MTD 463 User Manual Page 1

ARMY TECHNICAL MANUAL TM5-6115-465-34NAVY PUBLICATION NAVFAC P-8-625-34AIR FORCE TECHNICAL ORDERTO-35C2-3-446-2MARINE CORPS TECHNICAL MANUAL

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34C9Remove pages (con’t)5-28.1/(5-28.2 blank)5-59 and 5-60---5-69 and 5-708-39 throug

TM5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34Figure 3-15.Speed Switch Test Points3-7.COOLANT TEMPERATURE TRANSMITTER.Refer to t

TM5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34Figure 3-16. Engine Wiring Harness Assembly, Drawing No. 72-2284Change 23-21

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06868B/06895D-34c.Rebuild.If the wiring harness has sustainedprocedures.damage and requires repair

TM 5-6115-465-34SAVFAC P-8-625-34TO 35C2-3-446-2TM 06868B/06895D343-16.Figure 3-17. Main Fuel Tank (Metal), Removal and InstallationFUEL TRANSFER PUMP

TM 6115-465-34NAVAFAC P-8-625-34TO 35C2-W462TM 06868B/06895G34Figure 3-17A. Main Fuel Tank (Plastic), Removal and InstallationWARNING(7) Repair damage

TM5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34Figure 3-18.Fuel Injection Pump Assembly, Removal and Installation3-24Change 7

3-20. FUEL INJECTION PUMP ASSEMBLY.a.General. The Roosa Master Fuel InjectionPump is mounted on the timing gear case and is geardriven through an idle

TM 5-6115-465-34TM35C2-3-446-2NAVFACP -8-625-34TM06858B/06859D-34Figure 3-19.Fuel Injection Pump, Exploded View (Sheet 1 of 7)3-26

TM 5-6115-465-34TO35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 3-19. Fuel Injection Pump, Exploded View (Sheet 2 of 7)Figure 3-19.Fuel Injec

Army Technical ManualNavy PublicationAir Force Technical OrderMarine Corps Technical ManualCHANGE}NO. 8TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-

TM 5-6115-465-34TO35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 3-19. Fuel Injection Pump, Exploded View (Sheet 4 of 7)Figure 3-19.Fuel Injec

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34Figure 3-19.Fuel Injection Pump, Exploded View (Sheet 6 of 7)Figure 3-19. Fuel Injec

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34(12) Remove and discard control spring pin(78).(13) Discard seals (74 andguide (75)

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34(3) While holding the rotor under fuel, insertthe plungers into their bore. With thu

TM 5-6115-465-34TO35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34(4) Insert regulating sleeve assembly into thebore in end plate (66).(5) Fit the tran

TM 5-6115-465-34TO35C2-3-446-2NAVFACP -8-625-34TM06858B/06859D-34(c) Using a 1 inch to 2 inch micrometer,measure the roller-to-roller dimension. If ro

TM 5-6115-465-34TO35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34NOTEMake sure that the power piston plug ison the right side of the pump as viewedfro

TM 5-6115-465-34TO35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34Figure 3-21.Throttle Linkage Adjustment(50) Install new insulating tubes (11 and 12,f

TM 5-6115-465-34TO35C2-3-448-2NAVFAC P-8-625-34TM06858B/06859D-34Figure 3-22.Solenoid Armature Adjustments3-36

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2Table 3-1.FUEL DELIVERYTM 06858B/06859D-34Observe for leaks and correct as necessary. Backout high idl

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B.06859D-34By Order of the Secretaries of the Army, the Navy, and the Air Force:CARL E. VUONOO

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34Figure 3-23.Fuel Injection Nozzle Holder, Exploded View(q) Remove pump from test st

b. Disassembly.(1) Unscrew spray cap (1, figure 3-23) andremove pintle holder (2) and pintle (3).(2) Remove cap (4) and washer (5).(3) Remove lock nut

Figure 3-24.Shutter Control Assembly, Exploded View

TM 5-6115-465-34TO35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34Section III.ENGINE COOLING SYSTEM3-24. GENERALThe engine cooling system is a circulat

TM 5-6115-465-34TO 35C2-S-446-2NAVFAC P-8-625-34TM 06858B/06859D-S4Figure 3-25.Shutter Assembly, Exploded View(4) Check interior of radiator for rust

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 3-26.Water Pump Assembly, Exploded View(3) Inspect control lever forand exce

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34(6) Disconnect water inlet housing (15) by re-moving screw (13) and lockwasher (14)

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34(6) Install water inlet housing (15) and new3-31.COOLANT THERMOSTAT AND HOUSING.gas

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 3-28.Oil Cooler Assembly Removal and Installation(3) Inspect and replace oil

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34Figure 3-29.Oil Pan Assembly(4) Using a suitable puller, remove gear (12).(5) Remove

CHANGE}NO. 7DOD MODELMEP-005AMEP-104AMEP-114ATM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34C 7DEPARTMENTS OF THE ARMY, THENAVY, A

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/0685D-S4Figure 3-30. Oil Pump Assembly, Exploded View3-48

TM S-6115465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 3-31.Oil Pump Assembly Dimension(2) Insert shaft into pump body (22) and pres

TM 5-6115465-34TO 35 C2-3446-2NAVFAC P-8-625-34TM 06858B/06859D-34Section V.HYDRAULIC SYSTEM3-38. GENERAL.The hydraulic system used on MEP-104A sets o

TM 5-6115-465-94TO 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34Figure 3-32. Hydraulic Sump, Removal and Installation3-51

3-52Figure 3-33.Hydraulic Pump Assembly, Exploded View

TM 5-6115-465-34TM 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 3-34. Hydraulic System Filter Assembly, Exploded View3-53

TM 5-6115-465-34TM 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34c.Cleaning, Inspection, and Repair. (8) Tighten locknut and remove hydraulicpump ass

3-55Figure 3-35. Hyderaulic Actuator Unit, Removal and Installation

TM5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34e.Installation.Install hydraulic system filterin reverse order of removal procedu

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3446-2TM 06858B/06859D34Figure 3-36.Hydraulic Actuator Unit, Exploded View (Sheet 1 of 2)3-57

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34C7By Order of the Secretaries of the Army, the Navy, and the Air Force:Official:Gen

TM 5-6115-465-34NAVFAC P-8-625-34TO 35 C2-3-446-2TM 06858B/06859D-341.2.3.4.5.6.7.8.9.10.11.12.13.14.15.16.17.18.19.20.21.22,23.24.25.26.27.28.29,30.3

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34Figure 3-38. Hydraulic Actuator Test3-59

TM 5-6115465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34(9) Inspect cover and valve block for cracks,corrosion, and other damage..(10) Check

TM 6-6115465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34(i) Set switch S1 to connect power (PS) to coilL1 and apply 700 ma ± 40 ma. Pressure

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34Table 3-2. HYDRAULIC ACTUATOR TEST VALUESACTUATOR STYLES69-600-213217E5390-2, 32D15

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859DFigure 3-38.1 Hydraulic Actuator Tests, Schematic DiagramChange 33-60.3 /(3-60.4 blank

