MTD 464 Operations Instructions

ARMY*TM 9-6115-464-34AIR FORCETO-35C2-3-445-2NAVYNAVFAC P-8-624-34TECHNICAL MANUALDIRECT AND GENERAL SUPPORT AND DEPOT LEVELMAINTENANCE MANUALGENERATO

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34LIST OF ILLUSTRATIONSFigure2-1.2-2.2-3.3-2.3-3.3-4.3-5.3-6.3-8.3-9.3-10.3-11.3-12.3-1

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-19. Main Fuel Tank (Plastic), Removal and Installation3-20. DAY TANK ASSE

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34WARNINGCompressed air used for cleaning and drying purposes can create airborne pa

ARMY TM 9-6115-464-34AIR FORCE TO 36C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-20. Fuel Injection Pump Assembly, Removal and Installation3-48

ARMY TM 9-6115464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-6-624-34(1) Refer to the Operator and Unit Maintenance Manual and drain the day tank assemb

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-6-624-34Figure 3-21. Fuel Injection Pump, Exploded View (Sheet 1 of 7)3-50

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-6-624-34Figure 3-21. Fuel Injection Pump, Exploded View (Sheet 2 of 7)Figure 3–21. Fuel In

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-6-624-34Figure 3–21. Fuel Injection Pump, Exploded View (Sheet 4 of 7)Figure 3-21. Fuel In

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-6-624-34Figure 3–21. Fuel Injection Pump, Exploded View (Sheet 6 of 7)Figure 3-21. Fuel In

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(10)(11)(12)(13)(14)(15)(16)(17)(18)(19)(20)(21)(22)(23)(24)(25)To disassemble tra

(26)(27)(28)ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Lift off the cam ring (121 ). Check and record the roller-to-roller di

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34LIST OF ILLUSTRATIONS (Cont.)Figure3-43.3-44.3-45.3-47.3-48.3-49.3-50.3-51.3-52.3-

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-446-2NAVY NAVFAC P-8-624-34(10)(11)(12)(13)(14)(15)Examine the junction points of the metering valve pin hole

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34NOTEThe thrust plate may be reversed if one side appears worn or scratched. A smal

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-22. Adjusting Fuel Injection Pump Roller-to-Roller Dimension(15) Carefull

ARMY TM 9-6115 464 34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34NOTEMake sure that the assembly is wrung into position past the hydraulic head se

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-4452NAVY NAVFAC P-8-624-34(38)(39)(40)(41)(42)(43)(44)(45)(46)(47)(48)(49)(50)(51)Slide speed droop guide (75

-ARMY TM 9-6115-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-23. Throttle Linkage Adjustmentf. Fuel Inject Pump Bench Test.(1) General. T

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2 NAVY NAVFAC P-8-624-34NOTEPump runs at half the engine speed.(c) Start the test stand at lowest speed a

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3–24. Solenoid Armature Adjustments3-63

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 3-1. FUEL DELlVERYPUMP RPMDELlVERYPRESSUREMAX VAR BETWEEN(mm3/stroke)PSIGCYL

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(o) At a pump speed of 200 rpm, repeat steps (n) and (o). Delivery shall be 2 mm3

LIST OF ILLUSTRATIONS (Cont.)TitlePageFigure3-92.3-93.3-94.3-95.3-96.3-97.3-98.3-99.3-100.3-101.3-102.3-103.3-104.3-105.3-106.3-107.3-108.3-109.3-110.

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-343-23. FUEL INJECTION NOZZLE HOLDERS AND LINES.a. Removal. Refer to the Operator an

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-25. Fuel Injection Nozzle Holder, Exploded View(7) Observe fuel spray. Fu

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Section Ill. MAINTENANCE OF ENGINE COOLING SYSTEM3-26. GENERAL.The engine cooling

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-26. Shutter Control Assembly, Exploded View3-69

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(7) Inspect bushings for scores and excessive wear.(8) Refer to the Operator and U

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(7) Replace radiator if damaged beyond repair.3-30. SHUTTER ASSEMBLY.a. Removal. R

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34c. Cleaning, Inspection, and Repair.(1)(2)(3)(4)(5)(6)(7)(8)WARNINGSolvent, Dry Cl

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-28. Water Pump Assembly, Exploded View(1)(2)(3)(4)(5)(6)(7)(8)WARNINGSolv

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34d. Asssembly.CAUTIONWhen installing seal, press on outer flange to avoid damaging

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-343-33. COOLANT THERMOSTAT AND HOUSING.Refer to the Operator and Unit Maintenance Ma

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34LIST OF ILLUSTRATIONS (Cont.)Figure3-134.3-135.3-136.3-137.3-138.3-139.3-140.3-141

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(3)(4)(5)(6)(7)(8)(9)Scrape gasket remains from oil pan and cylinder block mating

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-343-38. OIL PUMP ASSEMBLY.a. Removal.(1) Lower oil pan assembly (paragraph 3-37).(2)

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3–31. Oil Pump Assembly, Exploded View3-78

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34d. Assembly.(1) Press drive gear (19, figure 3-31) onto shaft (20).(2) Insert shaf

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-44Figure 3-32. Oil Pump Assembly Dimensions3-80

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Section V. MAINTENANCE OF HYDRAULIC SYSTEM(ELECTRO-HYDRAULIC GOVERNOR EQUIPPED PRE

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-341. Hydraulic line2. Nut3. Lockwasher4. Screw5. Hydraulic sump6. Cap and di

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(6) Test hydraulic sump for leaks as follows:(a) Securely install cap and dipstick

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34c. Cleaning, Inspection, and Repair.(1)(2)(3)(4)(5)(6)(7)(8)(9)(10)WARNINGSolvent,

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(8) Tighten locknut and remove hydraulic pump assembly from test hookup.f. Install

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure5-29.5-30.5-31.5-32.5-33.5-34.5-35.5-36.5-37.TableLIST OF ILLUSTRATIONS (Cont.)

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-34. Hydraulic Pump Assembly, Exploded View(Electro-Hydraulic Governor Equ

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-343-42. HYDRAULIC SYSTEM FILTER ASSEMBLY.a. Removal.(1) Disconnect hydraulic lines (

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-62434Figure 3-35. Hydraulic System Filter Assembly, Exploded View(Electro-Hydraulic Gove

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-343-43 HYDRAULIC ACTUATOR UNIT.a. Removal.(1) Refer to the Operator and Unit Mainten

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-36. Hydraulic Actuator Unit, Removal and Installation(Electro-Hydraulic G

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-37. Hydraulic Actuator Unit, Exploded View (Sheet 1 of 2)(Electro-Hydraul

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-342.3.4.5.6.7.8.9.10.11.12.13.14.15.16.17.18.19.20.21.22.23.24.25.26.27.28.29.30.31.

