TM 9 6115 668 13

TM 9-6115-668-13
SUPERSEDES TM 9-6116-668-13, 02 AUGUST 1996
TECHNICAL MANUAL
OPERATOR, UNIT, AND DIRECT SUPPORT MAINTENANCE MANUAL
GENERATOR SET, DIESEL ENGINE DRIVEN,

SKID MOUNTED,
150 kW, 400 Hz, ALTERNATING CURRENT
(NSN 6115-12-337-8494)
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY

JUNE 1998
TM 9-6115-668-13
C2
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 2 WASHINGTON, D.C. 15 February 2001
Technical Manual
for
GENERATOR SET, DIESEL ENGINE DRIVEN.
SKID MOUNTED,
150 KW, 400 HZ, ALTERNATING CURRENT
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.
TM 9-6115-668-13, dated 01 June 1998, is changed as follows:
1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the
margin. An illustration change is indicated by a miniature pointing hand.
Remove Insert
A and B A and B
4-17 thru 4-20 4-17 thru 4-20
5-239 thru 5-243/5-244 blank
2. Retain this sheet in front of manual for reference purposes.

TM 9-6115-668-13
By Order of the Secretary of the Army:
ERIC K. SHINSEKI
General, United States Army
Official: Chief of Staff
JOEL B. HUDSON
Administrative Assistant to the
Secretary of the Army
0102401
DISTRIBUTION:
To be distributed in accordance with the initial distribution number (IDN) 256400 requirements for TM 9-6115-668-13.
TM 9-6115-668-13
C1
CHANGE HEADQUARTERS
NO. 1 WASHINGTON, D.C. 20 September 1999
Technical Manual

for
GENERATOR SET, DIESEL ENGINE DRIVEN,
SKID MOUNTED,
150 KW, 400 HZ, ALTERNATING CURRENT
DISTRIBUTION STATEMENT A; Approved for public release; distribution is unlimited.
TM9-6115-668-13, dated 01 June 1998, is changed as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar
in the margin. An illustration change is indicated by a miniature pointing hand.
Remove pages Insert pages

AandB
1-9 and 1-10 1-9 and 1-10
2-9 and 2-10 2-9 and 2-10
2-17 and 2-18 2-17 and 2-18
2-21 and 2-22 2-21 and 2-22
2-27 thru 2-30 2 - 27 thru 2 - 29/(2 - 30 blank)
2-31 thru 2-34 (2 - 33 blank)/2 - 34
2-39 and 2-40 2-39 and 2-40
2-45 thru 2-48 2-45 thru 2-48
2-53 and 2-54 2-53 and 2-54
2-59 thru 2-62 2-59 thru 2-62
2-67 and 2-68 2-87 and 2-68
4-17 thru 4-20 4-17 thru 4-20
4-41 and 4-42 4-41 and 4-42
4-45 thru 4-48 4-45 thru 4-48
4-73 thru 4-74 4-73 thru 4-74
4-77 and 4-78 4-77 and 4-78
4-81 and 4-82 4-81 and 4-82
4-85 and 4-86 4-85 and 4-86
4-89 and 4-90 4-89 and 4-90
4-97 and 4-98 4-97 and 4-98
4-103 and 4-104 4-103 and 4-104
4-179 and 4-180 4-179 and 4-180
4-185 thru 4-192 4-185 thru 4-192
4-199 and 4-200 4-199 and 4-200
4-203 and 4-264 4-203 and 4-204
TM 9-6115-668-13
C1
Remove pages Insert pages

4 - 209 and 4 - 210 4-209 and 4-210
4-217 and 4-218 4-217 and 4-218
4-221 thru 4-224 4-221 thru 4-224
5-1 thru 5-4 5 - 1 thru 5 - 4
5-95 and 5-96 5-95 and 5-96
5-113 and 5-114 5-113 and 5-114
5-117 and 5-118 5-117 and 5-118
5-121 and 5-122 5-121 and 5-122
5-127 and 5-128 5-127 and 5-128
5-137 thru 5-140 5-137 thru 5-140
5-159 thru 5-182 5-159 thru 5-162
5-187 and 5-168 5-167 and 5-168
5-171 and 5-172 5-171 and 5-172
5-175 and 5-176 5-175 and 5-176
5-179 and 5-180 5-179 and 5-180
5-183 thru 5-186 5-183 thru 5-186
5-191 and 5-192 5-191 and 5-192
5-197 thru 5-214 5-197 thru 5-214
5-217 and 5-218 5-217 and 5-218
5 - 223 thru 5 - 235/(5 - 236 blank) 5-223 thru 5-238
Index - 3 and Index - 4 Index - 3 and Index - 4
2. Retain this sheet in front of manual for reference purposes.
Official: ERIC K. SHINSEKI

General, United States Amy
Chief of Staff
JOEL B HUDSON
Secretary of the Amy
9922103
Distribution:
To be distributed in accordance with the initial distribution number (IDN) 256400,

requirements for TM 9-6115-668-13.
TM 9-6115-668-13
LIST OF EFFECTIVE PAGES
Insert latest changed pages; dispose of superseded pages in accordance with regulations.
NOTE: On a changed page, the portion of the text affected by the latest change is indicated by a vertical line, or other
change symbol, in the outer margin of the page. Changes to illustrations are indicated by miniature pointing hands.
Changes to wiring diagrams are indicated by shaded areas.
Dates of issue for original and changed pages are:
Original 01 Jun 1998 Change 1 20 Sep 1999

Change 2 15 February 2001
Page *Change Page *Change
No. No. No. No.
Cover................................0 4-42 and 4-44 ....................0

a thru c..............................0 4-45 thru 4-47....................1
d blank ..............................0 4-48 thru 4-73....................0
A and B.............................1 4-74..................................1
i thru xxi ............................0 4-75 and 4-76 ....................0
1-1 thru 1-8........................0 4-77..................................1
1-9 and 1-10......................1 4-78 and 4-81 ....................0
1-11 thru 1-26....................0 4-82..................................1
2-1 thru 2-9........................0 4-83 thru 4-85....................0
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2-11 thru 2-16....................0 4-87 and 4-89 ....................0
2-17.................................. I 4-90..................................1
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2-31 thru 2-33 deleted ........1 4-186 ................................1
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4-21 thru 4-40....................0 5-1 ....................................0
4-41..................................1 5-2 ....................................1
*Zero an this column indicates an original page.
Change 2 A
TM 9-6115-668-13
5-3 ....................................0 5-227 and 5-228 ................1

5-4 ....................................1 5-229 ................................0
5-5 thru 5-94......................0 5-230 thru 5-235................1
5-95..................................1 5-236 thru 5-238 added ......1
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5-114 thru 5-117................0 A-1 and A-2 .......................0
5-118 ................................1 B-1 thru B-16 .....................0
5-119 thru 5-121................0 C-1 thru C-4.......................0
5-122 ................................1 D-1 and D-2.......................0
5-123 thru 5-126................0 E-1 and E-2 .......................0
5-127 ................................1 F-1 and F-2 .......................0
5-128 thru 5-137................0 G-1 and G-2 ......................0
5-138 ................................1 GLOSSARY-1 and
5-139 ................................0 GLOSSARY-2....................0
5-140 ................................1 INDEX-1 thru INDEX-3.......0
5-141 thru 5-159................0 INDEX-4............................1
5-160 and 5-161 ................1 INDEX-5 thru INDEX-10 .....0
5-162 thru 5-166................0 FP-1..................................0
5-167 ................................1 FP-2 blank.........................0
5-168 thru 5-171................0 FP 3..................................0
5-172 ................................1 FP-4 blank.........................0
5-173 thru 5-175................0 FP-5..................................0
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5-177 and 5-178 ................0 FP-7..................................0
5-179 ................................1 FP-8 blank.........................0
5-180 thru 5-182................0 FP-9..................................0
5-183 ................................1 FP-10 blank .......................0
5-184 and 5-185 ................0 FP-11................................0
5-186 ................................1 FP-12 blank .......................0
5-187 thru 5-191................0 FP-13................................0
5-192 ................................1 FP-14 blank .......................0
5-193 thru 5-196................0 FP-15................................0
5-197 ................................1 FP-16 blank .......................0
5-198 ................................0 FP-17................................0
5-199 thru 5-207................1 FP-18 blank .......................0
5-208 and 5-209 ................0 FP-19................................0
5-210 thru 5-214................1 FP-20 blank .......................0
5-215 and 5-216 ................0 FP-21................................0
5-217 ................................1 FP-22 blank .......................0
5-218 thru 5-222................0 FP-23................................0
5-223 ................................1 FP-24 blank .......................0
5-224 ................................0 FP-25................................0
5-225 ................................1 FP-26 blank .......................0
5-226 ................................0
*Zero in this column indicates an original page.
B Change 2
TM 9-6115-668-13
Dry cleaning solvent used to clean parts is potentially dangerous to per-

sonnel and property. Clean parts in a well-ventilated area. Avoid inhala-
tion of solvent fumes. Wear goggles and rubber gloves to protect eyes
and skin. Wash exposed skin thoroughly. Do not smoke or use near open
flame or excessive heat. Failure to observe this warning can cause severe
personal injury or death.
With any access flap open, the noise level of this Generator Set 150 kW
could cause hearing damage when operating. Hearing protection must be
worn when working near the Generator Set 150 kW during operation.
The fuel in this Generator Set 150 kW is highly explosive. Do not smoke
or use open flame when performing maintenance. Fire and explosion
could occur, resulting in severe personal injury or death.
High voltage is produced when this Generator Set 150 kW is in operation.

Improper operation could result in personal injury or death.
Never attempt to connect control or power cables while the Generator Set
150 kW is running. Failure to observe this warning could result in severe
personal injury or death by electrocution.
Do not operate Generator Set 150 kW unless it is properly grounded and

all load terminals are not shorted. Failure to observe this warning can re-
sult in severe personal injury or death.
a
TM 9-6115-668-13
Never attempt to disconnect control or power cables while Generator Set

150 kW is running. Failure to observe this warning could result in severe
personal injury or death by electrocution.
l Potential 150 kW shock hazard with failure to adhere to this warning.

Contact with this high power could result in death or severe injury. If
the removal of one generator from the EPP Ill is required, replace it with
an extra generator. Always make sure that two generators are mounted
to the EPP Ill. Continued use of the EPP Ill with only one generator
could result in a catastrophic shock hazard.
l Do not operate one of the EPP Ill generators when the other generator
is dismounted.
l Prior to energizing the equipment the operator must check for exposed
electrical terminals.
l Always install protective covers on control and power cables when
cables are not connected.
l Be sure to observe all warning signs on equipment.
Always wear gloves when operating actuator. Failure to observe this

warning could result in severe personal injury.
l Do not stand in the operating area of the crane or forklift.

l Do not walk under the suspended load.
l Move the container slowly so that it remains in the horizontal position.
Failure to observe these warnings could result in severe personal in-
jury or death.
b
TM 9-6115-668-13
Make sure that there are no open flames in the vicinity, and that fuel can-
not splash onto hot components. Failure to observe this warning could
result in severe personal injury.
To prevent severe personal injury from hot engine, perform this inspec-
tion only when engine is cold.
To prevent personal injury, wear protective gloves when loosening nuts

from corrugated hoses.
Refer to FM 21-11 for first aid.
c/(d blank)
*TM 9-6115-668-13
TECHNICAL MANUAL HEADQUARTERS

NO. 9-6115-668-13 WASHINGTON D.C., 01 June 1998
GENERATOR SET, DIESEL ENGINE DRIVEN, SKID MOUNTED,

150 kW, 400 Hz, ALTERNATING CURRENT (NSN: 6115-12-337-8494)
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes, or if you know of a way to improve
these procedures, please let us know. Mail your letter or DA Form 2028 (Recommended
Changes to Publications and Blank Forms), or DA Form 2028-2 located in the back of this
manual directly to: Commander, U. S. Army Communications-Electronics Command and Fort
Monmouth, ATTN: AMSEL-LC-LEO-D-CS-CFO, Fort Monmouth, New Jersey 07703-5000.
The fax number is 732-532-1413, DSN 992-1413. You may also e-mail your recommendations
to [email protected]. Instructions for sending an
electronic 2028 may be found at the back of this manual immediately preceding the hard copy
2028. In either case a reply will be furnished to you.
DISTRIBUTION STATEMENT A. Approved for public release, distribution is unlimited.
TABLE OF CONTENTS
Page
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv
CHAPTER 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Section I. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Section II. Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Section III. Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
This manual supersedes TM 9-6115-668-13, 02 August 1996.
I
TM 9-6115-668-13
TABLE OF CONTENTS - continued

Page
CHAPTER 2 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Section I. Description and Use of Controls and Indicators . . . . . . . . . . . . . . . . . . . . 2-2
Section II. Operator Preventive Maintenance Checks and Services (PMCS) . . . 2-12
Section III. Operation under Usual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Section IV. Operation under Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 63
CHAPTER 3 OPERATOR MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Section I. Operator Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Section II. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Section III. Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
CHAPTER 4 UNIT MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Section I. Repair Parts; Tools; Special Tools; Test, Measurement and

Diagnostic Equipment (TMDE); and Support Equipment . . . . . . . . . . . . 4-5
Section II. Service Upon Receipt of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Section III. Unit Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Section IV. Unit Preventive Maintenance Checks and Services (PMCS) . . . . . . . . 4-15
Section V. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Section VI. Radio Interference Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Section VII. Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
ii
TM 9-6115-668-13