TM 5-6115-465-S4TO 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06869D-34(7) Return the generator set START-RUN-SHORT switch to the OFF position.STOP switch

TM5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3446-2TM 06858B/06859D-34Figure 3-39. Engine Front Support, Removal and Installation.i. The cylinder block a

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 3-40. Flywheel and Flywheel Housing, Exploded View(6), screws (7) and lockwa

CHANGENO. 6}DOD MODELMEP-005AMEP-104AMEP-114ATM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34C 6DEPARTMENTS OF THE ARMY, THENAVY, A

TM5-6115-465-34NAVFAC P-8-62534T.O. 36C2-3-446-2TM 068S8B/06869D-34Figure 3-41. Checking Flywheel Concentricity and Alignment(7) Repair defective pain

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-343-65Figure 3-42. Timing Gears and Cover, Exploded View

TM 5-6115-465-34T035C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34(4) Remove the front engine support (para-graph 3- 48).(5) Remove screws (l, figure3-

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34Figure 3-43.Timing Gear Relationships3-53. CYLINDER HEAD AND ROCKER ARMASSEMBLY.a. R

TM 6-0118-466-34TO 35D2-3-446-2NAVFAC P-8-625-34TM 06858B/06869D-34Figure 3-44. Cylinder Head and Rocker Arm Assembly, Exloded View3-68

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Change 1 3-69

TM 5-6115-465-34TO 35C2-3446-2NAVFAC P-8-625-34TM 06858B/06859D-34(figure. 3-45)(figure 3-46).figure 3-47.Paragraph 1-6 v.3-54. Camshafta. Removal.(1)

TM 5-6115465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34Figure 3-45.Rocker Arm Mounting Blocks InstallationFigure 3-46. Rocker Arm Shaft Pos

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-S4TM 06858B/06859D-34Figure 3-47. Cylinder Head Nut Tightenlng SequenceNOTERotate crankshaft as necessar

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 3-48.Camshaft, ExplodedViewChange 5 3-73

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34C6By Order of the Secretaries of the Army, the Navy, and the Air Force:JOHN A.WICKH

TM5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 3-49.Dimensional Inspection of Camshaft(7) If runout of any bearing exceeds l

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34(a) Attach a dial indicator to the cylinder blockand position so that the foot con

TM 5-6115-465-34TO 35C2-3464NAVFAC P-8425-34TM 06856/06859D-34Figure 3-50. Crankshaft, connecting rods and pistons, exploded view.CAUTIONWhen regrindi

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34(12) Remove minor nicks and burrs frompiston by polishing with crocus cloth. Clean t

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM06B58B/06859D-34NOTEProper position of the oil ring gap is withthe gap aligned with either piston pi

TM5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 3-51. Cylinder Block Assembly, Exploded View3-79

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34(12) Check camshaft bearing bore diameter.Diameter shall be 2.1870 to 2. 1880 inches

TM 5-6115-465-34TO 35C2-3446-2NAVFAC P-8-625-34TM 06858 B/068 S9D-34CHAPTER 4GENERATOR SET CONTROLS AND INTERCONNECTING WIRING HARNESSSection I.GENERA

TM 5-6115465-34TO 35 C2-3446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 4-2.Thermal Watt Converter Test Circuit Schematicfrequency meter being tested

TM 5-6115-465-34T035C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34(o) Refer to the Operator and Organiza-tional Maintenance Manual and install thermal

TM 5-6115-465-34NAVFAC P-8-625-34CHANGENO. 5}DOD MODELMEP-005AMEP-104AMEP-114ADOD MODELMEP-005AWFMEP-005AWEMEP-005ALMMEP-005AWMTO 35C2-3-446-2TM 06858

TM 5-6115-465-34TO35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-344-4Figure 4-3. Control Cubicle Housing Assembly, Exploded View

TM 5-6115-465-94T035C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34Figure 4-4.Control Cubicle Relay Assembly, Exploded View4-5

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34Figure 4-5.Control Cubicle Relay Assembly, Schematic Diagramrelay (K6) is defective.

(1) Refer to the Operator and OrganizationalMaintenance Manual for wiring harness removal,cleaning, inspection, and repair procedures.(2) If the wirin

TM 5-6115-465-34T035C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 4-6. Control Cubicle Wiring Harness (Sheet 1 of 3) Drawing No. 69-6774-8

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 4-6. Control Cuticle Wiring Harness (Sheet 2 of 3) Drawing No. 69-677 4-9

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-344-10Figure 4-6. Control Cubicle Wiring Harness (Sheet 3 of 3) Drawing No. 69-677

TM5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34Figure 4-7. Fault Locating Indicator, Exploded View (Sheet 1 of 2)Change 24-11

TM5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34Figure 4-7. Fault Locating Indicator,Exploded View (Sheet 2 of 2)(b) Inspect Indic

TM 5-6115-465-34TO 35C2-W&2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 4-8.Fault Locating lndicator, Schematic DiagramChange 94-13

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34C52. Retain this sheet in front of manual for reference purposes.By Order of the Se

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-344-14Figure 4-9.Fault Locating Indicator Component Board Assembly

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 4-10. Fault Locating Indicator Wiring Harness Drawing No. 72-22474-15

TM 5-6115-465-34TO 35 C2-3-446-2NAVFAC P-8-625-34TM 06858B 06859D-34Figure 4-11. Load Measureing Unit, Exploded View4-16

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34e. Testing,c. Cleaning and Inspection.(1) Refer to figure 4-8 and connect the posi-t

TM 5-6115-465-34T035C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-344-18Figure 4-12. Load Measuring Unit Wiring Harness, Drawing No. 69-511

TM 5-6115-465-34TO 35C2-3446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 4-13 Load Measuring Unit Component Test and Replacements DiagramChange 94-19

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-344-7. GOVENOR CONTROL UNIT. (MEP 104A)(25.figure 4-11).(26. figure 4-11).figure 4-

TM 5-6115-465-S4TO 35C2-3-S-446-2NAVFAC P-8-625-34TM 088S8B/06859D-S4Figure 4-14. Load Measuring Unit Test Circuit and Test Data Relationship4-21

TM 5-6115-465-34T035C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34(1) If the FL - NL or NL - FL transient ex-ceeds 1-1/2 percent of rated speed and/or

TM 5-6115-465-34T035C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34Figure 4-15.Governor Control Unit, Exploded View (Sheet l of 2)4-23

CHANGENO. 4TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34C 4}DEPARTMENTS OF THE ARMY, THENAVY, AND THE AIR FORCE (INCLUDINGTHE US

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-341. Screw30. Nut2. Lockwasher 31. Tooth lockwasher3. Nut32. Potentiometer (R12)4. Lo

(8) Repair housing and cover as follows:(a) Straighten dents and warping.(b) Remove defective paint and cor-rosion. Treat and paint.(9) Repair wiring

TM 5-6115465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 068 S8B/06859D-34Table 4-2.50/60 Hz GOVERNOR CONTROL UNIT RESISTANCE TEST VALUESP1CONNECTIONPOTENTIO