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(18) Remove screws (57), lockwashers (58), and nuts (59) to remove mounting plates

ARMY TM 9-6115-464-34AIR FORCE TO 36C2-3-445-2NAVY NAVFAC P-8-624-34d. Assembly.(1) Install coils (69, figure 3-37), Iockwashers (68), and screws (67)

(4)(5)(6)(7)(8)(9)ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Place test stand switch (S2) in the off position to turn off hyd

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34HOW TO USE THIS MANUALThis manual provides information for use in operating and ma

ARMY TM 9-6115-464-34AIR FORCE TO 33C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-39. Hydraulic Actuator Unit Test(Electro-Hydraulic Governor Equipped Prec

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(c)(d)(e)(f)Move the piston gradually towards the fully closed throttle position.

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-40. Hydraulic Actuator Tests, Schematic Diagram(Electro-Hydraulic Governo

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 3-2. HYDRAULIC ACTUATOR TEST VALUES3-99

ARMY TM 9-6115-484-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Section VI MAINTENANCE OF INTAKE AND EXHAUST SYSTEMS AND BREATHER344. GENERAL.a. T

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34h. The connecting rods are heavy alloy steel forgings with precision type bearings

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-41. Engine Front Support, Removal and Installation3-50. FLYWHEEL AND FLYW

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-42. Flywheel and Flywheel Housing, Exploded Viewb. Cleaning, Inspection.

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34WARNINGWear heat resistant gloves when handling heated flywheel to avoid serious b

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-43. Checking Flywheel Concentricity and Alignment3-51. TIMING GEARS AND C

ARMY TM 9-6115-464-34AIR FORCE 35C2-2445-2NAVY NAVFAC P-8-624-34h. Wiring diagrams and schematics located in the manual, are valuable aids in troubles

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(10) If inspection indicates that idler bearings must be replaced, disassemble idl

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34NOTE:Spacers (35) located topand bottom holes of cover (17).Figure 3-44. Timing Ge

ARMY TM 9-6115-464-34AIR FORCE TO 36C2-3-446-2NAVY NAVFAC P-8-624-34(8) Install gasket (18) and cover (17) and secure with Iockwashers (8, 10,12,14, a

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-341. Crankshaft gear2. Idler assembIy3. Camshaft gear4. Fuel pump drive gear5. Timin

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-343-52. INTAKE MANIFOLD.Refer to the Operator and Unit Maintenance Manual for intake

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-46. Cylinder Head and Rocker Assembly, Exploded View3-111

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34c. Cleaning, Inspection, and Repair.WARNINGSolvent, Dry Cleaning P-D-680, Type II is

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(13) Perform magnetic particle inspection in accordance with established procedure

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34(n) Make ten or twelve pencil marks, equally spaced, across valve seat.(o) Install va

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-47. Rocker Arm Mounting Blocks InstallationFigure 3-48. Rocker Arm Shaft

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34CHAPTER 1INTRODUCTIONSection I. GENERAL INFORMATION1-1. SCOPE.a. This manual conta

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-49. Cylinder Head Nut Tightening Sequence3-55. CAMSHAFTa. Removal.(1) Remove

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34b. Disassembly.(1) Remove nut (3, figure 3–50) and support drive gear (4) on arbor

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-824-34Figure 3-50. Camshaft, Exploded View3-118

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-51 .Dimensional Inspection of Camshaft(11) If dimension obtained in step

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34(3) Install camshaft (5, figure 3-50) with Iockwashers (2) and screws (1).(4) Refer t

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34CAUTIONConspicuously mark each main bearing cap as to position to aid at assembly.

ARMY TM 9-6115-484-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-52. Crankshaft, Connecting Rods and Pistons, Exploded View3-122

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34c. Cleaning, Inspection, and Repair.(1)(2)(3)(4)(5)(6)WARNINGSolvent, Dry Cleaning

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34(7) If necessary, regrind crankshaft bearing journals to accept undersized bearings i

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34d. AssembIy.(1) Using a piston ring expander install oil control ring (23, figure

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-341-5. DESTRUCTION OF MATERIAL TO PREVENT ENEMY USE.Destruction of the generator set

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34(11) Apply a liberal coating of engine Iubricating oil to cylinder bores, pistons, pi

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(13) Do not remove plug (15) from cylinder block (16) unless replacement is necess

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34(6)(7)(8)(9)(lo)(11)(12)(13)(14)If removed, install stud (4) and oil filler neck and

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-53. Cylinder Block Assembly, Exploded View3-129

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Section Vlll. MAINTENANCE OF GENERATOR SET CONTROLS3-58. GENERAL.This section contain

ARMY TM 9-115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-54. Frequency Meter and Transducer Test Setup Figure 3-55. Thermal Watt Co

ARMY TM 9-6115-46-34AIR FORCE 35C2—3-445-2NAVY NAVFAC P-8-624-34(c) Vary the load while comparing the generator set kilowatt meter reading to that of

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(d) Remove nut (5), Iockwasher (6), flatwasher (7), screw (8), relay (9) k6, and s

ARMY TM 9-6115-464-34AIR FORCE 35C2-344-2NAVY NAVFAC P-8-624-34Figure 3-56. Control Cubicle Housing Assembly, Exploded View3-134

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3–57. Control Cubicle Relay Assembly, Exploded View3-135

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-341-10. TABULATED DATA.a. General. This paragraph contains all maintenance data pert

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-6-624-34(5) Testing.(a)(b)Using an ohmmeter or similar device, check relay assembly continuit

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-24-34e. Control Cubicle Terrminal Board.(1) Removal.(a) Tag and disconnect electrical le

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34(a) Clean all parts in dry cleaning solvent (Federal Specification P-D-680) and dry w

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34c. Cleaning, Inspection, and Repair.WARNINGSolvent, Dry Cleaning P-D-680, Type II

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 3-4. COMPONENT BOARD TEST VALUES(8)(9)(l0)(11)(12)Use an ohmmeter to test resis

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34WIREFROMTOMARKINGNOSTATIONLUG FINDSTATIONLUG FINDWIRE FINDCUTMARKINGNO NO NONO NO.

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34WIREFROM TOMARKINGNOSTATIONLUG FINDSTATIONLUG FIND WIRE FINDCUTMARKINGNONO NO NO NO.L

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34WIREMARKINGNOP55DD18P55EE18P55FF18P55GG18P55HH18P55KK16P55MM16P55XX18P56A16P56B16P

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-446-2NAVY NAVFAC P-8--624-34WIRE FROM TOMARKINGNOSTATIONLUG FINDSTATIONLUG FINDWIRE FINDCUTMARKINGNO NO NO NO NO

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-59. Control Cubicle Wiring Harness (Sheet 5 of 6) Drawing No. 69-6773-145

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Piston and piston pin:Piston material . . . . . . . . . . . . . . . . . . . . . .