Page
CHAPTER 5 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . 5-1

Diagnostic Equipment (TMDE); and Support Equipment . . . . . . . . . . . . 5-3
Section II. Troubleshooting .............................................. 5-4
Section III. Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
APPENDIX A REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
APPENDIX B MAINTENANCE ALLOCATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Section I. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Section II. MAINTENANCE ALLOCATION CHART FOR GEN SET 150 kW . . . . B-4
Section III. Tool and Test Equipment Requirements for Gen Set 150 kW . . . . . . . B-10
Section IV. REMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11
APPENDIX C COMPONENTS OF END ITEM (COEI) AND

BASIC ISSUE ITEMS (Bll) LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Section I. Introduction.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Section II. Components of End Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Section III. Basic Issue Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
APPENDIX D ADDITIONAL AUTHORIZATION LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Section I. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Section II. Additional Authorized Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
APPENDIX E EXPENDABLE AND DURABLE ITEMS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Section I. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Section II. Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
iii
TM 9-6115-668-13

Page
APPENDIX F OPERATOR’S LUBRICATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . F - 1
Section I. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1
APPENDIX G TORQUE LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GLOSSARY - 1
Section I. Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GLOSSARY - 1
Section II. Definition of Unusual Terms . . . . . . . . . . . . . . . . . . . . . . . . . GLOSSARY - 2
INDEX .............................................................. INDEX - 1
iv
TM 9-6115-668-13
LIST OF ILLUSTRATIONS
Figure Title Page
1-1 Generator Set 150 kW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-2 Generator Set 150 kW, Location of Major Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
1-3 Generator Set 150 kW, Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 14
1-4 Generator Set 150 kW, Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
2-1 Control Cabinet Assembly, Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 Control Cabinet Assembly, Circuit Breakers (sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-3 Control Cabinet Assembly, Receptacles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 10
2-4 Base Frame Assembly, J3 SLAVE RECEPTACLE 24 VOLTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11
2-5 Operator PMCS Routing Diagram (sheet 1 of 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 15
2-6 Control Cabinet Assembly Lamp Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 35
2-7 Diesel Engine Oil Removal Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 39
2-8 Diesel Engine Oil Level Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 40
2-9 Viscosity Class (SAE Class). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 42
2-10 Refueling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 45
2-11 Connect Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 46
2-12 Connecting Control and Power Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 48
2-13 Generator Set 150 kW Identification Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 49
2-14 Generator Set 150 kW CG Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 49
2-15 Generator Set 150 kW Transportation Data Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 49
2-16 Engine Preheating Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 50
2-17 Generator Set 150 kW Short Operating Instructions Plate (sheet 1 of 2). . . . . . . . . . . . . . . . . . . . 2 - 51
2-18 Operating the Generator Set 150 kW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 56
v
TM 9-6115-668-13
LIST OF ILLUSTRATIONS - continued
Figure Title Page
2-19 Generator Set 150 kW Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 57
2-20 BATTLE SHORT Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 59
2-21 Disconnecting Control and Power Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 61
2-22 Disconnect Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 62
2-23 Disconnect Ground Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 62
2-24 Operating the Engine Preheating Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
2-25 Operating the Flame Glowplug System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 66
2-26 Fuel Injection Pump Actuator Linkage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 68
3-1 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up. . . . . . . . . . . . . . 3-4
3-2 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON

lamp does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-3 GLOWPLUG ON lamp does not light up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-4 Oil pressure too low, or no oil pressure indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-5 Generator frequency cannot be adjusted, or no frequency indication. . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-6 Generator voltage cannot be adjusted, or no voltage indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-7 AC CIRCUIT INTERRUPTER ON lamp does not light up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10
3-8 Air Filter Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13
4-1 Original Packaging in Container. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-2 Unpacking the container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10
4-3 Generator Set 150 kW, Unpacked. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11
4-4 Lubricate synchronous generator bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 14
4-5 Unit PMCS Routing Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 17
vi
TM 9-6115-668-13
Figure Title Page
4-6 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up. . . . . . . . . . . . . . 4 - 22

lamp does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 23
4-8 GLOWPLUG ON lamp does not light up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 24
4-9 Diesel engine cannot be started. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 25
4-10 Oil pressure too low, or no oil pressure indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26
4-11 Battery set is not being charged, or no charging current indication. . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 27
4-12 Generator frequency cannot be adjusted, or no frequency indication. . . . . . . . . . . . . . . . . . . . . . . . 4 - 28
4-13 Generator voltage cannot be adjusted, or no voltage indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 29
4-14 AC CIRCUIT INTERRUPTER ON lamp does not light up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 30
4-15 No line currents are flowing, or no line current indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 31
4-16 No power indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 32
4-17 BATTERY CHARGING CONTROL lamp lights up during operation. . . . . . . . . . . . . . . . . . . . . . . . . 4 - 33
4-18 OIL PRESSURE lamp lights up during operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 34
4-19 OIL TEMP-CYLINDER HEAD lamp lights up during operation, . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 35
4-20 UNDER/OVER FREQUENCY lamp lights up during operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 36
4-21 UNDER/OVER VOLTAGE lamp lights up during operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 37
4-22 GENERATOR OVER TEMPERATURE lamp lights up during operation. . . . . . . . . . . . . . . . . . . . . 4 - 38
4-23 OVERLOAD lamp lights up during operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 39
4-24 Unit Hood Flap Ground Strap Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 44
4-25 Unit Hood Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 47
4-26 Unit Hood-Base Frame Ground Strap Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 49
Vii
TM 9-6115-668-13
Figure Title
4-27 Unit Hood Assembly Air Ducts and Air Cooling Inlet Grate Maintenance Maintenance. . . . . . . . . 4-54
4-28 Unit Hood Flap Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
4-29 Control Cabinet Assembly, Light Indicator Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 61
4-30 Bulb in Indicator Lamps Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 63
4-31 Bulb illuminated Switch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
4-32 Panel Light H6 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
4-33 Illuminated Meter Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69
4-34 Cabinet Light Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 71
4-35 Air Fitter Cartridge Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
4-36 Oil Filter, Subcurrent Filter Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
4-37 Fuel Prefilter Cartridge, Two Step Fuel Filter Cartridges Maintenance. . . . . . . . . . . . . . . . . . . . . . 4 - 82
4-38 Battery Charging Alternator V Belt Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
4-39 Diesel Engine Cylinder Cooling Fins and Oil Cooler Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
4-40 Priming Pump Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 90
4-41 Diesel Engine Fuel Pipes and Fuel Filter Assembly Maintenance. ......................... 4-93
4-42 Fuel Prefilter, Two Step Fuel Filter Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 98
4-43 Fuel Line Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-103
4-44 Control Cabinet Assembly Maintenance (Sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-107
4-45 Control Cabinet Assembly, Pushbutton Switch and Indicator Assembly Maintenance. . . . . . . . . 4 - 113
4-46 Control Cabinet Assembly, Pushbutton Switch Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-116
4-47 Control Cabinet Assembly, Panel Illumination H6 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-118
viii
TM 9-6115-668-13
Figure Title Page
4-48 Control Cabinet Assembly, Preheating Resistor R1, BATTLE SHORT Switch S21,
VOLTAGE SELECTOR SWITCH S11, GLOWPLUG/START Switch S2, MASTER SWITCH S1
Maintenance ...................................................................... 4 - 127
4-49 Control Cabinet Assembly, FREQUENCY ADJUST R4, VOLTAGE ADJUST R3,
PANEL DIMMER S16/R2 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 134
4-50 Control Cabinet Assembly, Meter Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-139
4-51 Control Cabinet Assembly, Cabinet Illumination H7, Door Contact Switch S3,
Brightness Control N5 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 143
4-52 Control Cabinet Assembly, Auxiliary Contactor with Semiconductor, Auxiliary Contactor,
Transformer, Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 146
4-53 Diodes, Time Relay, Power Supply Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 151
4-54 Control Cabinet Assembly, Circuit Breaker F1 to F11, Thermistor relay F12, . . . . . . . . . . . . . . . . 4 - 157
4-55 Control Cabinet Assembly, Relays K19, K20, Digital lsochronous Load Sharing Module N4,
Speed Governor Assembly N1, Resistor Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 160
4-56 Control Cabinet Assembly, Contactor K1 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 164
4-57 Control Cabinet Assembly, Engine Preheating Control Board, Circuit Breaker Maintenance. . . . 4 - 170
4-58 Control Cabinet Assembly, Connection Panel, Connector Maintenance. . . . . . . . . . . . . . . . . . . . . 4 - 177
4-59 Air Filter Assembly, J3 Slave Receptacle 24 V Connector Maintenance. . . . . . . . . . . . . . . . . . . . . 4 - 179
4-60 Shunt Resistor R11, EHG Regulator N7, Generator Regulator N6, Battery Set Maintenance. . . 4 - 186
4-61 Fuel Tank Assembly, Electrical Fuel Pump Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 192
4-62 Fuel Level Switch and Sensor Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 199
4-63 Silencer Assembly, Left Side Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 204
4-64 Silencer Assembly, Right Side Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 209
4-65 Scavenge Pump Assembly, Oil Outlet Pipe, Oil Pressure Switch 1S2 and Oil Pressure Sensor
1R2 Oil Temperature Switch 1S3 and Oil Temperature Sensor 1R3 Maintenance. . . . . . . . . . . . . 4-217
ix
TM 9-6115-668-13
Figure Title Page
4-66 Battery Charging Alternator Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 221
4-67 Generator, Starter Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 224
5-1 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up (sheet 1 of 7). . 5-7

lamp does not light up (sheet 1 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-3 GLOWPLUG ON lamp does not light up (sheet 1 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21
5-4 Diesel engine cannot be started (sheet 1 of 10). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 25
5-5 Oil pressure too low, or no oil pressure indication (sheet 1 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 35
5-6 Battery set is not being charged, or no charging current indication (sheet 1 of 2). . . . . . . . . . . . . 5 - 38
5-7 Generator frequency cannot be adjusted, or no frequency indication (sheet 1 of 5). . . . . . . . . . . 5 - 40
5-8 Generator voltage cannot be adjusted, or no voltage indication (sheet 1 of 7). . . . . . . . . . . . . . . . 5 - 45
5-9 AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 1 of 11). . . . . . . . . . . . . . . . . . . . 5 - 52
5-10 No line currents are flowing, or no line current indication (sheet 1 of 5). . . . . . . . . . . . . . . . . . . . . . 5 - 63
5-11 No power indication (sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 68
5-12 BATTERY CHARGING CONTROL lamp lights up during operation. . . . . . . . . . . . . . . . . . . . . . . . . 5 - 70
5-13 OIL PRESSURE lamp lights up during operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 71
5-14 OIL TEMP-CYLINDER HEAD lamp lights up during operation (sheet 1 of 3). . . . . . . . . . . . . . . . 5 - 72
5-15 UNDER/OVER FREQUENCY lamp lights up during operation (sheet 1 of 6). . . . . . . . . . . . . . . . . 5 - 75
5-16 UNDER/OVER VOLTAGE lamp lights up during operation (sheet 1 of 6). . . . . . . . . . . . . . . . . . . . 5 - 81
5-17 GENERATOR OVER TEMPERATURE lamp lights up during operation (sheet 1 of 4). . . . . . . . . 5 - 87
5-18 OVERLOAD lamp lights up during operation (sheet 1 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 91
5-19 Control Cabinet Assembly, Auxilliary Contactor with Semiconductor, Auxiliary Contactor,
Transformer, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101
x
TM 9-6115-668-13
Figure Title Page
5-20 Time Relays K3, K10, K13 and K26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 105
5-21 Time Relay K17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 106
5-22 Time Relay K25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 107
5-23 Diodes, Time Relay, Power Supply Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 109
5-24 Control Cabinet Assembly, Circuit Breaker F1 to F11, Thermistor relay F12,
True Power Measuring Transformer P4A Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 111
5-25 Digital lsochronous Load Sharing Module N4, Location of Potentiometers and Test Points, . . . . 5 - 114
5-26 Speed Governor Assembly N1, Location of Potentiometers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 119
5-27 Control Cabinet Assembly, Relays K19, K20, Digital lsochronous Load Sharing Module N4,
Speed Governor Assembly N1, Resistor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 120
5-28 Voltage Regulator N2, Location of Circuit Boards and Potentiometers. . . . . . . . . . . . . . . . . . . . . . 5 - 123
5-29 Control Cabinet Assembly, Voltage Regulator N2 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 125
5-30 Voltage regulator N2, Location of Circuit Boards and Potentiometers. . . . . . . . . . . . . . . . . . . . . . . 5 - 129
5-31 Control Cabinet Assembly, Safety Device N3 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 135
5-32 Control Cabinet Assembly, Filter Box FK, Current Transformers, Resistors Maintenance . . . . . . 5 - 141
5-33 Time Relay K106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 147
5-34 Time Relay K107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 148
5-35 Time Relay K108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 149
5-36 Time Relay K110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 151
5-37 Control Cabinet Assembly, Engine Preheating Control Board, Auxiliary Contactor K109,
Diodes, Time Relay Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 152
5-38 Miniature Relay, Power Relay Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 157
5-39 Control Cabinet Assembly, Connection Panel, Connector Receptacle L1 to L3 and N,

Interlock Switch Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 162
xi
TM 9-6115-668-13
Figure Title Page
5-40 Air Filter Assembly, J3 Slave Receptacle 24 V Connector Maintenance . . . . . . . . . . . . . . . . . . . . . 5-167
5-41 Subcurrent Fitter Assembly, Oil Lines Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 172
5-42 Flame Glowplug System Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 176
5-43 Preheating Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 179
5-44 Temperature Switch, Glowplug Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 183
5-45 Preheating Cable Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 186
5-46 Air Flap Puller Magnet, Electric Oil Pump, Air-Oil Heat Exchanger Maintenance. . . . . . . . . . . . . . 5 - 192
5-47 Oil Hose, Oil Temperature Switch Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 197
5-48 Actuator Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 200
5-49 Actuator Cable, Pick-up, Pick-up Cable Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 207
5-50 EHG and Cylinder Head Temperature Sensor Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-210
5-51 Generator Wiring Harness Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-213
5-52 Diesel Engine and Synchronous Generator Maintenance (Sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . 5 - 223
5-53 Diesel Engine Maintenance (Sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 228
5-54 Synchronous Generator Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 232
5-55 Clutch Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 235
FO-1 Generator Set 150 kW Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-1/FP-2 Blank
FO-2 Engine Preheating Assembly Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-23/FP-24 Blank
xii
TM 9-6115-668-13
LIST OF TABLES
Number Title Page
1-1 Nomenclature Cross-Reference List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-2 Description of Major Components, Generator Set 150 kW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-3 Tabulated Data for Generator Set 150 kW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
1-4 BATTLE SHORT Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1-5 J9 PARALLEL OPERATION Receptacle, Monitoring and Control Functions. . . . . . . . . . . . . . . . . 1-25
2-1 Control Cabinet Assembly, Description of Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-2 Control Cabinet Assembly, Description of Circuit Breakers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-3 Control Cabinet Assembty, Description of Receptacles, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 10
2-4 Operator Preventive Maintenance Checks and Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 21
2-5 SHPD Oils Approved for Diesel Engine BF8L513. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 41
2-6 Oil change intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 43
4-1 Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 12
4-2 Lubricating Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13
4-3 Unit Preventive Maintenance Checks and Services for Generator Set 150 kW. . . . . . . . . . . . . . . 4 - 18
xiii
TM 9-6115-668-13
HOW TO USE THIS MANUAL
DESCRIPTION OF THE MANUAL.