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/0685WY34Figure 4-16. 50/60 Hz Governer Control Unit Wiring Harness, Drawing No. 69-731 (Shee

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 4-1650/60 Hz Governer Control Unit Wiring Harness, Drawing No. 69-731 (Sheet

ME 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 4-17.400 Hz Governor Control Unit Wiring Harness, Drawing No. 69-814 ( Sheet

TM 5-6115-465-34T035C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 4-17.400 Hz Governer Control Unit Wiring Harness, Dwg. No. 69-814, (Sheet 2 o

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 4-18.Governor Control Unit Printed Circuit Board4-29

TM 5-6115-465-34TO35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 4-19. 50/60 Hz Governor Control Unit Wiring Diagram, Dwg No. 69-7304-30

TM 5-6115-465-34T035C2-3-446-2NAVFAC P-8-625-.34TM06858B/06859D-34Figure 4-20. 400 Hz Governor Control Unit Wiring Diagram Drawing No. 69-8334-31

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34C 4By Order of the Secretaries of the Army the Navy, and the Air Force:Official:JOH

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-344-32Figure 4-21. 50/60 Hz Governer Control Unit Schematic Diagram, Drawing No. 69-7

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34Figure 4-22. 400 Hz Governor Control Unit Schematic Diagram, Drawing No. 69-8124-33

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-826-34TM 06858B/06859D-34Figure 4-23.Positioning of Unpotted Governor Control Unit During TestingFigure 4-2

TM 5-6116-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34 Figure 4-25.Governor Control Unit Frequency Sensing Test Circuit(a) Install govern

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34Figure 4-26.Governor Control Unit Rectifier Bridge and Feedback Winding Test Circuit

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 4-27. GovernorControl(5) Using heavy gloves and safety glasses,slowly lower

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 4-28.Approximate Position Of Controls For Connecting Actuator(8) Adjust R12

TM 5-6115-465-34NAVFAC P-8-625-34T.0.35C2-3-446-2TM 06858B/06859D-34Figure 4-28.1.Approximate Position of Controls for Connecting Actuator (Effective

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06858D-34Figure 4-29.Governor Control Unit Control Panel4-39

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C3-3-446-2TM 06858B/06859D-34C 3CHANGE}DEPARTMENTS OF THE ARMY, THE NAVY,AND THE AIR FORCE(INCLUDING THE US MARI

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-344-40Figure 4-30. Tactical Relay Assembly to Special Relay Assembly Wiring Harness, D

4-7.1 GOVERNOR CONTROL UNIT (MEP-114A).a.General.(1) The electric governing system is a speed(frequency) sensing system used to maintain constanteng

TM 5-6115465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 4-30.1.Functional Theory of Operation4-40.2 Change 5

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Table 4-4. Governor Malfunction TestingPROBABLE CAUSE OFTERMINALNORMAL VALUENON-NOR

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34(14) Turn the control unit frequency adjustscrew clockwise until the proper engine

1. (P17)2. Hex head screws (4)3. Lockwasher (4)4. Nuts (4)5. Control unitTM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 4-3

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 4-30.3.Actuator Removal And Installation4-40.6Change 5

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 4-30.4.Magnetic Pickup Removal And InstallationChange 54-40.7/(4-40.8 Blank)

TM 5-6115-465-S4TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Section II. INTERCONNECTING WIRING HARNESSES4-8. GENERAL.The interconnecting wiring

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34C33.New or changed text material is indicated by a vertical barin the margin.An ill

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 4-31. Special Relay Assembly to Static Exciter Assembly Wiring Harness, Draw

TM 5-6115-465-34TO 35C2-3446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 4-32.Load Measuring Unit to Tactical Relay Assembly Wiring Harness, Drawing N

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34Tm 06858B/06859D-34Figure 4-33.Governor Control Unit to Hydraulic Actuator Unit Wiring Harness,Drawing

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 4-33.1.400 Hz Electric Governor System WiringHarness Assembly Drawing No. 84

TM 5-6115465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 4-33.1.400 HZ Electric Governor System WiringHarness Assembly Drawing No. 84-

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06858D-34Figure 4-34.AC Power Control Wiring Harness, Drawing No. 72-2259 (Sheet 1 of 2)4-45

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-344-46Figure 4-34. AC Power Control Wiring Harness, Drawing NO. 72-2259 (Sheet 2 of 2)

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 4-35. Exciter Control Wiring Harness, Drawing No. 73-22884-47

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-344-48Figure 4-36. Special Relay Assembly to Fault Locating Indicator Wiring Harness,

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-344-15. SPECLAL RELAY ASSEMBLY TO FAULTLOCATING INDICATOR WIRING HARNESS.a. Refer to t

TM5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34C2ChangeNo. 2}DOD MODELMEP-005AMEP-104AMEP-114ADOD MODELMEP-005AWFMEP-005AWEMEP-O0

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8625-34Tm 06858B/06859D-34Figure 4-37. Special Relay Assembly to Control Cubicle Wiring Harness, Drawing No. 7

TM 5-6115-485-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-344-51Figure 4-38. Precise Relay Assembly to Governor Control Unit Wiring Harness, Dr

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-344-52Figure 4-39. Special Relay Assembly to Precise Relay Assembly, Drawing No. 72-22

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34CHAPTER 5GENERATOR REPAIR INSTRUCTIONSSection I. CONVENIENCE AND PARALLELING RECEPT

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 5-1.Convenience and Paralleling Receptacles Wiring Harness, Drawing No. 72-2

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 5-2. Main Load Contactor, Exploded View (Sheet 1 of 3)5-3

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 5-2. Main Load Contactor, Exploded View (Sheet 2 of 3)5-4

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 5-2.Main Load Contactor, Exploded View (Sheet 3 of 3)5-5

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34(2) Tag and disconnect electrical leads toterminals.(13) Discard gaskets (20, 14, a

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 5-3. Actuator Assembly Adjustment Points(d) Insert a 0.150 ± 0.010 inch feel

TM5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34C2Remove pagesInsert pagesChapter 55-67 and 5-685-67 and 5-685-75 and 5-765-75 and

TM 5-8115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 5-4. Main Contact Preload Check Points Figure 5-5.Main Load Contactor Adjust

TM 5-6115-465-34NAVFAC P-8-625-34T.O. 3SC2-3-446-2TM 06858B/06859D-34(d) Adjust carrier bushing at point (B)(e) Bend the tab (point D, figure 5-5) of(

TM 5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34Figure 5-6. Main Load Contactor Schematic Diagram, Contactor to Load Terminals Wi

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 5-6.Main Load Contactor Schematic Diagram, Contactor to Load Terminals Wirin

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 5-7.Load Terminal Board Assembly, Explodod View5-12

TM-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D34(d) Apply 24 Vdc to connector pins A and B (seefigure 5-6).(e) Bend the tab (point D

TM 5-6115-465-34NAVFAC P-8-625-34T.0.35C2-3-446-2TM 06858B/06859D-34Figure 5-7.1. Main Load Contact.or, Exploded View (Effective with Serial No. RZ700

TM 5-6115465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34Figure 5.7.1.Main Load Contactor, Exploded View (Effective with Serial No. RZ7000

TM 5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-341.2.3.4.5.6.7.8.9.10.11.12.13.14.15.16.17.18.19.20.21.22.23.24.25.26.27.28.29.30.