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3–59. Control Cubicle Wiring Harness (Sheet 6 of 6) Drawing No. 69-6773-146

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-60. Fault Locating Indicator, Exploded View (Sheet 1 of 2)3-147

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-341. Screw and assembled washer2. Lockwasher3. Screw and captive washer assy4. Cover pl

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-61. Fault Locating Indicator, Schematic Diagram3-149

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-62. Fault Locating Indicator Component Board Assembly3-150

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-63. Fault Locating Indicator Wiring Harness Drawing No. 72–22473-151

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-343-63. LOAD MEASURING UNIT.a. Removal. Refer to the Operator and Unit Maintenance Manu

ARMY TM 9-6115-464-34AIR FORCE TO 35C22NAVY NAVFAC P-8-624-34Figure 3-64. Load Measuring Unit, Exploded View3-153

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-65. Load Measuring Unit Wiring Harness, Drawing No. 69-511.3-154

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34d. Testing and Repair.NOTEDisconnect leads to components prior to testing to avoid

e. Static Exciter and Voltage Regulator Assembly Classification and Rating.Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34LEGENDCR1 — DiodeCR2 — DiodeCR3 — DiodeCR4 — DiodeCR5 — DiodeCR6 — DiodeT1 — Transfor

(10)(11)(12)ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34If adjustment does not give the proper relationship or if relationship

(1)(2)(3)(4)(5)(6)If the FL-NL or NL - FL transient exceeds 1-1/2 percent of rated speed and/or does notreestablish stable engine operating conditions

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34LEGEND:G1 POWER SOURCE, 208 VAC, 3 PHASE, 47-430 HZM1 VOLTMETER, 0-250 VACM2 VOLTM

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34d. Disassembly.(1) Disassemble governor control unit (7 through 58) only as is necess

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-68. Electro-Hydraulic Governor Control Unit. Exploded View (Sheet 1 of 2)

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-341. Screw2. Lockwasher3. Nut4. Lockwasher5. Bracket6. Threaded rod7. Screw8. Lockwashe

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(9)(10)(11)Repair wiring harness as follows: If the wiring harness has sustained d

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34(e) Turn R12 to full counterclockwise position. Reading of M2 and M3 shall be 600-100

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 3-5. 50/60 Hz Governor Control Unit Resistance Test ValuesP1POTENTIOMETERNOM

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-341-6

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-69. 50/60 Hz Governor Control Unit Wiring Harness, Drawing No. 69-731 (Sheet

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34NOTES:INSTALL CABLE STRAPS, FIND NO. 7, AT 1.5 INTER-VALS AND AT EACH CABLE BREAKO

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-70. 400 Hz Electro-Hydraulic Governor Control Unit Wiring Harness, Drawing N

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-70. 400 Hz Electro-Hydraulic Governor Control Unit Wiring Harness, Drawin

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-341. Power transformer (T1)2. Filter reactor (L2)3. Filter reactor (L1)4. Fixed capacit

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34ELEC REFDESIGAR1C2C3,C4C5C6C8C9CR2CR3-CR18J3L1L2L3P1P2Q1,Q2A1A2DESCRIPTIONMAGAMPCA

Figure 3-73. 400 Hz EIectro-Hydraulic Governor Control Unit Wiring Diagram, DWG No. 69-6333-172ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-341.2.3.4.5.6.NOTES:EXACT VALUES DETERMINED DURING TEST, SEETEST PROCEDURES DWG 69-7

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-74, 50/60 Hz Governor Control Unit Schematic Diagram, Drawing No. 69-729 (Sh

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34NOTES:1. EXACT VALUES DETERMINED DURING TEST,SEE TEST PROCEDURES DWG 69-815.NOMINA

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34j. Underfrequency Relay Classification and Rating.DOD drawing number:50/60 Hz. . .

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-75. 400 Hz Electro-Hydraulic Governor Control Unit Schematic Diagram, Drawin

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3–76. Positioning of Unpotted Electro-Hydraulic Governor Control Unit Durin

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34(3)(4)(5)(6)(7)Figure 3-78. Electro-Hydraulic Governor Control Unit Frequency Sensing

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-79. Electro-Hydraulic Governor Control Unit Rectifier Bridge and Feedback

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-80. Electro-Hydraulic Governor Control Unit Parallel Winding Test Circuit(2)

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(7) Connect dc voltmeter across test points 1 and 2. Test point 1 is positive. A

Figure 3-81. Approximate Position of Controls for Connecting Hydraulic Actuator3-182ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-82. Approximate Position of Controls for Connecting Hydraulic Actuator(Ef

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-83. Electro-Hydraulic Governor Control Unit Control Panel3-184

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34NOTES:1. ALL SOLDERED CONNECTIONS SHALL BE IN AC-CORDANCE WITH MIL-STD454, REQUIRE

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-341-8

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-343-65. ELECTRIC GOVERNOR CONTROL UNIT (MEP-113A).a. General.(1) The electric governing

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(2) Install nuts (4), Iockwashers (3), 4 hex head screws (2).(3) Connect electr

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-85. Functional Theory of Operation3-188

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-86. Governor Control Unit Removal and Installation3-189

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 3-7. Electric Governor Malfunction TestingPROBABLE CAUSE OFTERMINALNORMALNON-NO

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(15) If the engine is unstable as indicated by continuous movement of the actuat

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34NOTEIf the actuator bracket has not been removed, proceed with paragraph (3). If theb

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-87. Actuator Removal and Installation3-193

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-88. Magnetic Pickup Removal and Installation3-194

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-343-69. TACTICAL RELAY ASSEMBLY TO SPECIAL RELAY ASSEMBLY WIRING HARNESS.a. Refer to

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-341-9

ARMY TM 9-6115-464-34AIR FORCE 35C2-445-2NAVY NAVFAC P-8-624-343-75. SPECIAL RELAY ASSEMBLY TO FAULT LOCATING INDICATOR WIRING HARNESS.a. Refer to the

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-341.2.3.4.5.6.NOTES:ALL SOLDERED CONNECTIONS SHALL BE IN AC-CORDANCE WITH MIL-STD-45

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34NOTES:1. ALL SOLDERED CONNECTIONS SHALL BE IN AC-CORDANCE WITH MIL-STD-454, REQUIREME

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-91. Governor Control Unit to Hydraulic Actuator Unit Wiring Harness, Draw

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-92.400 Hz Electric Governor System(Sheet)Wiring 1 of 2)Harness AssemblyDraw

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-824-34NOTES:1. ALL CONDUCTORS SHALL BE STRIPPED .50+ .12 ANDTINNED BEFORE ASSEMBLY USING

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34NOTES:1. ALL SOLDERED CONNECTIONS SHALL BEIN ACCORDANCE WITH MIL-STD-454,REQUIREMENT

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-93. AC Power Control Wiring Harness, Drawing No. 72-2259 (Sheet 2 of 2)3-

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-94. Exciter Control Wiring Harness, Drawing No. 73-2288NOTES:1. SOLDERING SH

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34NOTES:1. ALL SOLDERED CONNECTIONS SHALL BE IN ACCORDANCE WITH MIL-STD-454,REQUIREM

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34t. 50/60 Hz Generator Repair and Replacement Standards.Rotor:Number of coils . .