Manual Organization. This manual is designed to help you operate and maintain the genera-
tor set 150 kW. Warning pages are located in the front of this manual. Read the warnings be-
fore operating or doing maintenance on the equipment.
The major elements of this manual are the chapters and appendices. Each chapter has one or
more sections. The Table of Contents, beginning on page i, is provided for quick reference to
the subjects covered by each chapter, section, and appendix. Each chapter also has a chapter
index. The chapter index lists the chapter sections and pargraphs.
A glossary follows the last appendix. The glossary lists and explains the special or unique ab-
breviations and the unusual terms used in this manual.
An alphabetical index follows the glossary. That index is for use in locating specific items of in-
formation.
Chapters. This manual has five chapters and eight appendices. Each chapter is divided into
sections. Each section is divided into descriptive paragraphs. The paragraphs have specific
information about the generator set 150 kW and their major components.
Paragraph Numbering. All paragraphs are numbered. This helps you find what you need
when you need it. USE THE TABLE OF CONTENTS OR ALPHABETICAL INDEX TO FIND
THE SECTION OR PARAGRAPH YOU NEED. Some paragraphs have a related illustration, to
show the items discussed in the paragraph. Also, some paragraphs have a related table that
provides a detailed list of items introduced by the paragraph. Each primary paragraph, illustra-
tion, and table is identified by the number of the chapter in which it appears, followed by a
dash and another number. The number afte the dash indicates the sequence in which the
paragraph, illustration, or table appears in the chapter. Some paragraphs are further divided
into subparagraphs. Subparagraphs are identified by the number of the primary paragraph fol-
lowed by a decimal number, as follows:
Examples: 4.5. is the fifth paragraph in chapter 4.

4.5.1 is the first subparagraph of paragraph 4.5.
4.5.2 is the second subparagraph of paragraph 4.5.
4.5.2.1 is the first subparagraph under 4.5.2.
Figure 3-3. is the third illustration in chapter 3.
Table 2-1. is the first table in chapter 2.
Amendices. Each appendix covers a specific subject.
xiv
TM 9-6115-668-13
CHAPTER 1 - INTRODUCTION.
Chapter 1 provides an introduction to the generator set 150 kW. It is divided into three sections, as fol-
lows:
Section I - General Information. This section provides general information about this manual
and the related forms and records. Instructions are provided for making equipment improve-
ment recommendations, Coverage includes a reference to the TM that contains instructions on
destruction of material to prevent enemy use. Also, a nomenclature cross-reference list is pro-
vided.
Section II - Equipment Description. This section describes generator set 150 kW capabili-
ties, characteristics, and features. It provides basic equipment data and shows the locations of
major generator set 150 kW components. Descriptions of the major components are also pro-
vided.
Section Ill - Principles of Operation. This section provides functional descriptions of th gen-
erator set 150 kW.
CHAPTER 2 - OPERATING INTRODUCTIONS.

Chapter 2 provides introductions for operating the generator set 150 kW. The chapter is di-
vided into four sections, as follows:
Section I - Description and Use of Operator’s Controls and Indicators. This section con-
tains information on operator’s controls and indicators for the generator set 150 kW.
Section II - Operator Preventive Maintenance Checks and Services (PMCS). This section
contains detailed instructions for the before, during, and after operation preventive mainte-
nance checks and services that the operator must perform.
Section Ill - Operation Under Usual Conditions. This section contains instructions for pre-
paring the generator set 150 kW for use and operating under usual conditions.
Section IV - Operation Under Unusual Conditions. This section contains instructions for
preparing the generator set 150 kW for use and operating under unusual conditions.
CHAPTER 3 - OPERATOR MAINTENANCE INSTRUCTIONS.

Chapter 3 covers maintenance of the generator set 150 kW that is to be performed by the op-
erator. Its purpose is to provide you with the information you need to keep the equipment in
good operating condition. This chapter is divided into three sections, as follows:
Section I - Operator Lubrication. This section provides references to the applicable lubrica-
tion instructions.
Section II - Troubleshooting. This section covers troubleshooting procedures and corrective
actions that are to be performed at the operator maintenance level.
Section Ill - Maintenance Procedures. This section refers the operator to the preventive
maintenance checks and services required by section II of chapter 2.
xv
TM 9-6115-668-13
CHAPTER 4 - UNIT MAINTENANCE INSTRUCTIONS.

Chapter 4 provides instructions covering the generator set 150 kW maintenance that must be
performed at unit level. This chapter is divided into seven sections, as follows:
Section I - Lubrication Instructions. This section contains specific lubrication instructions for
the generator set 150 kW.
Section II - Repair Parts: Tools: Special Tools: Test, Measurement, and Diagnostic
Equipment (TMDE): and Support Equipment. This section lists the documents that contain
the needed information.
Section Ill - Service Upon Receipt of Equipment. This section contains instructions for in-
specting and servicing each generator set 150 kW when it is received. It includes instructions
for unpacking the equipment when it is received. The instructions include unpacking and stow-
ing the basic issue items that accompany the generator set 150 kw. Also included are instruc-
tions on positioning the generator set 150 kW for operating and connecting an external fuel
source.
Section IV - Unit Preventive Maintenance Checks and Services (PMCS). This section con-
tains instructions covering the PMCS that must be performed at the unit maintenance level. A
table provides information on maintenance intervals and actions required.
Section V - Troubleshooting. This section covers troubleshooting procedures and corrective
actions that are to be performed at the unit maintenance level.
Section VI - Radio Interference Suppression. This section describes procedures which
have been performed on the Generator Set 150 kW to avoid Electro Magnetic Induction (EMI).
Section VII - Maintenance Procedures. This section contains detailed instructions on unit
level maintenance of the generator set 150 kW.
CHAPTER 5 - DIRECT SUPPORT MAINTENANCE INTRODUCTIONS.

Chapter 5 provides instructions for the maintenance actions designated to be performed at the
direct support maintenance level. The chapter is divided into three sections, as follows:
Section I - Repair Parts: Tools: Special Tools: Test. Measurement, and Diagnostic Equip-
ment (TMDE); and Support Equipment. This section lists the documents that contain the
needed information.
Section II - Troubleshooting. This section includes instructions for troubleshooting faults in
the operation of the control cabinet assembly. It includes eighteen go-no-go flowcharts for
eighteen possible control cabinet malfunctions.
Section Ill - Maintenance Procedures. This section contains detailed instructions for direct
support maintenance of the generator set 150 kW.
xvi
TM 9-6115-668-13
APPENDICES.
Appendix A - References. This appendix lists all publications that are referenced in the vari-
ous chapters of the technical manual. The listing includes the title of each publication.
Appendix B - Maintenance Allocation Chart (MAC). This appendix has four sections, as
follows:
Section I - Introduction. This section explains what is covered in the maintenance allocation
chart.
Section II - Maintenance Allocation Chart. This section contains a tabular listing that as-
signs maintenance functions to specific maintenance levels. It lists the work time needed to
perform each maintenance function at the assigned level. It also contains a column that has
entries keyed to the tools and equipment listed in section III. Another column has entries keyed
to the remarks in section IV.
Section Ill - Tool and Test Equipment Requirements. This section contains complete identi-
fication information for the items referenced in the tools and equipment column of section II.
Section IV - Remarks. This section provides additional information for each entry in the re-
marks column of section II.
Appendix C - Components of End Item (COEI) and Basic Issue Items (Bll) Lists. This ap-
pendix lists the items that are usually packaged separately but needed for installation and op-
eration of the generator set 150 kW. The appendix has three sections, as follows:
Section I - Introduction. This section explains what is covered in section II and section III.
Section II - Components of End Item. The generator set 150 kW is shipped fully assembled,
so this section is not applicable.
Section Ill - Basic Issue Items. This section contains a list of the accessories needed for
installation and operation of the generator set 150 kW.
Appendix D - Additional Authorization List (AAL). This appendix lists additional items you
are authorized for support of the generator set 150 kW.
Appendix E - Expendable and Durable Items List. This appendix lists expendable/durable
supplies and materials needed to operate and maintain the generator set 150 kW. The appen-
dix contains two sections, as follows:
Section I - Introduction. This section explains the entries in section II.
Section II - Expendable and Durable Supplies and Materials List. The list indicates the
maintenance level that needs each item and identifies the items by National Stock Number,
description, and unit of measure.
Appendix F - Operator’s Lubrication Instructions. This appendix contains instructions for
lubrication, if necessary.
Appendix G - Torque Limits. This appendix lists standard torque values for bolts and screws
used in the generator set 150 kW.
xvii
TM 9-6115-668-13
Glossary. This Glossary has two sections, as follows:

Section I - Abbreviations. This section lists the special or unique abbreviations used in this
technical manual. Special or unique abbreviations are those not listed in MIL-STD-12D.
Section II - Definition of Unusual Terms. This section lists and defines the terms used in
this technical manual that are not listed in the Army dictionary (AR 310-25).
INDEX.
An alphabetical index at the back of this technical manual provides a listing of subjects cov-
ered, cross-referenced to the applicable paragraph.
HOW TO FIX A GENERATOR SET 150 kW MALFUNCTION.

Determining the Cause. Finding the cause of a malfunction, troubleshooting, is the first step
in fixing the generator set 150 kW and returning it to operation. Follow these simple steps to
determine the cause of the problem:
a. Turn to the Table of Contents in this manual (page i).
b. Locate “Troubleshooting” under the chapter that covers your level of maintenance.
Turn to the page indicated.
c. For operator troubleshooting, follow the instructions in the references listed in
Chapter 3.
d. For troubleshooting at the unit maintenance level, find the malfunction listing in the
troubleshooting symptom index. Follow the instructions in the figure (troubleshooting chart) in-
dicated by the symptom index.
Preparing for a Task. Be sure that you understand the entire maintenance procedure before
beginning any maintenance task. Make sure that all parts, materials, and tools are handy.
Read all steps before beginning. Prepare to do the task as follows:
a. Carefully read the entire task before starting. It tells you what you will need and
what you have to know to start the task. DO NOT START THE TASK UNTIL:
(1) You know what is needed
(2) You have everything you need
(3) You understand what to do
b. If parts are listed, they can be drawn from technical supply. Before you start the
task, check to make sure you can get the needed parts. National Stock Numbers
(NSNs) and part numbers for the generator set 150 kW parts are listed in the Re
pair Parts and Special Tools List (RPSTL) manual, TM 9-6115-668-23P.
c. If expendable/durable supplies or materials are needed, get them before starting
the task. Refer to Appendix E for the correct nomenclature and NSN.
xviii
TM 9-6115-668-13
How to do the Task. Before starting read the entire task. Be sure that you understand the en-
tire procedure before you begin the task. As you read, remember the following:
a. PAY ATTENTION TO WARNINGS, CAUTIONS, AND NOTES.
b. Use the GLOSSARY if you do not understand the special abbreviations or unusual
terms used in this manual.
c. The following are standard maintenance practices. Instructions about these prac
tices are usually not included in task steps. When standard maintenance practices
do not apply, the task steps will tell you. The standard maintenance practices are:
(1) Tag electrical wiring before disconnecting it.
(2) Discard used preformed packing, retainers, gaskets, cotter pins, lock wash
ers, and similar items. Install new parts to replace the discarded items.
(3) Coat packing before installation, in accordance with the task instructions.
(4) Disassembly procedures describe the disassembly needed for total autho
rized repair. You may not need to disassemble an item as far as described in
the task. Follow the disassembly steps only as far as needed to repair/re
place worn or damaged parts.
(5) Clean the assembly, subassembly, or part before inspecting it.
(6) Before installing components having mating surfaces, inspect the mating sur
faces to make sure they are in serviceable condition.
(7) Hold the bolt (or screw) head with a wrench (or screwdriver) while tightening
or loosening a nut on the bolt (or screw).
(8) Torque to the special torque cited when the task instructions include the
words “torque to.” Use standard torques at all other times.
(9) When a cotter pin is required, align the cotter pin holes within the allowable
torque range.
(10) Inspect for foreign objects after performing maintenance.
xix (xx blank)