(6) Check coil assembly (60) for swelling ofencapsulated material, burns, and evidence of corro-sion, Using an ohmmeter, check coil for continuity.(7)

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34CHANGE}No. 1DOD MODELMEP-005AMEP-104AMEP-114ADOD MODELMEP-005AWFMEP-005AWEMEP-005AL

TM 5-6115-466-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34NOTE 1. Drawing Reflects 30 KW 400 Hz Precise.NOTE 2. On 30 KW 50/60 Hz Precise a

TM 5-6115-465-34TO 35C2-S-446-2NAVFAC P-8-625-34TM 06858B/06859D-34 Figure 5-9.Transformer assemblies, Removal and Installationb. = Cleaning, Inspecti

TM 5-6115-465-34TO35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34Figure 5-10. Current Transformer Test Point5-16

5-9.GENERAL.TM 5-6115-465-34 NAVFAC P-8-625-34TO35C2-3-446-2TM06858B/06859D-34Section III. RELAY TABLE COMPONENTSThe relay table components consi

TM 5-6115-465-34NAVFACP-8-625-34TO35C2-3-446-2TM06858B/06859D-34Figure 5-11.Tactical Relay Assembly, Exploded View5-18Change 3

TM5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2 TM 06858B/06859D-34 ME5-6115-465-34/5-12(1)Figure 5-12. Tactical Relay Assembly Wiring Harness,Draw

TM5-6115-465-34NAVFAC P-8-625-34T.O.35C2-3-446-2TM06858B/06859D-34ME5-6115-465-34/5-12(2)Figure 5-12.Tactical Relay Assembly Wiring Harness, Drawing N

TM 5-6115-465-34TO35C2-3-446-2NAVFAC P-8-625-34 TM06858B/06859D-34Figure 5-13.Reverse Power Relay Test Circuit5-21

TM 5-6115-465-34TO35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34Figure 5-14.Overvoltage Relay Test Circuit(b) Activate power source G 1 and adjustvol

TM 5-6115-465-34TO35C2-3-446-2NAVFAC P-8-625-34 TM06858B/06859D-34Figure 5-15. Short Circuit Relay Test Circuit(f) Return output voltage of G1 below 2

TM 5-6115-465-34By Order of the Secretaries of the Army, the Navy, and the Air Force:BERNARD W. ROGERSGeneral, United States ArmyOfficial:Chief of Sta

TM 5-6115-465-34TO 35C2-3-446-2NAVFACP-8-625-34TM06858B//06859D-34Figure 5-16. Overload Protective Device Test Circuit 5-24 Change 4

TM 5-6115-465-34TO35C2-3-446-2NAVFACP-8-625-34TM06858B/06859D-34Figure 5-17.Tactical Relay Resistor Assembly Schematic Diagram(b) Touch other lead to

TM 5-6115-465-34TO35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34Figure 5-18.Tactical Relay Resistor Assembly, Exploded View(4) Inspect protective cap

TM5-6115-465-34NAVFACP-8-625-34TO35C2-3-446-2TM06858B/06859D-34Figure 5-19. Special Relay Assembly, Exploded View (Sheet 1 of 2)5-27

TM 5-6115465-34 TO 35C23446-2 NAVFACP-8-625-34TM06858B/06859D-34Figure 5-19. Special Relay Assembly, Exploded View (Sheet 2 of 2)(b) Use an ohmmeter t

TM5-6115-465-34TO35C2-3-446-2NAVFACP-8-625-34TM06858B/06859D-34Figure5-19.1. Connector plug, ElectricalChange 95-28.1

TM5-6115-465-34TO35C2-3-446-2NAVFACP-8-625-34TM06858B/06859D-34 units equiped with electric governor. *P81B18 from J5-F to E31-C is changed to P81B18

TM5-6115-465-34NAVFAC P-8-625-34T.O.35C2-3-446-2TM06858B/06859D-34ME5-6115-465-34/5-20(1)Figure 5-20. Special Relay Assembly Wiring Harness, Drawing

Figure 5-20. Special Relay Assembly Wiring Harness, Drawing No. 72-2239 (Sheet 2 of 3)5-30 Change 2

TM5-6115-465-34TO35C2-3-446-2NAVFACP-8-625-34TM06858B/06859D-34FIgure 5-20. Special Relay Assembly Wiring Harness, Drawing No 72-2239 (Sheet 3 of 3!)5

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06868B/06895D-34WARNINGAll specific cautions and warnings contained in this manual shall be strictl

TM 5-6115-465-34T035C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34Figure 5-21.DC Relay Assembly Schematic Diagrama. Removal.(1) Disconnect electrical c

TM5-6115-465-34TO35C2-3-446-2NAVDACP-8-625-34TM06858B/06859D-34Figure 5-22.DC Relay Assembly, Exploded View5-33

TM 5-6115-465-34TO35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34Figure 5-23. Precise Relay Assembly, Exploded View5-34

TM5-6115-465-34TO35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34Figure 5-24.Under Voltage Relay Test Circuit(b) Activate power source G1 and adjusto

TM 5-6115-465-34TO35C2-3-446-2NAVFACP-8-625-34TM06858B/06859D-34Figure 5-25.Under Frequency Relay Test Circuitinto test circuit shown in figure 5-26.5

TM5-6115-465-34TO 35 C2-3446-2NAVFACP-8-625-34TM 06858 B/06859D-34Figure 5-26.Permissive Paralleling Relay Test Circuit(j) Open switch (S1) and adjust

TM 5-6115465-34TO 35 C2-3446-2NAVFAC P-8-625-34TM 06858 B/06859D-34Figure 5-27.Electronics Components AssemblyDo not attempt to perform maintenanceon

TM5-6115-465-34NAVFAC P-8-625-34T.O.35C2-3-446-2TM06858B/06859D-34ME5-6115-465-34/5-28(l)Figure 5-28.50/60 Hz Precise Relay Assembly Wiring Harness, D

TM5-6115-465-34NAVFAC P-8-625-34T.O.35C2-3-446-2TM06858B/06859D-34ME5-6115-465-34/5-28(2)Figure 5-28.50/60 Hz Precise Relay Assembly Wiring Harness, D

TM5-6115-465-34TO35C2-3-446-2NAVFACP-8-625-34TM06858B/06859D-34Figure 5-29.400 Hz Precise Relay Assembly Wiring Harness,Drawing No. 72-2260 (Sheet 1 o

TM5-6115-465-34TO35C2-3_446-2NAVFACP8-625-34TM06858B/06859D-34Figure 5-29.400 Hz Precise Relay Assembly Wiring Harness, Drawing No. 72-2260 (Sheet 2 o

TM5-6115-465-34NAVFAC P-8-625-34T.O.35C2-3-446-2TM06858B/06859D-34ME5-6115-465-34/5-30(1)Figure 5-30. Static Exciter and Voltage Regulator Assembly, E

TM5-6115-465-34NAVFAC P-8-625-34T.O.35C2-3-446-2TM06858B/06859D-34Figure 5-30.Static Exciter and Voltage Regulator Assembly, Exploded View (Sheet 2 of

TM 5-6115-465-34TO 35 C2-3-446-2NAVFAC P-8-625-34TM 06858 B/06859D-341.2.3.4.5.6.7.8.9.10,11.12.13.14.15.16.17.18.19.20.21.22.23.24.25.26.27.28.29.30.