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-96. Special Relay Assembly to Control Cubicle Wiring Harness, Drawing No. 72

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-97. Precise Relay Assebly to Governor Control Unit Wiring Harness, Drawin

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-824-34Figure 3-98. Special Relay Assembly to Precise Relay Assembly, Drawing No. 72-22383-2

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Section X. MAINTENANCE OF CONVENIENCE AND PARALLELING RECEPTACLESAND WIRING HARNES

ARMY TM 9-6115-464-34AIR FORCE 35C2-445-2NAVY NAVFAC P-8-624-34Figure 3-99. Convenience and Paralleling Receptacles Wiring Harness, Drawing No. 72-228

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34e. There is a bypass capacitor connected from each of the output terminals to grou

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34(5)(6)(7)(8)(9)(lo)(11)(12)(13)(14)(16)(17)(18)(19)(20)(21)Remove nut (21) Iockwasher

ARMY TM 9-6115-464—34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(9) Remove connector (19) and gasket (20).(10) Remove locking spacer (21), Iockwa

ARMY TM 9-6115-464—34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34e. Cleaning Inspection and Repair (Type A and B.)(1) Clean all components with cloth

ARMY TM 9-6115-454-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-100. Main Load Contactor (Type A), Exploded View (Sheet 1 of 3)3-215

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-341-11

ARMY TM 9-6115-464-34AIR FORCE 35C2—34-445-2NAVY NAVFAC P-8-624-34Figure 3-100. Main Load Contactor (Type A), Exploded View (Sheet 2 of 3)3-216

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-100. Main Load Contactor (Type A), Exploded View (Sheet 3 of 3)3-217

Figure 3-101. Main Load Contactor Type B (Sheet 1 of 3)3-218ARMY TM 9-6115-464-34 AIR FORCE 35C2-3-445-2 NAVY NAVFAC P-8-624-34

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-101. Main Load Contactor (Sheet 2 of 3)3-219

Figure 3-101. Main Load Contactor (Sheet 3 of 3)3-220ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-102. Actuator Assembly Adjustment Points (Type A)3-221

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-103. Main Contact Preload Check Points(16) Check preload of each contact as

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(a) Move loosely installed bracket (3) to transfer switch.(b) Check that the sw

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-104. Main Load Contactor Adjustments (Type A)3-224

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-105. Main Load Contactor Schematic Diagram, Contactor to Load TerminalsWi

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-341-12

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3–105. Main Load Contactor Schematic Diagram, Contactor to Load Terminals Wiri

ARMY TM 9-6115-46444AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-6-624-34NOTES:1.3.4.5.6.INTERPRET DRAWING PER MlL-STD–100.ALL SOLDERED CONNECTIONS SHALL BE

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34(2) Economizing Switch.(a) Apply 24 Vdc to connector pins A and B (See figure 3-105)

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(b) If preload is not as specified, replace spring (48) with a known good spring.h

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-106. Load Terminal Board Assembly, Exploded View3-230

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-343-85. LOAD TERMINAL BOARD ASSEMBLY.a. Removal.WARNINGLethal voltages are present a

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-107. Routing of Generator Leads Through Current Transformers3-232

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3–108. Transformer assemblies, Removal and Installationb. Cleaning. Inspect

ARMY TM 9-6115-454-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34(1)(2)(3)(4)(5)(6)(7)If removed, install mounting brackets (17, figure 3–108) flat wa

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3–110. Electromagnetic Interference Capacitors3-87. ELECTROMAGNETIC INTERFE

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-341-13

ARMY TM 9-6116-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-6-624-34c. Installation.(1) Install four capacitors (7, figure 3-110), four washers (6), nut

ARMY TM 9-6115-484-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(7) Remove nut & captive washer assembly (18), flatwashers (19), ground scre

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-111. Tactical Relay Assembly, Exploded View3-238

2)(3)(4)(5)(6)(7)(8)(9)(a)(b)(c)(d)(e)(f)(9)(h)(i)(j)ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Inspect cover and chassis for

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-341.2.3.4.NOTES:ALL SOLDERED CONNECTIONS SHALL BEIN ACCORDANCE WITH MIL-STD-454.REQUIRE

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-112. Tactical Relay Assembly Wiring Harness, Drawing No. 72–2243 (Sheet 2

Figure 3-113. Reverse Power Relay Test Circuit3-242ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34

ARMY TM 9-6115-464-34 AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-114. Overvoltage Relay Test Circuit(h) Set output frequency of power so

(g)(h)(i)(j)(k)Figure 3-115. Short Circuit Relay Test CircuitPlace switch S2 in B position and dose switch S1.Repeat steps (d) through (f).Place switc

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-445-2NAVY NAVFAC P-8-624-34Figure 3-116. Overload Protective Device Test Circuit3-245

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34WARNINGAll specific cautions and warnings contained in this manual shall be strict

ARMY TM 9-6115 464 34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 1-1. FITS AND TOLERANCESMfg’s Tolerances Desired Clearance Maximum Maximum

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34(b)(c)(15)(16)Figure 3–117. Tactical Relay Resistor Assembly Schematic DiagramTouch o

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-343-90. SPECIAL RELAY ASSEMBLY.WARNINGDo not attempt to perform maintenance on the s

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34WARNING(1)(2)(3)(4)(5)(6)(7)(8)(9)(10)(11)(12)(13)(a)(b)(c)(d)(14)(15)Solvent, Dry Cl

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-4Figure 3-118. Tactical Relay Resistor Assembly, Exploded View(16) Test dc relay ass

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-119. Special Relay Assembly, Exploded View (Sheet 1 of 2)3-250

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-341.Screw2. Lockwasher3. Screw & captive washer assy4. Cover5. Locking nut

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34(13) Install screw & captive washer assembly (10), and nut (9).(14) Install poten

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-120. Special Relay Assembly Wiring Harness, Drawing No. 72-2239 (Sheet 1

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-120. Special Relay Assembly Wiring Harness, Drawing No. 72-2239 (Sheet 2 of

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-120. Special Relay Assembly Wiring Harness, Drawing No. 72-2239 (Sheet 3

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 1-1. FITS AND TOLERANCES (CONTINUED)Mfg’s. Tolerances Desired Clearance Maxi

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P8-624-34Figure 3-120. Special Relay Assembly Wiring Harness, Drawing No. 72-2239 (Sheet 4 of 4

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(1)(2)(3)(4)(5)WARNINGCompressed air used for cleaning and drying purposes can cre

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34(6) Inspect resistors and capacitors of electronic components assembly for insecur

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3–122. DC Relay Assembly, Exploded View3-259

Figure 3-123. Precise Relay Assembly, Exploded View3-260ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445--2NAVY NAVFAC P-8-624-34Figure 3-124. Under Voltage Relay Test CircuitFigure 3-125. Under Frequency Relay

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34(e) Slowly raise output frequency of power source GI until test lamps transfer. Tes

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3–1 26. Permissive Paralleling Relay Test Circuit(15) Check individual wire

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-343-92. STATIC EXCITER AND VOLTAGE REGULATOR ASSEMBLY.a. General. The static exciter an