TM 9-6115-668-13
CHAPTER 1
INTRODUCTION
Subject Index Page
Section I. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Maintenance Forms and Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Destruction of Army Materiel to Prevent Enemy Use . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Preparation for Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Equipment Improvement Recommendation (EIR) . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Nomenclature Cross-Reference List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.7 List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.8 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Section II.
1.9 Equipment Characteristics, Capabilities, and Features . . . . . . . . . . . . . . . . . . . . . 1-5
1.10 Location and Description of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.11 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.12 Equipment Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Section III.
1.13 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.14 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.15 Related Technical Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1-1
TM 9-6115-668-13
Section I. GENERAL INFORMATION
1.1 SCOPE.
This Manual provides information for operation, troubleshooting and maintenance of the Generator Set
150 kW (figure 1-1). Information is provided on operating principles, controls and indicators, preventive
maintenance checks and services, lubrication, operation under usual and unusual conditions, trouble-
shooting, and maintenance.
1.2 MAINTENANCE FORMS AND RECORDS.
Department of the Army forms and procedures used for equipment maintenance will be those described
by DA Pam 738-750, The Army Maintenance Management System (TAMMS).
1.3 DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE.
Destruction of Army materiel to prevent enemy use shall be in accordance with TM 750-244-3.
1.4 PREPARATION FOR STORAGE AND SHIPMENT.
Refer to Chapter 4, Section VII.
1.5 EQUIPMENT IMPROVEMENT RECOMMENDATION (EIR).
If your Generator Set 150 kW needs improvement, let us know. Send us an EIR. You, the user, are the
only one who can tell us what you don’t like about your equipment. Let us know why you don‘t like the
design or performance. Put it on SF 368 (Product Quality Deficiency Report). Mail it to us at Commander,
U. S. Army Communications-Electronics Command and Fort Monmouth, ATTN: AMSEL-LC-LEO-D-CS-
CFO, Fort Monmouth, New Jersey 07703-3000. We will send you a reply.
1-2
TM 9-6115-668-13
Figure 1-1 Generator Set 150 kW.
1-3
TM 9-6115-668-13
1.6 NOMENCLATURE CROSS-REFERENCE LIST.
Refer to table 1-1 for nomenclature cross-reference list.
Table 1-1 Nomenclature Cross-Reference List.
Common Name Official Nomenclature
ECS Engagement Control Station
EHG Electra-hydraulic Fan
EPP III Electric Power Plant III
FK Filter Box
GEN SET 150 kW Generator Set 150 kW
KHD Klockner Humboldt Deutz (Diesel Engine Company)
OH Operating Hours
PDU Power Distribution Unit
RS Radar Set
1.7 LIST OF ABBREVIATIONS.
Refer to the glossary at the back of this manual.
1.8 GLOSSARY.
Refer to the glossary at the back of this manual.
1-4
TM 9-6115-668-13
Section II. EQUIPMENT DESCRIPTION
1.9 EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES.
The 400-Hz synchronous generator in the Generator Set 150 kW generates phase/line voltages of
120/208 volts. Maximum permissible phase current is 521 A. It is driven by an g-cylinder diesel engine
with a continuous power output of 186 kW at 2182 RPM. The air, fuel, and oil filters are dimensioned so
that the Generator Set 150 kW is suitable for desert conditions, An Engine Preheating Assembly is pro-
vided to allow operation at less than -22 °F (-30 °C). Fuel is supplied from a tank with a diesel fuel ca-
pacity of 101.7 gallons (385 liters). With a full tank and at full load, operating time is approximately 10
hours (correspondingly longer at partial load). The Generator Set 150 kW contains connection, activation,
deactivation, and operational monitoring systems and can be operated independently. The Generator Set
150 kW is mounted in pairs on the EPP III pallet frame. Both Generator Sets 150 kW are connected to
the PDU. They operate in parallel to generate the power delivered from the EPP III to the ECS and RS
loads (see TM 9-6115-669-13&P).
1.10 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS.
Figure 1-2 shows the location of major components of the Generator Set 150 kW. Table 1-2 provides a
short description of the major components of the Generator Set 150 kW.
1-5
TM 9-6115-668-13
Table 1-2 Description of Major Components, Generator Set 150 kW
Item
Item Name Short Description
No.
1 Unit Hood Assembly Protects assemblies from the elements, and muffles the noise
produced by the diesel engine and synchronous generator.
Diesel Engine Drives the Synchronous Generator Assembly.

2
3 Base Frame Assembly For installation of Generator Set 150 kW assemblies.
4 Engine Preheating Assembly Preheats the engine oil, fuel injection pump, cylinder heads,
and generator belts.
Scavenge Pump Assembly Pumps out engine oil, e.g. for oil changes or repair purposes.
5
Silencer Assembly Muffles noise produced by the diesel engine.
6
7 Battery Set Assembly Provides power for the Engine Preheating Assembly, diesel
engine glow plugs, starter, and 24 VDC electrical system.
Fuel Tank Assembly Capacity is approximately 101.7 gallons (385 liters) of fuel.
8
9 Ground Strap Grounds the Control Cabinet Assembly to the Unit Hood
Assembly.
10 Identification Plate Identifies the Generator Set 150 kW (NSN, P/N and
SERIAL NO).
11 Control Cabinet Assembly For activation, deactivation, control, and monitoring of

Generator Set 150 kW.
Air filter Assembly Filters incoming combustion air.

12
13 Synchronous Generator Assembly Generates electrical power.
14 Subcurrent Filter Assembly Filters the engine oil.
15 Slave Receptacle Connector Assembly For parallel connection of battery sets (onboard set with an
24V external battery set).
16 Lifting Ring For hoisting the Generator Set 150 kW.
17 Eyeboft For securing the Unit Hood Assembly.
1-6
TM 9-6115-668-13
1.11 CONSTRUCTION.
1.11.1 Base Frame Assembly and Unit Hood Assembly.
The Generator Set 150 kW consists of the base frame assembly (3, figure 1-2) on which the assemblies
and the unit hood assembly are mounted. The engine and generator compartments are separated from
one another by a panel and is fastened to the base frame assembly. The base frame assembly is a
welded aluminum frame on which the following components are mounted:
l Identification plate for the Generator Set 150 kW (10)

l Identification plate for the base frame, complete
l J3 SLAVE RECEPTACLE 24 VOLTS (15) and designation plate for the J3 SLAVE RECEPTACLE
24 VOLTS
l Four lifting rings (16) for hoisting the Generator Set 150 kW
l Six eyebolts (17) for securing the unit hood assembly
The unit hood assembly (1) protects the assemblies from the elements, and muffles the noise produced
by the diesel engine and synchronous generator. On each long side it has two swing-up flaps, supported
on gas cylinders, providing access to the engine and generator compartment and the control cabinet as-
sembly displays and controls. For voltage equalization, each flap is connected by a grounding strap to the
unit hood assembly, and the unit hood assembly is grounded to the base frame assembly with a strap.
The control cabinet assembly connectors are accessible through an opening in the unit hood assembly
that is covered by a protective profile. Four eyebolts are mounted on the top surface to allow removal of
the unit hood assembly.
1.11.2 Engine Compartment.

The engine compartment contains the diesel engine with starter, battery charging alternator, and fuel and
oil filters, the subcurrent filter assembly, the scavenge pump assembly, and the engine preheating assem-
bly.
The diesel engine (2) is fastened to the base frame assembly with two shock absorbers and two engine
mounts, and connected to the synchronous generator with a clutch. It is cooled by the electro-hydraulic
fan (EHG). Cooling air is drawn in at the front of the unit hood assembly, blown over the diesel engine
cooling fins, and exhausted through the two air leading ducts in the unit hood assembly. Combustion air is
drawn in at the back of the unit hood assembly and delivered to the diesel engine through the air filter
assembly (12) integrated into the partition, and the turbocharger. Exhaust gases are discharged through
the silencer assembly (6) mounted under the base frame assembly and then into two exhaust hoses. En-
gine oil is filtered through the oil filter located on the diesel engine, and the subcurrent filter assembly
(14). The subcurrent filter assembly is connected to the diesel engine by two oil lines. It performs the
function of the oil filter on the EHG, whose centrifugal oil cleaner is not accessible for maintenance. For
oil changes and repair operations, engine oil is pumped out with the manually operated scavenge pump
assembly (5), which is equipped with a stopcock. The intake side is connected to the oil sump with an oil
hose. A ball cock with handle is fitted to the oil drain hose.
1-7
TM 9-6115-668-13
The engine preheating assembly (4) provides a cold-start capability for the diesel engine. This assembly
consists of:
A heating system with air and exhaust hoses, supplied with fuel from the fuel tank assembly through
two fuel hoses (inflow and return flow);
An electric oil pump connected with oil hoses to the diesel engine sump and to an air-oil-heat
exchanger;
An air-oil-heat exchanger connected with an oil hose to the diesel engine oil filler neck;
A heat exchanger box containing the air-oil-heat exchanger and electric oil pump; and an air flap, ac-
tuated by a puller magnet, mounted on the heat exchanger box;
An air hose, located above the oil hose from the sump to the electric oil pump, through which hot air is
blown;
An air hose running from the air flap to the diesel engine, through which hot air is blown onto the fuel
injection pump and diesel engine cylinder heads;
A length of pipe flanged onto the heat exchanger box, through which hot air is blown onto the gen-
erator belts;
The control circuit installed in the control cabinet assembly.
Qualification for desert conditions - i.e. protection of the diesel engine from sand and dust - is the result
of suitably dimensioned air, fuel, and oil filters.
1.11.3 Generator Compartment.
The generator compartment contains the synchronous generator, control cabinet assembly, fuel tank as-
sembly, battery set assembly, and air filter assembly.
The synchronous generator (13) is fastened to the base frame assembly by two shock absorbers, and
connected to the diesel engine with a clutch. It is cooled by a fan wheel located on the engine end of the
generator shaft. Cooling air is drawn in at the back of the unit hood assembly, passes over the windings
of the synchronous generator, and is exhausted through an air guide box in the base frame assembly.
The synchronous generator cables, protected by corrugated hoses, are bolted to the control cabinet. The
control cabinet (11) is fastened to the base frame assembly by four shock absorbers, and connected to
the base frame assembly by a ground strap (9). Assemblies N1 to N5, the contactors, the timing relays,
the thermistor relay F12, the circuit breakers, and the filter box (FK) are mounted to the back wall either
directly or on mounting bars. The controls and displays are located in the front panel section. After un-
locking four quick- release fasteners, the upper front panel section can be swung to the right and se-
cured. The key that unlocks the fasteners is located on the housing frame. The connection panel with the
connectors is located in the lower front panel section, which is bolted to the control cabinet. The connec-
tion panel is used to connect the control and power cables that are permanently connected to the EPP III
power distribution unit.
The fuel tank assembly (8) consists of a tank with a capacity of 101.7 gallons (385 liters), on which an
electric fuel pump is mounted. The fuel tank is connected to the tank by a fuel hose. Mounted on the in-
1-8
TM 9-6115-553-13
take side is a 177 in. (4.5 meter) long fuel hose with a tank filling valve. It is coiled on a holder mounted on
one end of the tank.
The tank has a filler tube (21) and a rubber fuel fill hose (19) connected to a standard fuel filler neck (20)
and is secured by two metal band clamps (18). It also has a screw-on cap (22) located on top of the hood
assembly. Minimum and maximum tank level switches, and a level sensor, are installed in the tank. The
tank can be emptied through a drain plug at the bottom. Welded onto one long side of the tank is a brack-
et on which the generator regulator (N6) and EHG regulator (N7) are mounted. The engine preheating
assembly is connected to the tank by two fuel hoses (inflow and return flow). The diesel engine is con-
nected to the tank by three fuel hoses (manual pump inflow, fuel injection pump return flow, engine oil
overflow line).
The battery set assembly (7) consists of two sealed, maintenance-free, rechargeable 12-volt batteries with
terminal protector caps, a cable set, and the battery set holder. The battery set holder consists of an
upper and lower casing. The lower battery set holder casing is fastened to the base frame assembly. The
air filter assembly (12), integrated into the partition, consists of a chamber for the filter cartridge and a
dust collector. The built-in maintenance switch closes when the filter cartridge is dirty.
Change 1 1-9
TM 9-6115-668-13
Figure 1-2 Generator Set 150 kW, Location of Major Components.
1-10 Change 1
TM 9-6115-668-13
1.12 EQUIPMENT DATA.
1.12.1 Tabulated Data.
Refer to table 1-3 for tabulated data,
Table 1-3 Tabulated Data for Generator Set 150 kW
WEIGHTS AND DIMENSIONS
Operational weight 6,608 pounds (2,977 kg)

Shipping weight 8,139 pounds (3,692 kg)
Overall length * 113.38 in. (288.0 cm)
Overall width * 69.29 in. (176.0 cm)
Overall height * 62.99 in. (160.0 cm)
* See figure 1-3
GENERAL SPECIFICATIONS
Manufacturer Lechmotoren GmbH