TM5-6115-465-34TO35C2-3-446-2NAVFACP-8-625-34TM068578B/06859-D-34Figure 5-31. 50/60 Hz Static Exciter and Voltage Regulator Schematic Diagram, Drawing

TM5-6115-465-34NAVFAC P-8-625-34T.O.35C2-3-446-2TM 06858B/06859D-34(b) One direction shall give an indication (a) Connect static exciter and voltageof

TM5-6115-465-34NAVFAC P-8-625-34T.O.35C2-3-446-2TM06858B/06859D-34Table 5-1.STATIC EXCITER AND VOLTAGE REGUL.ATOR RESISTORAND CAPACITOR VALUES5-48Chan

TM5-6115-465-34NAVFAC P-8-625-34T. O. 35C2-3-446-2TM06858B/06859D-34ME5-6115-465-34/5-32Figure 5-32. 400 Hz Static Exciter and Voltage Regulator Sche

TM5-6115-465-34NAVFAC P-8-625-34T.O.35C2-3-446-2TM06858B/06859D-34A. STATIC EXCITER WIRING HARNESS (Shoot 1 of 2)ME5-6115-465-34/5-33(1)Figure 5-33. S

TM5-6115-465-34NAVFAC P-8-625-34T.O.35C2-3-446-2TM06858B/06859D-34Figure 5-33. Static Exciter Wiring Harness, Dwg. No. 72-262$ voltage Regulator Wirin

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-62534TM 06858B/06859D-34Reproduction for non-military use of the information or illustrations contained in t

TM5-6115-465-34NAVFAC P-8-625-34T.O.35C2-3-446-2TM06858B/06859D-34ME5-6115-465-34/5-33(3)Figure 5-33. Static Exciter Wiring Harness, Dwg. No. 72-2628,

TM5-6115-465-34NAVFAC P-8-625-34T. O.35C2-3-446-2TM06858B/06859D-34Figure 5-33. Static Exciter Wiring Harness, Dwg. No. 72-2628, Voltage Regulator Wi

TM5-6115-465-34NAVFAC P-8-625-34T.O.35C2-3-446-2TM06858B/06859D-34Figure 5-34. Static Exciter and Voltage Regulator Assembly Sensing Circuit Bench Te

TM 5-6l15-445-34TO35C2-3-446-2NAVFACP-8-625-34TM06858B/06869D-34[1]Position voltage ad-lust rheostat R2 ongenerator set control cubicle to the approxi

TM5-6115-465-34TO35C2-3-446-2NAVFACP-8-625-34TM06858b/06859D-34Figure 5-36. Generator Assembly, Exploded View (Sheet 1 of 2)5-56

TM 5-6115-465-34NAVFAC P-8-625-34TO 35 C2-3-446-2TM06858B/06859D-34Figure 5-36.Generator Assembly, Exploded View (Sheet 2 of 2)(9) Thread five turns o

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34Figure 5-37.Securing Generator Rotor to StatorFigure 5-38.End Bell Assembly, Explod

(26) Do not remove screws (35) or data plate(36) unless damage is present.(27) Remove gasket (37),(28) If inspection reveals damage to end bellassemb

TM5-6115-465-34TO35C2-3-446-2NAVFACP-8-625-34TM06858B/06859D-34Figure 5-39. Generator Rotor and Balance Assembly, Exploded View (sheet 1)5-60 Change

TM5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34Figure 5-39. Generator Rotor and Balance Assembly, Exploded View (sheet 2) Change 9

CHANGENo. 12TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34C 12HEADQUARTERSDEPARTMENTS OF THE ARMY, NAVY AND AIR FORCEAND HEADQUAR

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 5-40. Lead Block Assembly, Exploded View(6) Inspect blower and coupling disc

Figure 5-41.Generator Stator Assembly, Exploded View

(17) Using a double bridge, measure resis-tance of rotor core. Resistance shall be 0.2154 to0.2486 ohms at 77°F (25°C).(18) Install rotor and balance

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/0685D-34Figure 5-42.50/60 Hz Generator Stator Winding Procedures(Sheet 1 of 2)5-64

Figure 5-42. 50/60 Hz Generator Stator Winding Procedures (Sheet 2 of 2).

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 5-43.400 Hz Generator Stator Winding Procedures(sheet 1 of 2)5-66

TM 5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34Figure 5-43.400 Hz Generator Rater Winding Procedures (Sheet 2 of 2)Change 25-67

TM5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34Figure 5-44.50/60 Hz Generator, Rewind Procedures5-68Change 2

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34Figure 5-45.400 Hz Generator Rotor Winding Procedures5-69

DEPARTMENT OF THE ARMY, THE NAVYAND THE AIR FORCE(INCLUDING MARINE CORPS)WASHINGTON, D.C., 31 January 1975CHAPTER 1.Section I.Section II.CHAPTER 2.Sec

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34(h) Drain the core for aminimum of30 minutes.(i) Place the core in an oven and heat

TM 5-6115-465-94TO 35C2-3-446-2NAVFAC P-8-625-94TM 06858B/06859D-34Figure 5-46.Generator Exalter Stator Winding Procedures(Sheet 1 of 2)5-71

TM 5-6115-45-34TO 35C2-3-446-2NAVFAC P-8-625-94TM 06858B/06859D-34Figure 5-46.Generator Exciter Stator Winding Procedures(Sheet 2 of 2)5-72

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 5-47.Generator Exciter Rotor Winding Procedures (Sheet 1 of 2)5-73

Figure 5-47.Generator Exciter Rotor Winding Procedures (Sheet 2 of 2)

TM 5-6115-465-34NAVFAC P-8-625-34T.0. 35C2-3-446-2TM 06858B/06859D-34(a) Secure end bell assembly (34, figure5-36) to stator (26) using lockwashers (3

TM5-6115-465-34NAVFAC P-8-625-34T.O.35C2-3-446-2TM 06858B/06859D-34is not present,the problem may be the wiringbetween the special relay box end the s

TM5-6115-465-34NAVFAC P-8-625-34T.O.35C2-3-446-2TM 06858B/06859D-34SectionV. ELECTROMAGNETIC INTERFERENCE SUPPRESSION COMPONENTS5-17. TESTING FOR ELEC

TM5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34CHAPTER 6ENCLOSURE ASSEMBLY REPAIR INSTRUCTIONSSection I.HOUSING ASSEMBLY6-1.GENER

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34SectionSectionSectionSectionTABLE OF CONTENT (CONT)3-8.Overtemperature Switch. . .