ARMY TM 9-5115-454-34AIR FORCE TO 35C2—3-445-2NAVY NAVFAC P-8-62-434(15)(16)(17)(18)(19)(20)(21)(22)(23)(24)(25)(26)Remove nut & captive washer as

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 1-1. FITS AND TOLERANCES (CONTINUED)Mfg’s. Tolerances Desired ClearanceCompo

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-127. Electronics Components Assembly3-266

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34NOTES:1.2.3.4.ALL SOLDERED CONNECTIONS SHALL BE5. CRIMPED TERMINALS SHALL MEET THE

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-128. 50/60 Hz Precise Relay Assembly Wiring Harness, Drawing No. 72-2242 (Sh

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34NOTES:ALL SOLDERED CONNECTIONS SHALL BE IN ACCORDANCEWITH MIL-STD-454, REQUIREMENT

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-129. 400Hz Precise Relay Assembly Wiring Harness, Drawing No. 72-2260 (Sheet

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3–130. Static Exciter and Voltage Regulator Assembly, Exploded View (Sheet

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-130. Static Exciter and Voltage Regulator Assembly, Exploded View (Sheet 2 o

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-341.Screw2. Lockwasher3. Screw4. Chassis cover5. Nut & captive washer assy6.Flat

ARMY TM 9-6115-464-34AIR FORCE 36C2-3-445-2NAW NAVFAC P-8-624-34Figure 3-131. 50/60 Hz Static Exciter and Voltage Regulator Schematic Diagram, Drawing

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(b) One direction shall give an indication of less than 100 ohms. The other direct

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 1-1. FITS AND TOLERANCES (CONTINUED)Mfg’s. Tolerances Desired ClearanceMaxim

(11) Install cable clamp (61), screw (60), and nut and captive washer assembly (59).(12) Install resistor R3 (58), mounting bracket (57), screw (56)

(a)(b)(c)(d)ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34With chassis cover (4, figure 3-130) removed, connect positive lead of

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 3-8. STATIC EXCITER AND VOLTAGE REGULATOR RESISTORAND CAPACITOR VALUESVALUESCOM

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3–132. 400 Hz Static Exciter and Voltage Schematic Diagram, Drawing No. 72-

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34NOTES:1.2.3.4.ALL SOLDERED CONNECTIONS SHALL BE5.IN ACCORDANCE WITH MIL-STD-454,6.REQ

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34B. Static Exciter Wiring (Sheet 2 of 2)Figure 3-133. Static Exciter Wiring Harness

1.2.3.4.5.6.ALL SOLDERED CONNECTIONS SHALL BEIN ACCORDANCE WITH MIL-STD-454,REQUIREMENT 5.CUT INSULATION SLEEVING, FIND NO. 5,INTO 9 PIECES, .750 INCH

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3–133. Static Exciter Wiring Harness, Dwg. No. 72–2628, Voltage Regulator W

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3–134. Static Exciter and Voltage Regulator Assembly Sensing Circuit Bench Tes

ARMYTM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Section XIII. MAINTENANCE OF GENERATOR ASSEMBLIES3-94. GENERAL.This section contain

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-136. Generator Assembly, Exploded View (Sheet 1 of 2)3-286

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-341.Screw2. Lockwasher3. Drip cover4. Screw5. Lockwasher6. Screen guard7. Screw8. Lo

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34(23) Remove Iifting eye bolt and steel bar.NOTEIf a steel bar is not available, care

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-137. Securing Generator Rotor to Stator3-289

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-138. End Bell Assembly, Exploded View3-290

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-139. Generator Rotor and Balance Assembly, Exploded View (Sheet 1 of 2)3-

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-139. Generator Rotor and Balance Assembly, Exploded View (Sheet 2 of 2)3-292

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3–140. Lead Block Assembly, Exploded View(30) If inspection reveals damage

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-141. Generator Stator Assembly, Exploded View3-294

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(2) Ultra sonic cleaning may be used if available. Consult manufacturer’s recomme

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34CHAPTER 2GENERAL MAINTENANCE INSTRUCTIONSSection I. REPAIR PARTS, SPECIAL TOOLS, A

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34(19)(20)(21)(22)(23)(24)(25)(26)(27)(28)Install blower and coupling disc assembly on

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(30) Impregnate the wound rotor as follows:(a)(b)(c)(d)(e)(f)(g)(h)(i)Mark all fit

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3–142. 50/60 Hz Generator Stator Winding Procedures(Sheet 1 of 2)3-298

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-142. 50/60 Hz Generator Stator Winding Procedures (Sheet 2 of 2)3-299

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-143. 400 Hz Generator Stator Winding Procedures (Sheet 1 of 3)3-300

ARMY TM 9-6115-4-34AIR FORCE TO 35C2—3-445-2NAVY NAVFAC P-8-624-34Figure 3-143. 400 Hz Generator Stator Winding Procedures (Sheet 2 of 3)3-301

Figure 3-143. 400 Hz Generator Stator Winding Procedures (Sheet 3 of 3)3-302ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-343.4.5.6.7.8.9.10.INTERPRET DRAWING PER MlL-STD-100.STACK LAMINATIONS, FIND NOS. 1

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34NOTES:1.2.3.4.5.6.LOCATE HEAD STUD AS SHOWN, 45° ± 5°FROM ROTOR RETWIST.SOLDERING SHA

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(c)(d)(e)(f)(g)(h)(i)(j)(k)(l)(m)(n)(o)(p)(q)(r)(s)CAUTIONDo not use press which c

Table 2-1. TOOLS AND SUPPORT EQUIPMENT (CONTINUED)ReferenceItemFSN or Part No.Figure Para.UseTest gauge and hose4910-00-799-7616 or3-41Testing hydraul

ARMY TM 9-6115-464—34AIR FORCE 35C2-3-44-2NAVY NAVFAC P-8-624-342.4.6.7.8.10.NOTES:2.3.4.5.6.7.8.9.10.11.12.Bobbin, woundWireInsulation sleevingInsula

ARMY TM 9-6115-464—34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-146. Generator Exciter Stator Winding Procedures (Sheet 2 of 2)3-307

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-147. Generator Exciter Rotor Winding Procedures (Sheet 1 of 2)3-308

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-147. Generator Exciter Rotor Winding Procedures (Sheet 2 of 2)3-309

ARMY TM 9-6115 464 34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(c) Pull all slack from the leads and tighten the clamping screws of lead block.(

ARMY TM 9-6115 464 34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34a. Testing Exciter Stator (On Equipment Test). Locate and disconnect exciter sta

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-824-343-97. REPLACEMENT OF INTERFERENCE SUPPRESSION COMPONENTS.a. Refer to the Operator

ARMY TM 9-6115 464 34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34c. Cleaning. Inspection. and RepairWARNINGSolvent, Dry Cleaning P-D-680, Type I

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34c. Cleaning, Inspection, and Repair.WARNINGSolvent, Dry Cleaning P-D-680, Type II

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-824-34(7) Install flatwasher (10), Iockwasher (9), and screw (8).(8) Install terminal blo