Apparent output 187.5 kVA
Rated power factor cos 0.8
Rated voltage 3 400 Hz, 120/208 V
Maximum inclination maximum 10° (18%)
TRANSPORTATION
Truck, rail, air and trailer transportable Tiedown rings provided
Inclined transport (angle) 25° (maximum), any direction
PERFORMANCE CHARACTERISTICS
UNIT HOOD ASSEMBLY
Weight 352.4 pounds (160 kg)
Overall length 113.38 in. (288.0 cm)
Overall width 68.11 in. (173.0 cm)
Overall height 46.73 in. (118.7 cm)
1-11
TM 9-6115-668-13
Table 1-3 Tabulated Data for Generator Set 150 kW (continued).
DIESEL ENGINE
Manufacturer Klockner-Humboldt-Deutz
Model no. BF8L513
Continuous power output 186 kW
Rated speed 2182 RPM
Number and arrangement of cylinders V-8, 90°
Firing sequence 1-8-4-5-7-3-6-2
Operating mode Four-stroke diesel engine with direct fuel injection and
exhaust-driven turbochargers
Cubic capacity 13820 cm3
Lubrication Pressurized recirculating system
Lubricating oil pressure >0.5 bar at 600 RPM with engine warmed up
Oil capacity, with/without filter 5.8 gallons (22 1)/5 gallons (19 I)
Direction of rotation counterclockwise, facing flywheel
Starting aid Flame glow plug system
Cooling Electra-hydraulic fan
Fuel consumption Approximately 10.8 gallons/hr (41 I/hr) at full load
Air filter Dry air filter with dust collector
Weight with starter and generator 2,312.8 lb (1050 kg)
STARTER
Manufacturer Bosch
Starter voltage 24 VDC
Starter actuation Electromagnetic
BATTERY CHARGING ALTERNATOR
Manufacturer Bosch
Rated voltage 28 VDC
Rated current 55 A
BATTERY SET ASSEMBLY
Wiring pattern Two 12-V batteries in series

Rated voltage 24 V
Rated capacity 100 Ah
Weight 154.2 lb (70 kg)
FUEL TANK ASSEMBLY
Weight (empty) 84.6 lb (38.4 kg)
Length 41.38 in. (105.0 cm)
Width 17.72 in. (45.0 cm)
Height 34.25 in. (87.0 cm)
Capacity 101.7 gallons (385 I) incl. reserve
1-12
TM 9-6115-668-13
Table 1-3 Tabulated Data for Generator Set 150 kW (continued).
SYNCHRONOUS GENERATOR ASSEMBLY

Model no. SDV 52.25-22
Apparent output 187.5 kVA
Rated power factor cos 0.8
Rated voltage 3 400 Hz, 120/208 V
Rated current 521 A
Length 38.27 in. (97.2 cm)
Width 29.92 in. (76.0 cm)
Height 26.89 in. (68.3 cm)
Cooling Built-in fan
CONTROL CABINET ASSEMBLY

Model no. SA 150-400
Input/output power 187.5 kVA
Input/output voltage 3 400 Hz, 120/208 V
Input/output current 521 A
Length 43.31 in. (110 cm)
Width 14.76 in. (37.5 cm)
Height 39.57 in. (100.5 cm)
ENGINE PREHEATING ASSEMBLY

Manufacturer Webasto
Model no. HL 10011
Rated voltage 24 VDC
Rated output 120 W
Heating current maximum 11.6 kW
Fuel consumption maximum 1.34 kg/h
Weight 30.8 pounds (approximately. 14 kg)
Length 25.59 in. (65 cm)
Width 7.87 in. (20 cm)
Height 9.65 in. (24.5 cm)
BASE FRAME ASSEMBLY

Length 113.38 in. (288.0 cm)
Width 68.89 in. (175.0 cm)
Height 11.81 in. (30.0 cm)
Construction Welded aluminum frames
1-13
TM 9-6115-668-13
Figure 1-3 Generator Set 150 kW, Dimensions.
1-14
TM 9-6115-668-13
Section III. PRINCIPLES OF OPERATION
1.13 GENERAL DESCRIPTION.
1.13.1 Diesel Engine.
The engine is an 8-cylinder diesel engine with exhaust-driven turbochargers, direct fuel injection, elec-
tronic speed control, and an electro-hydraulic fan (figure 1-4).
In the speed control system, the speed pick-up detects actual engine speed at the flywheel toothed ring.
That value is sent to speed governor assembly N1, which compares actual engine speed to the adjust-
able engine speed setpoint. If there is a discrepancy, N1 sends a control signal to the speed control de-
vice. The speed control device converts the control signal to a rotary motion that acts on the fuel injection
pump through a linkage. The engine speed setpoint, and therefore the generator frequency, are adjusted
with the FREQUENCY ADJUST potentiometer (R4).
If the load changes, digital isochronous load sharing module N4 generates, from the current changes de-
tected by T2 to T4, a control signal that is superimposed on the voltage (engine speed setpoint) picked
off from the FRQUENCY ADJUST potentiometer (R4). N1 and the speed control device thus counteract
any decrease in engine speed caused by increased load, or any increase in engine speed resulting from
a load falloff. Speed governor assembly N1, which has a slower control response, then performs fine ad-
justments.
The diesel engine is cooled by an electro-hydraulic fan (EHG). To achieve temperature-dependent speed
regulation of the EHG, the engine oil and cylinder head temperatures are sensed by temperature-depen-
dent resistors (1830.1 at cylinder 6 and 1B30.2 at cylinder 1). These are connected to EHG controller N7,
which controls solenoid valve 1Y11. The solenoid valve modifies the volume of oil flowing through the
EHG (and therefore the fan rotation speed) as a function of temperature.
The pressure and temperature of the diesel engine oil are determined by sensors, and displayed on the
OIL PRESSURE (P9) and OIL TEMPERATURE (P10) meters. If values go above or below the allowable
range, pressure and temperature sensitive switches close and shut down the Generator Set 150 kW.
Faults are indicated by the OIL PRESSURE (H3) and OIL TEMP-CYLINDER HEAD (H4) lamps.
All electrical cables to the fuel tank assembly and the diesel engine (except the shielded cables to the
control device and the pick-up) pass through the filter box (FK) for filtration and interference suppression.
The low-pass filters dissipate HF voltages to ground, and the varistors suppress voltage spikes.
1.13.2 Fuel Tank Assembly.
The tank can be filled with a fueling nozzle, a canister, or the electric fuel pump. The fuel pump is turned
on with the FUEL TANK PUMP ON illuminated pushbutton switch (S19), and shut down with the FUEL
TANK PUMP OFF pushbutton switch (S18). The maximum tank level switch automatically shuts off the
fuel pump at maximum tank capacity. The fuel level sensor delivers a tank level signal that is displayed
on the FUEL LEVEL meter (P11). The minimum tank level switch delivers a signal indicating that two
hours of operating time remain.
The LOW FUEL lamp (H15) lights up when this level is reached. The alarm signal is applied to PAR-
ALLEL OPERATION receptacle J9, and sent via the EPP III to the ECS.
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TM 9-6115-668-13
1.13.3 Maintenance Free Battery Set Assembly.
The battery set consists of 12-volt batteries 2G1 and 2G2, connected in series. It provides power for the
diesel engine glow plugs and starter, and for the 24-V power circuits in the engine preheat assembly and
switching system. Since battery capacity is one of the factors determining the cold-starting ability of a
diesel engine, at temperatures below about 19.4 °F (-7 “C) the onboard battery set is connected in paral-
lel to an external battery set through the J3 SLAVE RECEPTACLE 24 VOLTS.
1.13.4 Starter.
The 1M1 starter, flange-mounted on the diesel engine, is an electromagnetically actuated DC series-
characteristic motor. During starting, it turns the diesel engine until the engine can run on its own.
1.13.5 Battery Charging Alternator.
The 1G3 battery charging alternator, flange-mounted on the diesel engine, is a self-excited synchronous
generator with a threephase current rectifier and a generator regulator N6. It charges battery set 2G1 and
2G2 via shunt R11. N6 limits charging voltage when the battery set is charged, and charging current
when it is discharged. Charging current is displayed on the BATTERY CHARGE meter (P7). If the battery
set is not being charged during operation, the BATTERY CHARGING CONTROL lamp (H2) will light up.
1.13.6 Engine Preheating Assembly.
The engine preheating assembly consists of a heating unit with fan, an air/oil heat exchanger, an electric
oil pump, and an air guide system with air flap. Air heated by the heating unit is blown through the air/oil
heat exchanger connected to the engine oil circuit. Cold engine oil is drawn up from the sump and moni-
tored by temperature switch S103/S104. Engine oil heated in the air/oil heat exchanger is pumped back
to the engine by the electric oil pump. A portion of the heated air is blown through an air flap onto the fuel
injection pump and engine cylinder heads. Another portion of the heated air is blown onto the generator
1G3 belts.
1.13.7 Synchronous Generator Assembly.
The synchronous generator is a 400-Hz generator with an apparent output of 187.5 kVA and a rated
power factor of 0.8. It consists of the exciter (external pole generator), a rotating rectifier, and the actual
generator (internal pole generator). Voltage regulator N2 prepares and regulates exciter voltage in order
to regulate the output voltage. N2 consists of the Equal Power Distribution, Linear Regulator, Averaging
Circuit, and Voltage Sensing Transformer boards.
The current-proportional voltage tapped at T11/R12, T12/R13, and T13/R14 is transformed by a voltage
sensing transformer to values that can be processed by the averaging circuit. The reason for the averag-
ing circuit is that the sensed voltage can be overlain by interference pulses that falsify the readings. The
linear regulator generates exciter output for the synchronous generator (or generators, in parallel opera-
tion).
The equal power distribution circuit detects the reactive power component of the current based on the
current-proportional voltage tapped at T1/R15. Without reactive power compensation, synchronous gen-
erators operated in parallel would experience different loads. The outcome of this process affects the ex-
citer voltage of the linear regulator.
1-16
TM 9-6115-666-13
The exciter voltage and therefore the phase/line voltages are adjusted with the VOLTAGE ADJUST po-
tentiometer (R3) to 120/208 V, and displayed on the VOLTAGE meter (P6). They are applied to recep-
tacles L1 (0A), L2 (0B), L3 (0C) and N.
The temperature of the stator winding is monitored by a thermistor (control line ), which is connected to
thermistor relay F12 in the control cabinet. If the stator winding reaches or exceeds a temperature of
approximately 302 °F (150 °C), F12 shuts down the Generator Set 150 kW and the GENERATOR OVER
TEMPERATURE illuminated pushbutton switch (H10, S6) lights up. The alarm signal is applied to PAR-
ALLEL OPERATION receptacle J9, and is sent via the EPP III to the ECS.
Key to Figure 1-4
Monitoring
Setpoint
Actual value
Preheat
Figure 1-4 Generator Set 150 kW, Block Diagram.
1-17
TM 9-6115-668-13
1.14 FUNCTIONAL DESCRIPTION.
1.14.1 Engine Preheating Assembly Operation.
l Circuit breakers F1 to F11 and F101 to F103 in control cabinet assembly are closed (figure FO-1).
1.14.1.1 Start- up, Time t = 0.
On control cabinet assembly, MASTER SWITCH (S1) to ON:

+24V is applied to the control cabinet 24-V circuits through F1 to F9.
BATTERY CHARGING CONTROL indicator lamp (H2) and OIL PRESSURE indicator lamp (H3) light up
(+Vreg from N5).
+24 V is present at terminal X101, connector 1 of the engine preheating assembly.
On control cabinet, press HEATING ON illuminated pushbutton switch (S102):
+24 V is applied, through S102, to the coils of K111, K107, K110, K101 and K106.
Auxiliary contactor K111 energizes and switches +24 V, through N-O contact 30-87, to N-O contacts
30-87 of K103 and K104 (input voltage to heating control system).
Auxiliary contact K101 energizes and switches +24 V:
through N-O contact 30-87 and R100 to R102 to glowplug R108, which preheats the combustion
chamber. R100 to R102 heat speed governor assembly N1 in the control cabinet through N-O
contact 30-87 and V106 to the coil of K109. Auxiliary contactor K109 energizes:
+Vreg is applied through N-O contact 13-14 to the HEATING ON indicator lamp (H101), which
lights up; S102 is bridged through N-O contact 23-24 and S103/S104 (latch);
+24 V is applied through N-O contact 33-34 to the puller magnet of the air flap, which opens;
N-C contact 71-72 disconnects the coil of K10 (oil pressure) from +24 V (shutoff delay due to
insufficient oil pressure).
Time relay K106 energizes and blocks excitation of K103. K103 prevents the excitation of K105, i.e.
the solenoid valve in the intake manifold is not connected to +24 V through N-O contact 30-87 of
K105.
1.14.1.2 Time t approximately 1 minute.
K106 deenergizes. +24V is applied through N-C contact 15-16 to the coil of K103.
Auxiliary contactor K103 energizes and switches +24 V, through N-O contact 30-87:
and V105 to the coil of K109;
and V102 to the fan motor of the heating system;
to the coils of K104, K105, and K108.
Auxiliary contactor K105 energizes and switches +24 V, through N-O contact 30-87, to the solenoid
valve in the intake manifold (diesel fuel can be drawn into the heating system).
If burner monitor temperature switch S109 is closed (burner ignited), auxiliary contactor K104 energizes
and latches itself through N-O contact 30-87. The fuel-air mixture is ignited and heats the air-oil-heat
exchanger.
1-18
TM 9-6115-668-13
1.14.1.3 Time t approximately 2.8 minutes.
K106 energizes and disconnects the coil of K103 from +24 V. K103 deenergizes.
If burner monitor temperature switch S109 is open, i.e. K104 is not excited, the heating system must be restarted.
1.14.1.4 Time t approximately 3 minutes.
Time relay K110 energizes:

N-C contact 15-16 is open, disconnecting the coil of K101 from +24 V. K101 deenergizes. The combustion
chamber is no longer preheated, and N1 is no longer heated.
+24 V is applied through N-O contact 15-18 to the coil of K102. Auxiliary contactor K102 energizes and
switches +24 V, through N-O contact 30-87, to the oil pump motor (2M3).
If burner monitor temperature switch S109 is closed, K109 remains excited. Engine oil is pumped through
the air-oil-heat exchanger and heated. Residual heat from the preheating assembly is blown through the air
flap and a hose onto the fuel injection pump, cylinder heads, and generator belts. This status is maintained
for a timed period.
If temperature switch S109 is open, K109 deenergizes and H101 goes out. The heating system must be restarted.
1.14.1.5 Time t approximately 13 minutes.
Time relay K108 energizes:

N-C contact 25-26 is open, disconnecting the air flap puller magnet from +24 V. The air flap closes. This
prevents the engine EHG from forcing cold air into the heating system.
The READY TO START IF HEATING IS ON indicator light (H102) is connected to +Vreg through N-O contact
15-18, and lights up. The diesel engine can be started.
If the diesel engine is started before the READY TO START IF HEATING IS ON lamp lights up, the air flap puller
magnet is disconnected from +24 V by the open N-C contact 21-22 of K6, and the air flap closes (see above).
1.14.1.6 Starting Up, the Engine Preheating Assembly at Temperatures above 14 °F (-10 °C).
If the engine preheating assembly is started up at a temperature above 14 °F (-10 °C), one of the two temperature
switches S103/S104 is open. As a result, K109 does not latch, i.e. the heating system shuts down again within one
minute (paragraph 1.14.1.1).
1.14.1.7 Shutting Down the Engine Preheating Assembly.
Normal Operation
When the engine oil has reached a temperature of approximately 140 °F (60 °C) either temperature switch S103
(60-degree, 3%) or S104 (63-degree, 6%) opens, and shuts down the heating system.
1-19
TM 9-6115-668-13
Manual Shutdown
If the engine reaches a stable speed prior to automatic shutdown, the heating system can be shut down with the
HEATING OFF pushbutton switch (S101).
Overtemperature Shutdown
If the heating system overheats, temperature switch S110 opens. If S110 is open, K105 de-energizes:
+24 V is switched to R103 through N-C contact 30-87a.
The >0,5 A current produced by R103 triggers circuit breaker F103:
N-O contact 1-2 is open; K109 deenergizes and the HEATING ON indicator lamp (H101) goes out.
The HEATING FAILURE indicator lamp (H103) is connected to +Vreg through N-C contact 21-22, and lights up.
After every heating system shutdown (for any reason including a fault), time relay K107 remains energized for
about 90 seconds. This causes the heating system fan motor to continue running for about 90 seconds, since it is
connected to +24 V through N-O contact 15-18 of K107. This run-on function prevents hot air from building up,
thus preventing the heating system from overheating.
1.14.2 Operating the Generator Set 150 kW.
l Circuit breakers F1 to F11 in the control cabinet assembly closed (figure FO-1),
l BATTLE SHORT function (K11) not activated.
1.14.2.1 Operating the Flame Glowplug System.
MASTER SWITCH (S1) in control cabinet assembly to ON:

+24 V is applied, through F1 to F9, to the control cabinet 24-V circuits.
BATTERY CHARGING CONTROL indicator lamp (H2) and OIL PRESSURE indicator lamp (H3) light up
(+Vreg from N5).
Auxiliary contactor K2 (fault message) energizes.
GLOWPLUG/START rotary switch (S2) to GLOWPLUG:
Flame glowplugs (1R5, 1R6) and fuel delivery solenoid valve (1Y1) are activated through R1.
After no more than 90 seconds, the GLOWPLUG ON indicator lamp (H1) lights up. The diesel engine can be
started.
1.14.2.2 Operating the Diesel Engine and Synchronous Generator.
GLOWPLUG/START rotary switch (S2) to START

Auxiliary contactor K28 energizes and latches through N-O contact 13-14.
+24 V is applied to connector 50 of the starter (1 Ml) via N-O contacts 13-14 and 23-24 of K2, and 1-2 and 3-4
of K28. The starter turns the engine at the speed required to catch, until it starts running under its own power.
K28 prevents the starter from shutting down.
Time relay K10 (oil pressure) energizes after a delay (delayed shutdown due to insufficient oil pressure).
1-20
TM 9-6115-668-13
If oil pressure is >0.8 bar, the oil pressure switch (1S2) opens and the OIL PRESSURE indicator lamp (H3) goes
out. If oil pressure does not reach the required level because of a fault, 1S2 does not open and the OIL
PRESSURE lamp (H3) does not go out.
The battery charging alternator (1G3) charges the battery set (2G1/2) via R11, and the BATTERY CHARGING
CONTROL indicator lamp (H2) goes out.
If the battery charging alternator is not charging the battery set due to a fault (no indication on BATTERY
CHARGING meter (P7), the BATTERY CHARGING CONTROL lamp (H2) does not go out.
Auxiliary contactor K2 (error message) deenergizes. The time totalizing meter (P8) receives operating
voltage through N-C contact 81-82, and runs,
GLOWPLUG/START rotary switch (S2) to “0”:

GLOWPLUG ON lamp (H1) goes out.
Auxiliary contactor K28 deenergizes.
Starter shuts down, and cannot be restarted while engine is running (K2 provides starter lockout).
Speed governor assembly N1 and digital isochronous load sharing module N4 are provided with +24
V through N-C contacts 51-52 and 61-62 of K2 and K5.
N1 regulates engine speed, and therefore generator frequency, to the setpoint set with the FREQUENCY
ADJUST potentiometer (R4).
The coil of K3 is connected to +24 V through N-C contact 71-72 of K2.

lime relay K3 energizes after a time delay, and switches +24 V through N-O contact 15-18 to the coil of K6.
Auxiliary contactor K6 energizes and switches +24 V through N-O contacts 1-2 and 3-4 to the coil of K25 and
K26, the interlock chain, voltage regulator N2, and safety device N3.
Time relay K26 energizes after a time delay and switches +24 V through N-O contact 15-18 to the coil of K25,
thus enabling shutdown due to faults:
Under/over-frequency (K7);
Under/overvoltage (K8);
Reverse power (K27); and
Generator temperature too high (K9).
N2 regulates generator voltages to the setpoint set with the VOLTAGE ADJUST potentiometer (R3).
During the energizing delay of time relay K13, safety device N3 checks the generator for:
Under/overfrequency;
Under/overvoltage; and
Reverse power.
Thermistor relay F12 and auxiliary contactor K9 respond if the stator winding temperature reaches or
exceeds approximately 302 °F (150 °C).
1-21
TM 9-6115-668-13
1.14.2.3 Voltages Present at Control Cabinet Assembly Receptacles.
If the AC CIRCUIT INTERRUPTER ON illuminated pushbutton switch (S8) is pressed and the interlock chain is
closed, +24 V is applied to the coil of K14. The interlock chain consists of:
K13, N-O contact 15-18 closed, interlock chain operating;

S7, N-C contact 1-2 closed, AC CIRCUIT INTERRUPTER OFF pushbutton switch;
S8, N-O contact 3-4 closed, AC CIRCUIT INTERRUPTER ON illuminated pushbutton switch;
K16, N-C contact 21-22 closed, power systems of Generator Set 150 kW and Commercial Power Converter
are synchronized;
K17, N-O contact 15-18 closed, Generator Set 150 kW power systems are synchronized;
S12, N-O contact 13-14 closed, interlock switch in receptacle L1 (OA);
S13, N-O contact 13-14 closed, interlock switch in receptacle L2(OB);
S14, N-O contact 13-14 closed, interlock switch in receptacle L3 (OC);
S15, N-O contact 13-14 closed, interlock switch in receptacle N;
K27, N-C contact 21-22 closed, no reverse power from second Generator Set 150 kW;
K21, N-C contact 31-32 closed, no overload at one, at two, or at receptacles L1 (OA), L2 (OB), L3 (OC);
K12, N-C contact 81-82 closed, not activated at ECS EMERGENCY;
K25, N-C contact 15-16 closed, Commercial Power Converter in operation.
Auxiliary contactor K14 energizes and latches through N-O contact 1-2:
+24 V is applied through N-O contact 3-4 to the coil of K1. Main contactor K1 energizes and switches generator
voltages to control cabinet assembly receptacles L1 (OA), L2 (OB), L3 (OC) and N.
(See paragraph 1.14.4.1 for maximum current monitoring of receptacles L1 (OA), L2 (OB) and L3 (OC)).
AC CIRCUIT INTERRUPTER ON lamp (H14) is connected to +Vreg through N-O contact 5-6 and lights up.
The control signal (0 V) is applied to PARALLEL OPERATION receptacle J9 through N-O contact 43-44, and
is transfered through the EPP III to the second Generator Set 150 kW.
Generator voltages are applied through F10 to the VOLTAGE SELECTOR SWITCH (S11), with which the phase
and line voltages can be switched for display on the VOLTAGE meter (P6). These voltages are applied, through F10
(phases U, V, W) and the N-O contacts 2-1 and 4-3 of K1 (phase U, OA and phase V, OB), to power measuring
transducer P4a. This measures the active power output, based on the line currents detected by T8 to T10, which is
displayed on the KILOWATTS meter (P4).
The phase U phase voltage is applied, through the N-O contact 2-1 of K1 and F11, to the J1/120 V 400 Hz double
receptacle. Generator voltages arrive at the EPP III Power Distribution Unit through power cables L1, L2, L3, and N.
1-22
TM 9-6115-668-13
1.14.3 BATTLE SHORT Mode.
BATTLE SHORT mode is activated by the BATTLE SHORT switch (S21) in the control cabinet (or the
BATTLE SHORT switch in the ECS) (figure FO-1).
When BATTLE SHORT mode is active, auxiliary contactor K11 in the control cabinet is excited:
The BATTLE SHORT indicator light (H17) is connected to +Vreg through N-O contact 43-44, and
lights up; +24 V is applied through N-O contacts 13-14 and 23-24 to connector 50 of starter 1M1, i.e.
in BATTLE SHORT mode the starter can be turned on with the GLOWPLUG/START rotary switch;
N-C contact 51-52 is open: the coil of K2 is disconnected from +24 V and K2 cannot energize;
N-C contact 81-82 is open: K5 cannot energize if K8 or K9 is excited;
N-C contact 61-62 is open: K12 cannot energize.
1.14.3.1 Fault Shutdowns and Indications.
If the faults marked with a * occur in BATTLE SHORT mode, K11 prevents main contactor K1 from shut-
ting down (table 1-4). If the unmarked faults occur in BATTLE SHORT mode, the interlock chain is inter-
rupted and main contactor K1 shuts down voltages to control cabinet assembly receptacles L1 (OA), L2
(OB) L3 (OC) and N (paragraph 1.14.2.3). in BATTLE SHORT mode there is no restriction on fault in-
dication.
Table 1-4 BATTLE SHORT Mode.
Shutdown in
Fault display Source BATTLE SHORT
mode
BATTERY CHARGING CONTROL (H2) K2 No
OIL PRESSURE (H3) K2 No
OIL TEMP-CYLINDER HEAD (H4) K2 No
AIR FILTER (H5) K4 Indication only
UNDER/OVER VOLTAGE (H9) K8, K5 No
GENERATOR OVER TEMPERATURE (H10) K9, K5 No
UNDER/OVER FREQUENCY (H8) K7, K5 Yes
OVERLOAD (H13) K21 Yes
REVERSE POWER (H11) K27, N3 Yes
1-23
TM 9-6115-668-13
1.14.3.2 Emergency Shutdown.
If the EMERGENCY switch in the ECS is actuated in BATTLE SHORT mode, 0 V is applied to K12, A2 through con-
tact C of PARALLEL OPERATION receptacle J9. Because N-C contact 61-62 of K11 opens, disconnecting K12, A1
from +24 V, auxiliary contactor K12 cannot energize and the interlock chain is interrupted. This means that the volt-
ages to control cabinet assembly receptacles L1 (OA), L2 (OB), L3 (OC) and N are not shut down.
1.14.4 Control Cabinet Assembly.
1.14.4.1 Maximum Current Monitoring for L1 (OA). L2 (OB) and L3 (OC).
Safety device N3 provides synchronization as well as monitoring of the voltage, frequency, and maximum current of
receptacles L1 (OA), L2 (OB) and L3 (OC) and reverse power. To perform these tasks, it consists of the Synchroniz-
ing Relay, Voltage Sensing Transformers, Voltage/Frequency Error Detection, and Overcurrent/Rev. Power Detection
boards.
Current transformers T5, T6, and 17 generate current-proportional voltages at resistors R5, R6, and R7 (figure FO-1).
The voltages are applied to N3 and J/JT/JS/JR. For example, if too high a current is flowing in the T5, T6, or T7
line, N3 triggers self-locking auxiliary contactor K21. N-C contact 31-32 of K21 opens, interrupting the interlock
chain of K14. Auxiliary contactor K14 and main contactor K1 de-energize. K1 shuts down voltages to control cabi-
net assembly receptacles L1 (OA), L2 (OB), L3 (OC) and N.
The OVERLOAD indicator lamp (H13) is connected to +Vreg through N-O contact 43-44 of K21, and lights up. The
alarm signal is applied to PARALLEL OPERATION receptacle J9, and is delivered through the EPP III to the ECS.
Once the fault has been remedied, the fault is canceled with the OVERLOAD illuminated pushbutton switch (S10).
K21 is reset, and lamp H13 goes out. If a Generator Set 150 kW is in operation, K1 can be turned back on.
1.14.4.2 indicator Lamp Brightness Adjustment.
The PANEL DIMMER (S16/R2) can be used to adjust the output voltage +Vreg of brightness regulator N5 (positive
controller) between a minimum and maximum value (figure FO-1). When the PANEL DIMMER is turned all the way to
the left, S16 is open and the three front panel lights H6 and meter lights P9, P10, and P11 receive no voltage. For
lamps H2 to H15, H8 to H10, H12 to H17, and H101 to H103, voltage +Vres is set to its minimum value. When S16 is
turned on, the three front panel lights H6 and the meter lights P9, P10, and P11 also receive voltage, and +Vreg can
be adjusted between its minimum and maximum values with R2.
1.14.4.3 Lamp Test.
When the LAMP TEST pushbutton switch is pushed, lamps H1, H8 to H17, and H101 to H103 are connected to
+Vreg through a diode and S20, contact 23-24, and lamps H2 to H5 are connected through a diode and S20, con-
tact 13-14 to 0 V; they should all light up (figures FO-1 and FO-2). Lamp brightness can also be adjusted during
the LAMP TEST.
1.14.4.4 Reporting and Control Functions.
Table 1-5 lists reporting and control functions that are exchanged, through PARALLEL OPERATION receptacle
J9, with the second Generator Set 150 kW, EPP III, ECS, and Commercial Power Converter. Contacts V, W, a,
b, c, d, e, and f of J9 are unoccupied (figure FO-1).
1-24
TM 9-6115-668-13
Table 1-5 J9 PARALLEL OPERATION Receptacle, Monitoring and Control Functions.
Control Cabinet Assembly, J9 PARALLEL