TM5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34Figure 6-1.Relay Table Assembly, Exploded View6-2

TM5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34Figure 6-1.1. Relay Table Assembly, Exploded ViewChange 26-2.1/(6-2.2 blank)

TM5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34Figure 6-2.Lifting Frame, Exploded ViewChange 2 6-3

TM 5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34b.Cleaning, Inspection, and Repair.(1) Clean all parts in dry cleaning solvent(Fe

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 6-3. Skid Base Assembly, Exploded Viewd. Assembly. Assemble skid base assemb

GENERATOR SET TESTS AFTERSection I.7-1. GENERAL.a. A thorough inspection of the generator set shallbe conducted to insure that workmanship and materia

TM 5-6115-465-34TO 36C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34as in the Operator and Organizational MaintenanceManual.e. All test results for gen

7-12. MALFUNCTION INDICATOR TEST.a. The malfunction indicator system is electricallyisolated and independent of the protection system.Testing of the i

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34TABLE OF CONTENTS (CONT)Section VI.INTAKE AND EXHAUST SYSTEMS AND BREATHER. . . . .

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Table 7-1.OPERATING TESTSTEST1.2.3.4.5.6.7.8.9.10.11.12.13.14.15.16.17.18.a.b.Regul

7-4Table 7-2. ENGINE GENERATOR SET CLASSIFICATIONCLASS121MODEIIIIC0MMONNAMETacticalPreciseTacticalUtilityTacticalPreciseOUTPUTFREQUENCY50/60 Hz50/60 H

TM 5-6115-465-94T035C2-3-446-2NAVFAC P-8-625-24TM 06858B/06859D-34Table 7-3.ELECTRICAL PERFORMANCE CHARACTERISTICPARAMETERS AC PRECISE (CLASS 1)TEST M

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Table 7-3.ELECTRICAL PERFORMANCE CHARACTERISTIC PARAMETERSAC PRECISE (CLASS 1) (CON

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34varying the regulated voltage throughout the limitsand under the various load condit

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34% Regulation =(No-Load Voltage) -(Rated-Load Voltage) x 100(Rated- Load Voltage)e.Re

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34of this test, At each of the following load conditions(one step) operate the set for

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/08859D-34Figure 7-1. Overshoot and Undershoot Chart Recording7-10

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34it re-enters and remains within the prescribed volt-age band for the next load cond

TM 5-6115465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34TABLE OF CONTENTS (CONT)Page4-16.Special Relay Assembly to Control CubicleAssembly W

TM 5-6115-485-34T0 3SC2-9-446-2NAVFAC P-8-625-34TM 06858B/06859D-34no load and actuation of the protection devices (ifapplicable). Compare these resul

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34(a)Calculate the short-circuit current usingthe peak-to-peek amplitudes of the curr

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34b. Apparatus.Instrumentation for measuringvoltage and frequency shall be as describ

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34(j) Close the switch and close the circuitinterrupter.(e) Slowly open the bleeder v

TM 5-6115-46-534T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34correct, serious damage or injury could be done toconnected equipment and to person

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34(c) For Class II Sets:1.Alternately increase the load, volt-age and frequency in sm

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34CHAPTER 8REPAIR INSTRUCTIONS FOR MATERIAL USED IN CONJUNCTION WITH THE GENERATOR SE

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Table 8-1.FUEL-BURNING WINTERIZATION KIT TROUBLESHOOTING CHART (CONT)MALFUNCTIONPRO

8-3.HEATER CONTROL ASSEMBLY.a.Removal. Refer to the Operator and Or-ganizational Maintenance Manual for heater controlassembly removal instructions.b.

TM 5-6115-465-34TO-35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Section IV.Section V.APPENDIX A.Figure2-1.2-2.3-1.3-2.3-3.3-4.3-5.3-6.3-7.3-8.3-9.3

8-4Figure 8-1.Fuel Burning Heater Control Assembly

8-5Figure 8-2. Fuel Burning Heater Control Assembly Wiring Diagram, Drawing No. 72-2863

8-5Figure 8-3.Fuel Burning Heater Assembly, Exploded View (Sheet 1 of 2)

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-341. Cover39. Casing grommet2. Screw40. Clamp3. Receptacle assembly41. Hose4. Screw42

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 8-4.Coolant Pump Test Diagram8-8

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34adapter must be parallel within 0.001 inch. Adapterbore diameter must be 0.315 to 0

8-10Figure 8-5.Fuel Burning WinterizationKit Wiring Harness,Drawing No. 72-2856

8-11Figure 8-6. Fuel Burning Winterization Heater Control Assembly to Special Relay Assembly Wiring HarnessDrawing No. 72-2875

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34not exceed 6 amperes during this test. Observesmoothness of operation of both pump

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Table 8-2.ELECTRIC WINTERIZATION KIT TROUBLESHOOTING CHART (CONT)MALFUNCTIONPROBABL

TM 5-6115465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 068S8B/06859D-34TABLE OF CONTENTS (CONT)PageCHAPTER 8.REPAIR INSTRUCTIONS FOR MATERIAL USED INCONJUN

8-14Figure 8-7.Electric Winterization Kit Heater Control Assembly, Exploded View (Sheet 1 of 2)

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-341. Screw31. Flat washer2. Lockwasher32. Tooth lockwasher3. Nut33. Semiconductor4. T

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34(d) Apply 230 Vac RMS to winding 1-2with all secondaries open circuit. Voltage acro

8-17ME 5-6115-465-34/8-9(1)Figure 8-9. Electric Winterization Kit Heater Control Assembly, Wiring Harness (Sheet 1 of 2), Drawing No. 70-1233

8-18Figure 8-9. Electric Winterization Kit Heater Control Assembly Wiring Harness (Sheet 2 of 2), Dwg. 70-1233.

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-341. Plug2. Spring3. Ball4. Screw5. Port plate6. O-ring7. Cam ring8. Setscrew9. Vane1

8-20Notes:1.ALL SOLDERED CONNECTIONS SHALL BE IN ACCORDANCE WITHMIL-STD-454, REQUIREMENT 5.2. INSTALL STRAPS, FIND NO. 4, AT 3.0 MAXIMUM INTERVALSAND

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Section III.WHEEL MOUNTING KIT8-14. GENERAL.The wheel mounting kit provides added m

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34ME 5-6115-465-34/8-12NOTEFigure 8-12. Wheel Mounting Kit InstallationIf king pins a

8-23Figure 8-13.Wheel Mounting Kit, Exploded View (Sheet 1 of 2)

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34LIST OF ILLUSTRATIONSFigureTitlePage2-0.2-1.2-2.3-1.3-2.3-3.3-3.13-4.3-5.3-6.3-7.3-

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-S4TM 06858B/06859D-341. Nut2. Rod3. Bolt4. Lockwasher5. Nut6. Spacer7. Cotter pin8. Washer9. Pin10. Hand

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Section IV.LOAD BANK8-20.GENERAL.The load bank is used to apply up to 50 percent of