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 2-1. TOOLS AND SUPPORT EQUIPMENT (CONTINUED)ReferenceItemFSN or Part No.Figu

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(4) Check all threads for crossing, stripping, and other damage.(5) Repair cracks

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-149. Relay Table Assembly, Exploded View3-316

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-150. Relay Table Assembly, Exploded View effective on generator sets seri

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-151. Lifting Frame, Exploded View3-318

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Section XVII. MAINTENANCE OF SKID BASE ASSEMBLY3-102. GENERAL The skid base assem

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34d. Assembly.(1) Position skid base (12, figure 3-152) to install panel blank (11), Io

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-152. Skid Base Assembly, Exploded View3-321/(3-322 blank)

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-445-2NAVY NAVFAC P-8-624-34CHAPTER 4GENERATOR SET TESTS AFTER OVERHAUL REPAIR INSTRUCTIONSSection I. INSPECTION

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Section Il. OPERATING TESTS4-6. GENERAL.a. The tests described in this section req

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Section II. TROUBLESHOOTING2-4. GENERAL.This section provides information useful in d

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-445-2NAVY NAVFAC P-8-624-344-9. LOW FUEL PROTECTIVE DEVICE.a. Disconnect cable to the day tank fuel solenoid va

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 4-1. OPERATING TESTSCAUTIONPrior to performing any of the operating tests li

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-445-2NAVY NAVFAC P-8-624-34Table 4-2. ENGINE GENERATOR SET CLASSIFICATIONSPECIALCOMMON OUTPUTGOVERNINGCOMPONENT

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 4-3. ELECTRICAL PERFORMANCE CHARACTERISTICPARAMETERS AC PRECISE (CLASS 1)TES

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-445--2NAVY NAVFAC P-8-624-34Table 4-3. ELECTRICAL PERFORMANCE CHARACTERISTIC PARAMETERSAC PRECISE (CLASS 1) (CO

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34c. Generator With Separate Excitation.(1) Preparation for test.(a) Completely isol

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-445-2NAVY NAVFAC P-8-624-34(2) Test.(a) Start and operate the generator set and allow the set to stabilize at

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(r) Adjust voltage to the minimum attainable value or a value just prior to acti

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-445-2NAVY NAVFAC P-8-624-34c. Procedure.(1) Preparation for test.(a)(b)Connect the load and field instrumentati

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(c) The recording meter chart speed(s) shall be 12 inches per minute throughout

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 2-2. TROUBLESHOOTING (CONTINUED)MALFUNCTIONTEST OR INSPECTIONCORRECTIVE ACTI

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-445-2NAVY NAVFAC P-8-624-34(3) To determine the maximum voltage variation at constant load:(a) One-half the ob

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Trace and definitions apply to either voltage orfrequency.NOTEChart marked at star

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-445-2NAVY NAVFAC P-8-624-34(b) Convert each of the values obtained in (a) above to a percentage of rated volt

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(h)(i)NOTEThis step is not applicable to generator sets having governors that util

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-445-2NAVY NAVFAC P-8-624-344-17. CIRCUIT INTERRUPTER TEST (SHORT CIRCUIT).a. General. A circuit interrupter is

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(2) Calculate the short-circuit current using the peak-to-peak amplitudes of the

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-445-2NAVY NAVFAC P-8-624-34(e) The generator set contains an overload malfunction indicator. Check and record

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(f) Read and record both voltmeter readings.(g) With the oscillograph recording

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-445-2NAVY NAVFAC P-8-624-34e. Results.(1) From the oscillograms made in 4-20c, determine and tabulate the time

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34c. Procedure.(1) Preparation for test.(a) Connect the load instrumentation in acc

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34WARNINGDRILLINGWhen drilling holes in skid base, do not allow drill bit to enter fuel

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 2-2. TROUBLESHOOTING (CONTINUED)MALFUNCTIONTEST OR INSPECTIONCORRECTIVE ACTIONS

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-445-2NAVY NAVFAC P-8-624-344-23. MAXIMUM POWER TEST.a. General. The maximum power of a generator set is a funct

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(2) Test.(a) Start and operate the generator set and allow it to stabilize at rat

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-445-2NAVY NAVFAC P-8-624-34(e) Results.1.Average the three valid power readings. This average is the observed m

REPAIR INSTRUCTIONSSection 1.5-1. GENERAL.ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34CHAPTER 5FOR MATERIAL USED IN CONJUNCTIO

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 5-1. FUEL BURNING WINTERIZATION KIT TROUBLESHOOTING CHART (Continued)MALFUNC

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 5-1. FUEL BURNING WINTERIZATION KIT TROUBLESHOOTING CHART (Continued)MALFUNC

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 5-1. FUEL BURNING WINTERIZATION KIT TROUBLESHOOTING CHART (Continued)MALFUNC

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-345-3. HEATER CONTROL ASSEMBLY.a. Removal. Refer to the Operator and Unit Maintenanc

ARMY TM 9-6116-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(11) Replace damaged connectors and terminals by unsoldering and removing electric

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 2-2. TROUBLESHOOTING (CONTINUED)MALFUNCTIONTEST OR INSPECTIONCORRECTIVE ACTI

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-1. Fuel Burning Heater, Control Assembly5-7

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-2. Fuel Burning Heater Control Assembly Wiring Diagram, Drawing 72-28635-

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-345-4. HEATER ASSEMBLY.a. Removal. Refer to the Operator and Unit Maintenance Manual

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-6-624-34c. Cleaning, lnspection, and Repair.(1)(2)(3)(4)(5)(6)(7)(8)(9)(10)(11)(12)(13)(14

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-3. Fuel Burning Heater Assembly, Exploded View (Sheet 1 of 2)5-11

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-3. Fuel Burning Heater Assembly, Exploded View (Sheet 2 of 2)5-12

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34d. Assembly.Assemble the fuel burning heater assembly in reverse order of disassem

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34e. Testing and Adjustment.(1) Flame Switch Adjustment. Refer to the Operator and

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-4 Coolant Pump Test Diagram5-15

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-5. Fuel Burning Winterization Kit Wiring Harness, Drawing No. 72-28565-16

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 2-2. TROUBLESHOOTING (CONTINUED)MALFUNCTIONTEST OR INSPECTIONCORRECTIVE ACTION

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-6. Fuel Burning Winterization Heater Control Assembly to Special Relay As

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Section Il. ELECTRIC WINTERIZATION KIT5-7. GENERAL.The electric winterization kit

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 5-2. ELECTRIC WINTERIZATION KIT TROUBLESHOOTING CHART (Continued)MALFUNCTION

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-345-9. HEATER CONTROL ASSEMBLY.a. Removal. Refer to the Operator and Unit Maintenanc

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(1)(2)(3)(4)(5)(6)(7)(8)(9)Clean all electrical parts with filtered compressed air

Figure 5-7. Electric Winterization Kit Heater Control Assembly, Exploded View (Sheet 1 of 2)5-22ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAV

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-7. Electric Winterization Kit Heater Control Assembly, Exploded View (She