Designation Source OPERATION, Affects
Contact
0 V (24 dcV system) --- EPP III, 0 V (24 dcV system)
BATTLE SHORT (S21) Excitation of K11 ECS, BATTLE SHORT switch
--- Excitation of K12 ECS, EMERGENCY switch
0V Excitation of K25 Commercial Power Converter

operation
+24 V Excitation of K17 EPP III operation
Interlock loop Excitation of K20 2nd Gen Set 150 kW, J9-G,
N-O contact K14
AC CIRCUIT INTERRUPTER ON N-O contact K14 G 2nd Gen Set 150 kW, J9-F,
excitation of K20
0V --- H 2nd Gen Set 150 kW, J9-J,

excitation of K18
PARALLEL OPERATION ON (S9) Excitation of K18 J 2nd Gen Set 150 kW, J9-H, 0 V
(24 dcV system)
BATTERY CHARGING
CONTROL, OIL PRESSURE, N-O contact K2 K ECS, fault message
OIL TEMP-CYLINDER HEAD
AIR FILTER N-O contact K4 ECS, fault message
UNDER/OVER FREQUENCY NO contact K7 ECS, fault message
UNDER/OVER VOLTAGE N-O contact K8 ECS, fault message
GENERATOR OVER N-O contact K9 ECS, fault message

TEMPERATURE
OVERLOAD N-O contact K21 ECS, fault message
REVERSE POWER N-O contact K27 ECS, fault message
+24 v N-O contact K1 ECS, ON message Gen Set

150 kW
LOW FUEL N-O contact K23 M ECS, LOW FUEL message Gen
Set 150 kW
1-25
TM 9-6115-668-13
Table 1-5 J9 PARALLEL OPERATION Receptacle, Monitoring and Control Functions (continued).
Control Cabinet J9 PARALLEL

Assembly, Source OPERATION, Affects
Designation contact
+24 v N-O contact K6 N EPP Ill, +24 V (24 dcV system)
+24 v Excitation of K19 P 2nd Gen Set 150 kW, J9-U,

N-C contact K19
Power distribution N4, connector 10 R 2nd Gen Set 150 kW, J9-R,
N4, 10
Active power output N4, connector 11 2nd Gen Set 150 kW, J9-S,
N4, 11
Cable shield --- 2nd Gen Set 150 kW, J9-T,

cable shield
0V N-C contact K19 2nd Gen Set 150 kW, J9-P,

excitation of K19
Power distribution N2, connector A X 2nd Gen Set 150 kW, J9-Y,
N2, E
Reactive power N2, connector E Y 2nd Gen Set 150 kW, J9-X,
N2, A
Cable shield 2nd Gen Set 150 kW, J9-Z,

cable shield
1.15 RELATED TECHNICAL MANUALS.
Refer to appendix A for related technical manuals.
1-26
TM 9-6115-668-13
CHAPTER 2
OPERATING INSTRUCTIONS
Subject Index Page
Section I. Description and Use of Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.1 Control Cabinet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Section II. Operator Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . 2 - 1 2
2.2 Introduction to Operator PMCS Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Section III. Operation under Usual Conditions . . . . . . . . . . . . . . . . . . . . . . ................ 2-34
2.3 Initial Adjustments, Checks, and Self Test . . . . . . . . . . . . . . . . ................ 2-34

2.4 Decals and Instruction Plates . . . . . . . . . . . . . . . . . . . . . . . . . . ................ 2-49
2.5 Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................ 2-53
2.6 Emergency Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................ 2-58
2.7 Preparation for Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................ 2-60
Section IV. Operation under Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
2.8 Operating the Engine Preheating Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

2.9 Operating the Flame Glowplug System (Below 32 °F (0 °C)) ................ 2-65
2.10 Operation in Extreme Cold (Below -22 °F (-30 °C)) . . . . . . . . . . . . . . . . . . . . . . . . 2-67
2-1
TM 9-6115-668-13
Section I. DESCRIPTION AND USE OF CONTROLS AND INDICATORS
2.1 CONTROL CABINET ASSEMBLY.
2.1.1 Controls and Indicators.

The controls and indicators of the control cabinet assembly are shown in figure 2-1 and listed in table 2-1.
Figure 2-1 Control Cabinet Assembly, Controls and Indicators.
2-2
TM 9-6115-668-13
Table 2-1 Control Cabinet Assembly, Description of Controls and Indicators.
Item Description Function

Number
1 AMPS L1 (OA) meter 0 - 600 A (P1) Indicates current in line 1
2 UNDER/OVER FREQUENCY illuminated H8 lights up if generator frequency is above or

pushbutton switch, red (H8, S4) below setpoint; S4 cancels the fault message
3 AMPS L2 (OB) meter 0 - 600 A (P2) Indicates current in line 2
4 UNDER/OVER VOLTAGE illuminated H9 lights up if generator voltage is above or

pushbutton switch, red (H9, S5) below setpoint; S5 cancels the fault message
5 GENERATOR OVER TEMPERATURE illu- H10 lights up if generator overheats; S6 cancels

minated pushbutton switch, red (H10, S6) the fault message
6 AMPS L3 (OC) meter 0 - 600 A (P3) Indicates current in line 3
7 OVERLOAD illuminated pushbutton switch, H13 lights up if generator overloads; S10 cancels
red (H13, S10) the fault message
8 REVERSE POWER illuminated pushbutton H11 lights up if reverse power is too high; S22
switch, red (H11, S22) cancels the fault message
9 Lights (H6) For front panel illumination; use PANEL

DIMMER switch/potentiometer (33) to turn on and
adjust brightness
10 BATTERY CHARGING CONTROL lamp, Must go out after start; if H2 lights up during
red (H2) operation, battery set is not being charged
11 VOLTAGE meter 0 - 250 V (P6) Indicates line or phase voltages L-L or L-N
12 OIL PRESSURE lamp, red (H3) Must go out after start; if H3 lights up during
operation, oil pressure is too low
13 OIL TEMP-CYLINDER HEAD lamp, red Lights up when oil and/or cylinder head
(H4) temperature is too high
14 FREQUENCY meter, digital display (P5) Displays generator frequency

(400.0 ± 0.2 Hz during operation)
2-3
TM 9-6115-668-13
Table 2-1 Control Cabinet Assembly, Description of Controls and Indicators (continued).

Number
15 AIR FILTER illuminated pushbutton switch, H5 lights up when the air filter is dirty; S17
red (H5, S17) cancels the fault message
16 LOW FUEL lamp, amber (H15) Lights up when fuel level in fuel tank has dropped
to minimum tank level
17 OIL TEMPERATURE meter, illuminated Indicates engine oil temperature:

P10)
l Green arc Operating temperature range
l Red arc Over temperature range
18 OIL PRESSURE meter, illuminated, Indicates engine oil pressure

0 - 5 bar (P9) (>4 bar during operation)
19 READY TO START IF HEATING IS ON Lights up when engine preheat time has elapsed
lamp, green (H102) and engine can be started
20 HEATING FAILURE lamp, red (H103) Lights up in the event of a heating system failure
21 HEATING ON illuminated pushbutton Turns heating system on:

switch, green (S102, H101) H101 lights up when heating system is on
22 HEATING OFF pushbutton switch (S101) Shuts heating system off;

H101 goes out when heating system is off
23 FUEL LEVEL meter 0 - 1/1, illuminated Indicates level in fuel tank

(P11)
24 HOURMETER meter (P8) Activated when diesel engine is operating
25 BATTLE SHORT switch (S21) Shuts off safety and monitoring functions
26 BATTLE SHORT lamp, amber (H17) Lights up when safety and monitoring functions
are off
27 FREQUENCY ADJUST potentiometer, Adjusts generator frequency:

10-gang (R4)
l Set between 4 and 5 For rated frequency indicated on FREQUENCY

meter (14)
2-4
TM 9-6115-666-13
Table 2-1 Control Cabinet Assembly, Description of Controls and indicators (continued).

Number
28 AC CIRCUIT INTERRUPTER ON illumi- Turns on power system (main contactor),

nated pushbutton switch, green (S8, H14) H14 lights up when power is ON
29 VOLTAGE ADJUST potentiometer, Adjusts generator voltage:

10-gang (R3)
l Set between 4 and 5 For rated voltage indicated on VOLTAGE meter

(11)
30 AC CIRCUIT INTERRUPTER OFF push- Shuts down power system (main contactor);
button switch (S7) H14 goes out when power is OFF
31 VOLTAGE SELECTOR SWITCH (S11)
l L3-L1, L2-L3, L1-L2 Line voltages
l L1-N, L2-N, L3-N Phase voltages
Indicated on VOLTAGE meter (11)
32 PARALLEL OPERATION ON illuminated Initiates synchronization;

pushbutton switch, white (S9, H12) H12 lights up during synchronization
33 PANEL DIMMER with switch (S16, R2) Adjusts panel light brightness and shuts off lights
l S16 off, R2 turned all the way left All active lights at minimum brightness
l S16 on, R2 turned to the right All lights at maximum brightness
34 FUEL TANK PUMP ON illuminated push- Turns fuel pump on;

button switch, green (S19, H16) H16 lights up when fuel pump is on
35 LAMP TEST pushbutton switch (S20) Tests operation of front panel lamps
36 FUEL TANK PUMP OFF pushbutton switch Shuts fuel pump off;
(S18) H16 goes out when fuel pump is off
37 GLOWPLUG ON lamp, amber (H1) Lights up about 90 seconds after glowplug

operation begins
2-5
TM 9-6115-668-13
Table 2-1 Control Cabinet Assembly, Description of Controls and indicators (continued).