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-341.2.3.4.5.6.7.8.9.10.11.Screw & captive washer assyBackup plateNutScrew & c

8-27ME 5-6115-465-34/8-15Figure 8-15.Control Box Assembly Wiring Harness, Drawing No. 72-2868

8-28Figure 8-16.Control BOX Assembly Branched Wiring Harness (Sheet 1 of 2), Drawing No. 72-2828

8-29Figure 8-16. Control Box Assembly Branched Wiring Harness (Sheet 2 of 2) Drawing No. 72-2828

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-341.2.3.4.5.6.7.8.9.10.NutScrew & captive washer assyProtective capNutScrew &

8-31ME 5-6115-465-34/8-18 (1)Figure 8-18.Load Bank Wiring Harness (Sheet 1 of 2), Drawing No. 72-2823

8-32Figure 8-18.Load Bank Wiring Harness (Sheet 2 of 2), Drawing No. 72-2823

8-33Figure 8-19.Top Load Bank Wiring Harness (Sheet 1 of 2), Drawing No. 72-2822

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34LIST OF ILLUSTRATIONS (CONT)FigureTitlePage3-45.3-46.3-47.3-48.3-49.3-50.3-51.4-1.4

TM 5-6115-465-34TO 35C2-3-446-2 NAVFAC P-8-625-34TM 06858B/06859D-34Figure 8-19. Top Load Bank WiringHarness (Sheet 2 of 2)Drawing No. 72-28228-34

8-35Figure 8-20.Bottom Load Bank Wiring Harness (Sheet 1 of 2), Drawing No. 72-2825

8-36Figure 8-20. Bottom Load Bank Wiring Harness (Sheet 2 of 2), Drawing No. 72-2825

8-37Figure 8-21.Load Bank Power Wiring Harness, Drawing No. 72-2829

8-38Figure 8-22.Load Bank Signal Wiring Harness, Drawing No. 72-2830ME 5-6115-465-34/8-22

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Section V.ACOUSTIC SUPPRESSION KITWARNING8-24. GENERALThe acoustic suppression kit

TM 5-6115-465-34TO 35C2-3-466-2NAVFAC P-8-625-34TM 06858B/06859D-34(1) Refer to operator and organizationalmaintenance manual, para 3-134, and remove

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-446-2TM 06868B/06895-34(6) Position the mounting member until it isparallel to the top of the skid base. Moun

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06868B/06895D-34(22) Remove lifting sling from side panel.(23) Repeat steps (20) thru (22) to insta

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34(35) Lower side panel skirts into proper posi-tion. Tighten capscrews on keepers.(3

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34LIST OF ILLUSTRATIONS (CONT)Figure4-30.4-30.14-30.24-30.34-30.44-31.4-32.4-33.4-33.

TM 5-6115-465-34TO-35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 8-23.Roof Stiffeners, Sealing Angle, Oil Drain,Isolators, Bottom Panel Tray

TM 5-6115-465-34TO-35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-348-46MARK WHERE THIS CORNERTOUCHES SKIDAFTER MAKING FOUR MARKSDRAW TWO LINES AS SHOW

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 8-25. Mounting Hardware and Hole Location for Side Panel AssemblyChange 98-4

TO-35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-341.2.3.4.5.6.7.8.Discharge Turn AssemblyInlet Turn AssemblyRoof Panel AssemblyRear Panel AssemblySid

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34APPENDIX AREFERENCESThis Appendix contains a list of reference man-uals that may be

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34A-5.MAINTENANCE (CONT)TM 5-6115-588-14 (A)Operator, Organizational, Intermediate (F

TM5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34AcousticAcousticAcousticALPHABETICAL INDEXSubjectAsuppression kit, general. . . .

NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34ILINDEX 2SubjectALPHABETICAL INDEX (CONT)Paragraph,F (CONT)Frequency adjust range test. . . . . .

TM5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34ALPHABET1CAL INDEX (CONT)Paragraph,SubjectO (CONT)Figure, Table,Overtemperature pr

TM 5-6115-465-34NAVFAC P-6-625-34TO 35C2-3-446-2TM 06858B/06859D-34By Order of the Secretaries of the Army, Air Force, and Navy (Including the Marine

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34LIST OF ILLUSTRATIONS (CONT)FigureTitlePage5-20.5-21.5-22.5-23.5-24.5-25.5-26.5-27.

TM5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34ALPHABETICAL INDEX (CONT)SubjectParagraph,Figure, Table,NumberVVoltage reconnectio

TM 5-6115-465-34NAVFAC P-8-625-34TO-35C2-3-446-2TM-06858B 06859D-34By Order of the Secretaries of the Army, the Navy, and the Air Force:Official:VERNE

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TO 06858B/06859D-34LIST OF ILLUSTRATIONS (CONT)Figure8-5.8-6.8-7.8-8.8-9.8-10.8-11.8-12.8-13.8-14.8-15

PIN: 013547-000

TM 5-6115-465-34TO-35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34LIST OF TABLES (CONT)Table4-1.4-2.4-3.5-1.7-1.7-2.7-3.8-1.8-2.TitleComponent board

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34CHAPTER 1INTRODUCTIONSECTION I. GENERAL1-1. Scopea. This manual contains instructio

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Section II. DESCRIPTION AND DATA1-5. DescriptionThe generator set is a fully enclos

TM 5-6115-465-34c.Starter Assembly Classification and Rating.Stalled current . . . . . .500 amps (max)Stalled torque . . . . . . 18 lbs. - ft. (min)Du

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Contact rating . . . . . . 10 amp, 28V, resistiveContact arrangement . . . .2 pole,

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34o. 50/60 Hz Generator Classification and Rating(Cont):Winding resistances (total):W

TM 5-6115-465-34T035C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34r. 50/60 Hz Generator Repair and ReplacementStandards (Cont):Dipping compound . . .

v. Nut and Bolt Torque Data.TM 5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34Engine:Cylinder head nuts:. . . . . . . . . . . . . .

CHANGENO. 11TM5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34C11HEADQUARTERSDEPARTMENTS OF THE ARMY, NAVY AND AIR FORCEAND HEADQUART

TM 5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34Table 1-1. FITS AND TOLERANCESComponent Mfg’s TolerancesDesired ClearanceMaximumM

TM 5-6115-465-34NAVFACP-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34Table 1-1. FITS AND TOLERANCES (CONT)Component Mfg’s TolerancesDesired ClearanceMa

TM 5-6115-465-34NAVFACP-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34Table 1-1. FITS AND TOLERANCES (CONT)ComponentMfg’s TolerancesDesiredMinimumIMaxim

TM 5-6115-465-34T035C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34Table 1-1.FITS AND TOLERANCES (CONT)Mfg’s. TolerancesDesired ClearanceMaximumMaximumC

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34GENERALSection I. REPAIR2-1. TOOLS AND SUPPORT EQUIPMENT.There are no special tools

TM 5-6115-465-34TO-35C-2-3-446-2NAVFAC P-8-624-34TM 06858B/06859D-34Table 2-1.TOOLS AND SUPPORT EQUIPMENT (CONT)ReferenceItem FSN or Part No.UseFigure