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34d. Assembly.(1)(2)(3)(4)(5)(6)(7)(8)(9)(lo)(11)(12)(13)(14)(15)Install transformer

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34WIRESIZELENGTH COLOR FROMEND PREPTO ENDNO.REF.REF.PREPPREPX9EA12C1221.00BLK MKGJ49

Figure 5-9. Electric Winterization Kit Heater Control Assembly, Wiring Harness (Sheet 2 of 2) Drawing No.70-12335-26ARMY TM 9-6115-464-34AIR FORCE TO

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 2-2. TROUBLESHOOTING (CONTINUED)MALFUNCTIONTEST OR INSPECTIONCORRECTIVE ACTI

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-345-10. HEATER ASSEMBLY.Refer to the Operator and Unit Maintenance Manual for electr

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(6) Place o-ring (6) into groove of port plate (5), then position port plate agai

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-11. Electric Winterization Kit Wiring Harness, Drawing No. 72-28555-29

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Section Ill. WHEEL MOUNTING KIT5-14. GENERAL.The wheel mounting kit provides added

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-12. Wheel Mounting Kit Installation5-18. AXLE ASSEMBLIES.a. Removal. Refe

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(10)(11)(12)(13)(14)(15)(16)(17)(18)Remove cotter pin (46), nut (47), bolt (48), a

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34d.Assembly.(1)(2)(3)(4)(5)(6)(7)(8)(9)(10)(11)(12)(13)(14)(15)(16)(17)Position ID

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-13. Wheel Mounting Kit, Exploded View (Sheet 1 of 2)5-34

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-13. Wheel Mounting Kit, Exploded View (Sheet 2 of 2)5-35

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Section IV. LOAD BANK5-19. GENERAL.The load bank is used to apply up to 50 percent

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 2-2. TROUBLESHOOTING (CONTINUED)MALFUNCTIONTEST OR INSPECTIONCORRECTIVE ACTIONS

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(4)(5)(6)(7)(8)(9)(10)Inspect mode selector switch for cracks, corrosion and other

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-14. Load Bank Control Box Assembly, Exploded View5-38

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-345-21. LOAD BANK HOUSING.a. Removal. Refer to the Operator and Unit Maintenance Man

Figure 5-15. Control Box Assembly Wiring Harness, Drawing No. 72-28685-40ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-16. Control Box Assembly Branched Wiring Harness (Sheet 1 of 2), Drawing

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-16. Control Box Assembly Branched Wiring Harness (Sheet 2 of 2), Drawing

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-17. Load Bank Housing, Exploded View5-43

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-18. Load Bank Wiring Harness (Sheet 1 of 2), Drawing No. 72-28235-44

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-18. Load Bank Wiring Harness (Sheet 2 of 2), Drawing No. 72-28235-45

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-19. Top Load Bank Wiring Harness (Sheet 1 of 2), Drawing No. 72-28225-46

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 2-2. TROUBLESHOOTING (CONTINUED)MALFUNCTIONTEST OR INSPECTIONCORRECTIVE ACTI

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-19. Top Load Bank Wiring Harness (Sheet 2 of 2) Drawing No. 72-28225-47

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-20. Bottom Load Bank Wiring Harness (Sheet 1 of 2), Drawing No. 72-28255-

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-20. Bottom Load Bank Wiring Harness (Sheet 2 of 2), Drawing No. 72-28255-

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-21. Load Bank Power Wiring Harness, Drawing No. 72-28295-50

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-22. Load Bank Signal Wiring Harness, Drawing No. 72-28305-51

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Section V. APPLICATIONS KIT5-23. GENERAL.The applications kit provides the MEP–113

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445--2NAVY NAVFAC P-8-624-34Table 5-3. APPLICATIONS KIT TROUBLESHOOTING CHARTMALFUNCTIONTEST OR INSPECTIONCOR

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34NOTESInsure the dust rover retaining chain (figure 5-25) on connector J1 is mounte

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(c)(1)(2)(3)(4)(5)(6)(7)(8)(9)(d)(e)(f)(g)(h)(i)(j)(k)Tag load cables for identifi

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 2-2. TROUBLESHOOTING (CONTINUED)MALFUNCTIONTEST OR INSPECTIONCORRECTIVE ACTIONS

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-25. Application Kit Cable Harness Assembly Installation (Right Side)5-57

Figure 5-26. Load Terminal Board Stud Assemblyb. Test.(1) Remote Battle Short Function.(a)(b)(c)(d)(e)(f)NOTERefer to the Operator and Unit Maintenanc

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-341. Fuel Level Sensor2. Connector P103. Connector P114. Connector J95. Connector P9

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-341. Cable Harness Assembly2. Remote Function Assembly3. Tiedown Strap (8 ea.)4. Cap

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(9)Place BATTLE SHORT switch in OFF position.NOTEThe AC circuit breaker indicator

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-29. Remote Functions Assembly5-62

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-30. Wiring Harness Assembly Diagram5-63

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-345-26. CABLE HARNESS ASSEMBLY.a. Test(1) Set multimeter on ohms scale.(2) Test eac

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-31. Relay Socket Replacement5-65

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAYFAC P-8-624-34Table 5-4. CABLE HARNESS ASSEMBLY WIRING LIST- ContinuedWireFromToNo.FunctionJIAL1

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Table 2-2. TROUBLESHOOTING (CONTINUED)MALFUNCTIONTEST OR INSPECTIONCORRECTIVE ACTI

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-32. Application Kit Cable Harness Diagram5-68

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-33. Application Kit Electrical Schematic Diagram5-69

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Section VI. ACOUSTIC SUPPRESSION KIT5-28. GENERALThe acoustic suppression kit prov

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34NOTERemove all data plates and schematics from generator panels. Remove generator

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAYFAC P-8-624-34(4) (5)(6)(7)(8)(9)(l0)(11)(12)(13)(14)(15)(16)(17)Where lines cross, drill a 1 /2

ARMY TM 9-6115464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(18)(19)(20)(21)(22)(23)(24)(25)(26)(27)Install keepers, washers, and capscrews to

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(28) Attach lifting sling to roof panel assembly, and position on generator set.

