAC P-8-624-34 Table 5-4. CABLE HARNESS ASSEMBLY WIRING LIST- Continued To From JIA JIB JIC JID JIE JIF JIG JIH JIJ J1K J1L JIM J I N JIP JIQ JIR P2A P2B P2C P2D P2E P2F P2G P2H P21 P2J P2K P2L P2M 5-66 L1 L2 Gnd P2L P21 Gnd Gnd P2B P2C Wire No.
PAGE 470
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-32.
PAGE 471
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-33.
PAGE 472
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Section VI. ACOUSTIC SUPPRESSION KIT 5-28. GENERAL The acoustic suppression kit provides the ability to lower the noise level of the generator set to 70 dB(A) at 7 meters. It consists of panels, doors, and components that rover or replace original components of the generator set. The generator set is operated and maintained in the same manner; however, access to components and operation will change slightly due to configuration changes.
PAGE 473
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 NOTE Remove all data plates and schematics from generator panels. Remove generator set data plate, and using data plate as a pattern for the rivet holes, mount data plate on right side of control panel. Mount data plates and schematics on rings supplied with acoustic suppression kit, and place behind document box mounted on rear panel. Data plates and schematics should be on separate rings.
PAGE 474
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAYFAC P-8-624-34 (4) Where lines cross, drill a 1 /2–inch hole. (Refer to figure 5-36.) NOTE DO not tighten capscrews in step 5. (5) Position mounting member on skid base, and install the capscrew, flatwashers, Iockwasher, and nut. (6) Position the mounting member until it is parallel to the top of the skid base. Mounting member’s top surface should be 7/8 inch lower than top of skid base. (Refer to figure 5-36.
PAGE 475
ARMY TM 9-6115464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (18) Install keepers, washers, and capscrews to secure the bottom tray assembly. (Refer to figure 5-34.) (19) Raise generator set, and remove 1“x4” block. Lower generator set and remove lifting device. CAUTION Do not allow side panel to fall from mounting members or set side panels on threaded studs. Failure to observe this caution could result in equipment damage. (20) Raise side panel skirt 90° and remove from side panel assembly.
PAGE 476
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 (28) Attach lifting sling to roof panel assembly, and position on generator set. Ensure alignment pins are in holes. It may be necessary to use C-clamps to pull the side panels into position using the lifting clevis as an anchor for the C-clamp. Remove plastic plugs from rotolock holes. Align male and female rotolocks and, using hex tool, turn rotolocks to secure the roof panel assembly. Remove the lifting sling. (Refer to figure 5-37.
PAGE 477
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-34.
PAGE 478
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-35.
PAGE 479
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-6-624-34 Figure 5-36.
PAGE 480
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 5-37.
PAGE 481
ARMY TM 9-6115 464 34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 APPENDIX A REFERENCES This Appendix contains a list of reference manuals that may be used in conjunction with this TM in the operation and maintenance of the 15 KW DOD Generator Set. Those manuals not coded are applicable for use by all services. The manuals are coded (A), for Army use (F) Air Force use, and (N) Navy use. A-1. A-2. A-3. A-4. A-5.
PAGE 482
ARMY TM 9-6115 464 34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 A-5 A-6 MAINTENANCE (CONT) TM 9-611 5 24P (A) TO 35C2-3-445-1 (F) NAVFAC P-8-624-24P (N) SL-4-07532A TM 9-6140-200-14 (A) T.O 36Y4-1-194 (F) T.O 34Y19-1-111 (F) TM 5-764 (A) Deleted SHIPMENT AND STORAGE T.O 35-1-4 (F) T.O 38-1-5 (F) TB 740-97-2 (A) A-7 A-8 Unit, DS, GS and Depot Maintenance Repair Parts and Special Tools List Operator’s and Unit, Intermedia.te Direct Support, and Intermedia.
PAGE 483
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2—3-445-2 NAVY NAVFAC P-8-624-34 APPENDIX B FABRICATION/ASSEMBLY OF PARTS B-1
PAGE 484
ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34 Figure 2-1.
PAGE 485
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445--2 NAVY NAVFAC P-8-624-34 Figure 2-1 Breakout Cable (Sheet 2 of 2) B-3/(B-4 blank)
PAGE 486
PAGE 487
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 ALPHABETICAL INDEX Paragraph Subject A AC POWER CONTROL WIRING HARNESS, 3-195 ACOUSTIC SUPPRESSION KIT INSTALLATION AND REMOVAL, 5-70 ACTUATOR UNIT, 3-191 Paragraph Subject COOLANT PUMP AND MOTOR ASSEMBLY, 5-27 COOLANT TEMPERATURE TRANSMlTTER, 3-39 COOLING FAN, 3-72 CRANKSHAFT, CONNECTING RODS AND PISTONS, 3-120 CURRENT TRANSFORMER ASSEMBLIES, 3-231 AIR CLEANER ASSEMBLY, 3-100 APPLICATIONS KIT INSTALLATION AND REMOVAL, 5-52 CYLIN
PAGE 488
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 ALPHABETICAL INDEX (CONT) Paragraph Subject ENGINE FRONT SUPPORT, 3-101 ENGINE INSPECTION, 4-1 Paragraph Subject GENERATOR MAINTENANCE INSTRUCTIONS, 3-285 EQUIPMENT IMPROVEMENT RECOMMENDATIONS, 1-2 GOVERNOR CONTROL UNIT TO HYDRAULIC ACTUATOR UNIT WIRING HARNESS.
PAGE 489
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34 ALPHABETICAL INDEX (CONT) Subject Paragraph Paragraph Subject R LOW OIL PRESSURE SWITCH, 3-39 LUBRICATION OIL FILTER, 3-75 RADIATOR, 3-70 M MAIN FUEL TANK (METAL), 3-42 MAIN FUEL TANK (PLASTIC), 3-43 MAIN LOAD CONTACTOR, 3-211 MAINTENANCE FORMS AND RECORDS, 1-1 REGULATOR RANGE TEST, 4-8 RELAY TABLE COMPONENTS ADJUSTMENTS, 3-277 RELAY TABLY MAINTENANCE, 3-312 REMOVAL/INSTALLATION REMOTE FUNCTIONS ASSEMBLY, 5-64 MALFUNCTION INDICA
PAGE 490
ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34
PAGE 491
ARMY TM 9-6115-464-34 AIR FORCE TO-35C2-3-445-2 NAVY NAVFAC P-8-624-34 By Order of the Secretaries of the Army, Air Force, and Navy: GORDON R. SULLIVAN General, United States Army Chief of Staff Official: MILTON H. HAMILTON Administrative Assistant to the Secretary of the Army 06362 MERRILL A. McPEAK General, USAF Chief of Staff Official: RONALD W. YATES General, USAF Commander, Air Force Materiel Command DAVID E.
PAGE 492
PAGE 493
PIN: 072239-001