TM 5-6115-465-34TO-35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Table 2-1.TOOLS AND SUPPORT EQUIPMENT (CONT)ReferenceItemFSN or Part No.UseFigure P

TM 5-6115-465-34TG35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 2-O. Breakout Cable (Sheet 1 of 2) 2-2.2 Change 8

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TO 06858B/06859D-34Change 82-2.3 /(2-2.4 blank) Figure 2-O.Breakout Cable (Sheet 2 of 2)

TM5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34CllBy Order of the Secretaries of the Army, Air Force, and Navy (Including the Marin

TM 5-6115465-34TO 35C2-3446-2NAVFAC P-8-625-34TM 06858B/06859D-342-4.GENERAL .This sectionSectionprovides information useful indiagnosing and correcti

TM 5-6115465-34TO 35C2-3446-2NAVFAC P-8-625-34TM 06858B/06859D-34MALFUNCTION4.Engine misses orruns erratically(Cont)5.Engine stopssuddenly6. Engine la

TM 5-6116-465-34NAVFAC P-8-625-34TO 35C2-3446-2TM 06858B/06859D-34Table 2-2.TROUBLESHOOTING (CONT)MALFUNCTIONPROBABLE CAUSECORRECTIVE ACTION,8. Engine

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34Table 2-2.TROUBLESHOOTING (CONT)MALFUNCTION11. Engine oil con-sumption excess-ive (

TM 5-6115465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34Table 2-2.TROUBLESHOOTING (CONT)1MALFUNCTIONPROBABLE CAUSECORRECTIVE ACTION17. Main

TM 5-6115465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D34MALFUNCTION18. Generator ter-minal voltagedrops when 1oadis applied19. Poor voltage,r

TM 5-6115465-34TO 35C2-3446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 2-1.Engine Assembly, Removal And Installation2-8

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B 06859D-34Section III.REMOVAL AND INSTALLATION OF MAJOR COMPONENTS2-5.GENERAL.a.The engine an

CHANGENO. 10TM 54115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34C 10HEADQUARTERS,DEPARTMENTS OF THE ARMY, NAVY AND AIR FORCEAND HEADQUAR

2-10Figure 2-2.Generator Assembly, Removal and Installation

TM5-6115-465-34CAUTIONMake a final, thorough check to ascertainthat the engine is completely disconnectedfrom the generator set prior to attempt-ing t

TM 5-6115-465-34T035C2-3-446-2NAVFACP-8-625-34TM06858B/06859D-34CHAPTER 3ENGINE REPAIR INSTRUCTIONSSection I.ENGINE ELECTRICAL SYSTEM3-1. GENERALThe e

Figure 3-1.TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-343-2

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-341, Nut42. Commutator end frame2. Lockwasher43. Packing9. Terminal lead44. Spacer was

TM 5-6115-465-34T0 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34(2) Clean field coils with a clean, lint-freecloth lightly moistened with an approv

TM5-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 06858B/06859D-34(c) Adjust rheostat until voltmeter indicates 22.5 volts.(1) Assemble starter ass

TM-6115-465-34NAVFAC P-8-625-34T.O. 35C2-3-446-2TM 0685B/06859D-34Figure 3-2. Starter Assembly Motoring Test CircuitFigure 3-3. Starter Assembly Stall

3-6.1Figure 3-31.1. Starter Assembly, Exploded View (Effective with Serial No. RZ70001 and KZ00001 thru KZ02752) (Sheet 1 of 2).

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34C 10By Order of the Secretaries of the Army , Air Force, and Navy (Including the Ma

TM5-6115-465-34NAVFAC P-8-625-34T. O. 35C2-3446-2TM 06858B/06859D-341.2.3.4.5.6.7.8.9.10.11.12.13.14.15.16.17.18.19.20.21.22.23.24.25.26.27.28.29.30.3

TM5-6115-465-34NAVFAC P-8-625-34T.O.35C2-3-446-2TM 06858B/06859D-34(1) Remove inspection plug(25) and gasket (26). Re-move adjusting nut (27) to remov

TM5-6115-465-34NAVFAC P-8-625-34T.O.35C2-3-446-2TM 06858B/06859D-34(d) Replace armature if a short is indicated.f. Assembly.(1) Assemble starter and s

(f) If current and speed are low, disassemblestarter. and check for high resistance at internal connec-tion.(g) If current is high and rpm low, disass

TM 5-6115-465-34TO35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34BATTERY CHARGING ALTERATORfront part of insulating bushings (36, 37, 38 and 39)and St

Figure 3-4. Alternator AssemblyTM 5-6115-465-34TO35C2-3-446-2NAVPAC P-8-625-34TM06858B/06859D-343-8

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-341. Screw28. Capacitor and clamp assembly2. Regulator and cover assembly29. Nut3. Fu

TM 5-6115-465-34NAVFAC P-8-625-34TO 35C2-3-446-2TM 06858B/06859D-34Figure 3–5. Rotor Assembly Current Draw Test Circuit.(c) Ammeter should indicate 2.

(18) Inspect fan forblades and other damage.cracks, corrosion, bent(19) Inspect bearings for pitting, excessivewear, and other damage.(20) Inspect hea

CHANGENO. 9GENERATORDOD MODELMEP-005AMEP-104AMEP-l14ADOD MODELMEP-005AWFMEP-005AWEMEP-005ALMMEP-005AWMMEP-005AASTM 5-6115-465-34NAVFAC P-8-625-34TO 35

TM5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34Figure 3-6.Alternator Test Leads Installation(c) Attach a 1/4 inch ring terminal to o

TM 5-6115-465-34TO35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34Figure 3-7.Total Circuit Voltage Test(4) Test alternator positive output circuit asfo

TM 5-6115-465-34TO35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34Figure 3-8.Alternator Positive Output Circuit TestFigure 3-9.Alternator Negative Outp

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858/06859D- 34Figure 3-10. Excitation Voltage Testbattery negative terminal and alternator negati

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM 06858B/06859D-34Figure 3-11 Faulty Voltage Regulator Circuit TestFigure 3-12.Field Current Test3-16

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8-625-34TM06858B/06859D-34(f) With the alternator rotating at 2500RPM the voltmeter should indicate 24 to 28 v

TM 5-6115-465-34TO 35C2-3-446-2NAVFAC P-8625-34TM06858B/0685D-34(e) Close switch (S2) to put carbon pileload on the batteries.(f) Check ammeter and vo

TM-6115-465-34NAVFAC P-8-625-34T.O.35C2-3446-2TM 06858B/06859D-34(2) Clean all other parts with cleaning solventand dry thoroughly.(3) Inspect base, r

TM5-6115-465-34NAVFAC P-8-625-34T.O.35C2-3-446-2TM 06858B/06859D-341.2.3.4.5.6.7.8.ScrewLockWireFlat WasherBody AssemblyPackingSpacerRotor AssemblyCap

(1) Screw the tachometer fitting onto the test stand.(2) Attach the connector and cable to J37 of the speedswitch.(3) Connect 24 volts dc to pins E. G