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-34. Roof Stiffeners, Sealing Angle, Oil Drain, Isolators, Bottom Panel Tr

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-35. Hole Locations on Skid Base Assembly5-76

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-6-624-34Figure 5-36. Mounting Hardware and Hole Location for Side Panel Assembly5-77

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 2-1. Engine Assembly, Removal and lnstallation2-14

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 5-37. Acoustic Suppression Kit Major Components5-78

ARMY TM 9-6115 464 34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34APPENDIX AREFERENCESThis Appendix contains a list of reference manuals that may b

ARMY TM 9-6115 464 34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34A-5 MAINTENANCE (CONT)TM 9-611 5 24P (A) Unit, DS, GS and Depot Maintenance Repai

ARMY TM 9-6115-464-34AIR FORCE TO 35C2—3-445-2NAVY NAVFAC P-8-624-34APPENDIX BFABRICATION/ASSEMBLY OF PARTSB-1

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 2-1. Breakout Cable (Sheet 1 of 2)B-2

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445--2NAVY NAVFAC P-8-624-34Figure 2-1 Breakout Cable (Sheet 2 of 2)B-3/(B-4 blank)

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34ALPHABETICAL INDEXSubjectAParagraphAC POWER CONTROL WIRING HARNESS, 3-195ACOUSTIC

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34ALPHABETICAL INDEX (CONT)SubjectParagraphENGINE FRONT SUPPORT, 3-101ENGINE INSPECT

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34ALPHABETICAL INDEX (CONT)SubjectParagraphLOW OIL PRESSURE SWITCH, 3-39LUBRICATION

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Section Ill. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS2-5. GENERAL.a. The engin

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34

ARMY TM 9-6115-464-34AIR FORCE TO-35C2-3-445-2NAVY NAVFAC P-8-624-34By Order of theSecretaries of the Army, Air Force, and Navy:GORDON R. SULLIVANGene

PIN: 072239-001

* ARMYTM 9-6115 464 34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34C1CHANGE HEADQUARTERS, DEPARTMENTS OFTHE ARMY, THE AIR FORCE, AND THE NAVYNO 1 W

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34(i) lf winterization kits are installed, tag and disconnect electrical Ieads to engin

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(9)(10)(11)(12)Install access cover (3), Iockwashers (2), and screw (1).Connect en

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34(9)(10)(11)(12)(13)(14)(15)(16)(17)(18)Remove nuts (14), Iockwashers (15), screws(18)

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(13) Position rear housing support (5), to install screws (4), fltat washers (3),

ARMY TM 9-6115-464-34AIR FORCE 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 2-2. Generator Assembly, Removal and Installation2-20

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34CHAPTER 3ENGINE AND GENERATOR REPAIR INSTRUCTIONSSection I. MAINTENANCE OF ENGINE

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(16)(17)(18)(19)(20)(21)(22)(23)(24)(25)(26)Remove nut (56), flat washer (57), and

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3–1. Starter Assembly, Exploded View (Sheet 1 of 2)3-3

1 Nut2 Lockwasher3 Terminal lead4 Screw5 Solenoid assembly6 Nut7. Flat washer8. Insulating washer9. Nut10. Lockwasher11. Nut12. Flat washer13. Insulat

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34CAUTIONDo not allow solvent to contact brushes. Failure to observe this caution co

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(21) Remove minor rough spots, scores, and scratches from bushings using fine cr

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34f. Installation. Refer to the Operator and Unit Maintenance Manual for starter ass

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-2. Starter Assembly Motoring Test Circuit3-8

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3–3. Starter Assembly Stalled Torque Setup3-9

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-4. Starter Assembly, Exploded View (Effective with Serial No. RZ60001) (S

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-341. Nut2. Lockwasher3. Nut4. Lockwasher5. Clamp6. Screw7. Solenoid Assembly8. Boot9

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(16)(17)(18)(19)CAUTIONUse care when removing armature to prevent damage to windin

ARMY TM 9-6115-454-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(6) Inspect housing and frames for cracks, corrosion, and distortion. Replace defe

ARMY TM 9-6115-464-34AIR FORCE TO 36C2-3-445-2NAVY NAVFAC P-8-624-34f. Assembly.(1) Assemble starter and solenoid in reverse order of disassembly proc

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(c) Ammeter should indicate 540 amperes maximum at a minimum torque of 26 ft-lb in

ARMY TM 9-6115 464 34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34TECHNICAL MANUAL HEADQUARTERS, DEPARTMENTS OFTHE ARMY, THE AIR FORCE, AND THE NAV

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(14) Pry woodruff key (47) from keyway in rotor shaft and remove spacer (48).(15)

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-5. Alternator Assembly, Exploded View (Sheet 1 of 2)3-17

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-341. Screw2. Regulator and cover assembly3. Fuse holder4. Nut5. Washer6. Cap7. Fuse8

ARMY TM 9-6115-464-34AlR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-6. Rotor Assembly Current Draw Test Circuit3-19

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34NOTEThe brushes are excessively worn if 3/16 inch or less extends beyond the botto

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(14) Remove wire, inserted in step 3-6d. (11).NOTEPerform steps in paragraph 3-6e(

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-7. Alternator Test Leads Installation(3) Check alternator total circuit v

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(b) If voltage is zero, check fuse (11, figure 3-5).(c) If voltage is greater than

ARMY TM 9-6115-464-34AIR FORCE TO 36C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-8. Total Circuit Voltage Test3-24

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-9. Alternator Positive Output Circuit Test3-25

TABLE OF CONTENTSPageLIST OF ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ivLIST OF TAB

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-10. Alternator Negative Output Circuit Test3-26

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3–11. Excitation Voltage Test3-27

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34CAUTIONRheostat must be set in maximum resistance position to protect the ammeter

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-12. Faulty Voltage Regulator Circuit Test3-29

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-13. Field Current Test3-30

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-343-7. SPEED SWITCH.a. General.(1)(2)(3)(4)(5)The speed switch provides sequenced co

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34b. Removal. Refer to Operator and Unit Maintenance Manual for speed switch removal

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(2) Refasten with lockwire after readjustment.(h). Assembly (Mechancial Type(1) Po

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34(12) After Element No. 3 has tripped, connect the VOM between pins F and J to che

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-15. Speed Switch, Exploded View (Electronic Switch) (Sheet 1 of 2)3-35

Section XVI.Section XVll.CHAPTERSectionSectionCHAPTERSectionSectionSectionSectionSectionSectionAPPENDIX4.I.II.5.I.Il.Ill.IV.V.VI.AARMY TM9-6115-464-34

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-15. Speed Switch, Exploded View (Mechanical Switch) (Sheet 2 of 2)NOTETo

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-16. Speed Switch Test Points (Electronic Switch) (Sheet 1 of 2)3-37

ARMY TM 9-6115-464-34AIR FORCE TO 36C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-16. Speed Switch Test Points (Mechanical Switch) (Sheet 2 of 2)3-38

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-343-8. COOLANT TEMPERATURE TRANSMllTER.Refer to the Operator and Unit Maintenance Ma

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-17. Engine Wiring Harness Assembly, Drawing No. 72-2267 (Sheet 1 of 2).3-

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-17. Engine Wiring Harness Assembly, Drawing No. 72-2267 (Sheet 2 of 2)3-4

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-343-16. MAIN FUEL TANK (METAL).a. Removal.(1) Refer to the Operator and Unit Manual

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34c. Installation.NOTEInstall filler neck hose with vent holes to top and outboard.(

ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Figure 3-18. Main Fuel Tank (Metal), Removal and Installation3-44

(1)(2)(3)(4)(5)(6)(7)(8)(9)ARMY TM 9-6115-464-34AIR FORCE TO 35C2-3-445-2NAVY NAVFAC P-8-624-34Clean exterior surfaces of fuel tank and other nonelect