Number
38 GLOWPLUG/START rotary switch (S2)
SWITCH POSITION
l O Off
l GLOWPLUG Activates flame glowplugs and solenoid valve;

GLOWPLUG ON lamp (37) lights up
l START Activates flame glowplugs, solenoid valve, and

starter
39 BATTERY CHARGE meter 0 ... 60 A (P7) Indicates battery charging current

(approximately 10 A when batteries are charged)
40 MASTER SWITCH key switch (S1) Removable key
SWITCH POSITION
l LOCK Off
l OFF 24 V power off
l ON 24 V power on;
Engine can be started with GLOWPLUG/START
rotary switch (38)
41 KILOWATTS meter 0 - 200 kW (P4) Indicates active power output
2.1.2 Circuit Breakers.
Control cabinet assembly circuit breakers are illustrated in Figure 2-2. Table 2-2 describes circuit breaker
functions.
2-6
TM 9-6115-668-13
Figure 2-2 Control Cabinet Assembly, Circuit Breakers (sheet 1 of 2),
2-7
TM 9-6115-668-13
Figure 2-2 Control Cabinet Assembly, Circuit Breakers (sheet 2 of 2).
2-8
TM 9-6115-668-13
Table 2-2 Control Cabinet Assembly Description of Circuit Breakers.
Item Description Protects:

Number
1. 24 V DC/50 A circuit breaker, 1 - pole (F1) Circuit breakers K4 and K28; time relay K10; control
cabinet 24 V circuits (not including J2 and H7)
2. 24 V DC/6 A circuit breaker, 1 - pole (F2) Cabinet light H7, J2/24 V receptacle
3. 24 V DC/16 A circuit breaker, 1 - pole (F3) Speed governor assembly N1 , digital isochronus
load sharing module N4
4. 24 V DC/6 A circuit breaker, 1 - pole (F4) Auxilliary contactor K2 (charging control system, oil
pressure, cylinder head and oil temperature)
5. 24 V DC/6 A circuit breaker, 1 - pole (F5) OIL PRESSURE, OIL TEMPERATURE, FUEL
LEVEL meters
6. 24 V DC/6 A circuit breaker, 1 - pole (F6) FREQUENCY meter, HOURMETER meter, bright-
ness regulator N5
7. 24 V DC/16 A circuit breaker, 1 - pole (F7) Auxilliary contactors K5, K7, K8, K9, K11 , K12, K19,
K21, K23 and K27; time relays K3 and K13; thermis-
tor relay F12, safety circuits
8. 24 V DC/16 A circuit breaker, 1 - pole (F8) Auxilliary contactor K24 (Tank maximum); FUEL
TANK PUMP ON illuminated pushbutton switch,
FUEL TANK PUMP OFF pushbutton switch
9. 24 V DC/20 A circuit breaker, 1 - pole (F9) Auxilliary contactors K6, K14, K16, K18 and K20; time
relays K25 and K26; main contactor K1; voltage regu-
lator N2; ssafety device N3
10. 120 V AC/6 A circuit breaker, 3 - pole (F10) FREQUENCY, KILOWATTS and VOLTAGE meters;
voltage regulator N2; safety device N3
11. 120 V AC/16 A circuit breaker, 1 - pole Jl/l20 V 400 Hz double receptacle
(F11)
12. 24 V DC120 A receptacle, 1 - pole (F101) Auxilliary contactors K101 to K105, K111, time relays
K106, K107 and K110, glowplug, air flap, fan motor,
circuit breaker F102
13. 24 V DC/20 A circuit breaker, 2 - pole Oil pump, HEATING FAILURE lamp H103
(F102)
14. 24 V DC/0,5 A circuit breaker, 2 - pole Time relay K108, auxilliary contact K109, solenoid
(F103) valve, HEATING FAILURE lamp H103
2-9
TM 9-6115-668-13
2.1.3 Receptacles.
Control cabinet assembly receptaclesare illustrared in figure 2-3. Receptacle functions are described in table 2-3. J3
SLAVE RECEPTACLE 24 VOLTS on the base frame assembly is illustrated in figure 24.
Figure 2-3 Control Cabinet Assembly, Receptacles.
Table 2-3 Control Cabinet Assembly, Description of Receptacles.
ltem Description Function

Number
1. L1 (ØA) receptacle with locking switch Connection to EPP Ill, PDU power cable
2. L2 (ØB) receptacle with locking switch Connection to EPP Ill, PDU power cable
3. L3 (ØC) receptacle with locking switch Connection to EPP Ill, PDU power cable
4. N receptacle with locking switch Connection to EPP Ill, PDU power cable
5. J9 PARALLEL OPERATION receptacle Connection to EPP Ill, PDU power cable
6. J1/120 V 400 Hz double receptacle Load connection (maximum 16 A)
7. J2/24 V receptacle Load connection (maximum 6 A)
8. WARNING plate WARNING 208 VAC
9. WARNING plate WARNING 208 VAC - Install Protective Covers
2-10 Change 1
TM 9-6115-668-13
Figure 2-4 Base Frame Assembly, J3 SLAVE RECEPTACLE 24 VOLTS.
2-11
TM 9-6115-668-13
Section II. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SER-

VICES (PMCS)
2.2 INTRODUCTION TO OPERATOR PMCS TABLE.
Table 2-4 (PMCS table) has been provided so you can keep your equipment in good operating condition
and ready for its primary mission.
2.2.1 Warnings. Cautions, and Notes. Always observe the WARNINGS, CAUTIONS, and NOTES
appearing in your PMCS table. Warnings and cautions appear before applicable procedures. You must
observe WARNINGS to prevent serious injury to yourself and others. You must observe CAUTIONS to
prevent your equipment from being damaged. You must observe NOTES to ensure procedures are per-
formed properly.
2.2.2 Explanation of Table Entries. The PMCS table is divided into five columns. Each column is ex-
plained in the following paragraphs.
2.2.2.1 Item No. Column. Numbers in this column are for reference. When completing DA Form 2404
(Equipment Inspection and Maintenance Worksheet), include the item number for the check/service indi-
cating a fault. Item numbers also appear in the order that you must do checks and services for the inter-
vals listed.
2.2.2.2 Interval Column. This column tells you when you must do the procedure in the procedure col-
umn “BEFORE” procedures must be done before you operate the equipment for its intended mission.
“DURING” procedures must be done during the time you are operating the equipment for its intended
mission. “AFTER” procedures must be done immediately after you have operated the equipment. Per-
form ‘WEEKLY” procedures at the listed interval.
2.2.2.3 Location. Item to Check/Service Column. This column lists the location and the item to be
checked or serviced. The item location is underlined.
2.2.2.4 Procedure Column. This column gives the procedure for checking or servicing the item listed in
the location, item to check/service column. You must perform the procedure to know if the generator set
150 kW is ready or available for its intended mission or operation. You must do the procedure at the time
stated in the interval column.
2.2.2.5 Not Fully Mission Capable If: Column. Information in this column tells you what faults will
keep your equipment from being capable of performing its primary mission. If you make checks or ser-
vices that shows faults listed in this column, do not operate the equipment.
2.2.3 Other Table Entries. Be sure to observe all special information and notes that appear in your
table.
2-12
TM 9-6115-668-13
2.2.4 Special Instructions. Preventive maintenance is not limited to performing the checks and ser-
vices listed in the PMCS table. Covering unused receptacles, stowing unused accessories, and other rou-
tine procedures such as equipment inventory, cleaning components, and touch-up painting are not listed
in the table. These are things you should do any time you see that they need to be done. If a routine
check is listed in the PMCS table, it is because experience has shown that problems may occur with this
item. Take along the tools and cleaning cloths needed to perform the required checks and services. Use
the information in the following paragraphs to help you identify problems at any time. Use the following
information to help identify potential problems before and during checks and services.
WARNING
Dry cleaning solvent used to clean parts Is potentially dangerous to

personnel and property. Clean parts In a well-ventilated area. Avoid
inhalation of solvent fumes. Wear goggles and rubber gloves to pro-
tect eyes and skin. Wash exposed skin thoroughly. Do not smoke or
use near open flame or excessive heat. Failure toobserve this warning
can cause severe personal Injury or death.
CAUTION
Keep cleaning solvents, gasoline and lubricants away from rubber or

soft plastic parts. They will deteriorate material.
a. Keep it clean. Dirt, grease, and oil get in the way and may cover up a serious problem. Use dry
cleaning solvent to clean metal surfaces,
b. Use soap and water to clean rubber or plastic parts and material.
c. Check all bolts, nuts, and screws to make sure they are not loose, missing, bent, or broken. Do not
try to check them with a tool, but look for chipped paint, bare metal, or rust around bolt heads. If
you find one loose, report it to the next higher level of maintenance.
d. Inspect welds for loose or chipped paint, rust, or gaps where parts are welded together. If a broken
weld is found, report it to the next higher level of maintenance.
e. Inspect electrical wires, connectors, terminals, and receptacles for cracked or broken insulation,
bare wires, and loose or broken connectors. Tighten loose connectors. Examine terminals and re-
ceptacles for serviceability. If deficiencies are found, report them to the next higher level of mainte-
nance.
f. Inspect hoses and fluid lines. Look for wear, damage, and leaks. Make sure that clamps and fittings
are tight. Wet spots and stains around a fitting or connector can mean a leak. If a leak comes from
a loose connector, or if something is broken or worn out, report it to the next higher level of mainte-
nance.
2-13
TM 9-6115-668-13
2.2.5 Leakage Definitions. You must know how fluid leakage affects the status of your equipment. The
following are definitions of the types/classes of leakage you need to know to be able to determine the sta-
tus of your equipment. Learn and be familiar with them. When in doubt, notify your supervisor.
Leakage Leakage Definition

Class
Class I Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops.
Class II Leakage of fluid great enough to form drops, but not enough to cause drops to drip from the item
being checked/inspected.
Class III Leakage of fluid great enough to form drops that fall from the item being checked/inspected.
2.2.6 Operation of Generator Set 150 kW with Minor Leaks.
CAUTION
Equipment operation is allowable with minor leakage (Class I or ii) of
any fluid except fuel. Fluid capacity must be considered before decid-
ing to continue operation of the equipment with minor leaks. When
operating with Class I or ii leaks, fluid level must be checked more
often than required by the PMCS table. Parts without fluid will stop
working and/or cause equipment damage.
a. Consider the equipment’s capacity for the fluid that is leaking. If the capacity is small, the fluid level
may soon become too low for continued operation. If in doubt, notify your supervisor.
b. Check the fluid level more often than required in the PMCS table. Add fluid as needed.
2.2.7 Corrosion Prevention and Control (CPC). CPC of Army material is of continuing concern. It is
important that any corrosion problems with the equipment be reported so that the problem can be cor-
rected and improvements can be made to prevent the problem in future items. While corrosion is typically
associated with rusting of metals, it can also include deterioration of other materials, such as rubber and
plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a corrosion problem.
If a corrosion problem is identified, it can be reported using Standard Form 368, Product Quality Defi-
ciency Report. Use of key words such as “corrosion,” “rust, ” “deterioration,” or “cracking” will ensure that
the information is identified as a CPC problem, The form should be submitted to the address specified in
DA Pam 738-750.
2.2.8 Order in Which PMCS Will be Done. Figure 2-5 shows the order in which you are to perform
your PMCS. The number callouts on figure 2-5 correspond to the numbers in the Item No. column of
table 2-4, for “Before” PMCS.
2-14
TM 9-6115-666-13
Figure 2-5 Operator PMCS Routing Diagram (sheet 1 of 6).
2-15
TM 9-6115-668-13
2-16
TM 9-6116-668-13
Change 1 2-17
TM 9-6115-668-13
Figure 2-4 Operator PMCS Routing Diagram Tm (sheet 4 of 6).
2-18
TM 9-6115-666-13
2-19
TM 9-6115-668-13
2-20
TM 9-6115866-13
Table 24 Operator Preventive Maintenance Checks and Services.
NOTE
If the equipment must be kept in continuous operation, check and service only those
items that can be checked and serviced without disturbing operation. Make the com-
plete checks and services when the equipment can be shut down.
Item Location Not Fully Mission

No. Interval Item to Check/Service Procedure Capable if:
The fuel in this generator set

150 kW is highly explosive. Do
not smoke or use open flame
when performing mainte-
nance. Fire and explosion
could occur, resulting in 88
vere personal Injury or death.
Ensure key is in control cabinet

panel in the switch.
UNIT HOOD ASSEMBLY
1. Before Plates Check that all plates are firmly
attached and readable.
2. Before Flaps Check condition and operation Flaps cannot be fully
of twist grips, gas cylinders, and opened or main-
door props. tained in the open
position.
3. Before Ground straps Inspect ground straps and Ground straps are
ground strap connections for loose, damaged, or
looseness, corrosion, or dam- corroded.
age.
4. Before Cover for receptacles Check condition and attach- Cover is damaged or
ment of cover. Check for loose loose.
or missing hardware.
5. Before Air leading ducts (cooling air Inspect air leading ducts for Air leading ducts are
inlet for diesel engine) looseness, damage, or dirt. loose, damaged, or
dirty.
6. Before Fuel Cap Inspect fuel cap, chain, hard- Fuel cap is missing.
ware, and strainer for looseness
or missing parts.
Change 1 2-21
T9-6115-668-13
Table 2-4 Operator Preventive Maintenance Checks and Services-continued.

UNIT HOOD ASSEMBLY
continued
7. Before Hood Check hood for damage. Check
for loose or missing hardware.
8. Before Eyebolts Check that eyebolts are proper- Eyebolts cannot be
ly attached, in good condition, secured to base.
and have cotter pins.
9. Before Lifting rings Check four lifting rings for
looseness or damage.
10. Before Base frame Check base frame for damage. Base frame is dam-
aged beyond repair.
11. Before Silencer assembly Check silencer assembly for Silencer assembly is
(diesel engine) leaks, corrosion, damage, or leaking or hardware
missing hardware. missing.
12. Before Gas exhaust endpip (en- Inspect for looseness or dam- Gas exhaust endpip
gine preheating asembly) age. Check for loose or missing is loose or damaged.
hardware.
13. Before Bolt connecting ground Check that bolt is firmly at- Bolt is loose or fas-
cable from EPP III tached and all fastener parts tener parts are miss-
are present (one nut and three ing.
washers).
ENGINE COMPARTMENT
14. Before Diesel engine Check diesel engine for loose, Any fuel leaks Or
damaged. missing parts and class Ill oil leak.
hardware and any unusual
wear, deterioration, or leaks.
15. Before Oil filter Inspect oil filter for leaks, loose- Class Ill oil leak
ness, or damage.
16. Before Subcurrent filter Inspect subcurrent filter for Class Ill oil leak
Ieaks, loose, or damage parts.
17. Before Oil cooler and cylinder cool- Check oil cooler and cylinder Class Ill oil leak.
ing fins cooling fins for dust buildup or
Off leaks.
2-22
TM 9-6116-668-13
tern Location Not Fully Mission
ENGINE COMPARTMENT-
continued
18 Before Scavenge pump Inspect scavenge pump for leaks or Class III oil leak.
loose, damaged, or missing parts. Loose, damaged, or
missing parts.
19 Before Supply air duct (cooling air in- Inspect supply air duct for loose- Supply air duct is
let for diesel engine) ness, damage, or dirt. clogged.
20 Before Slave receptacle Inspect slave receptacle, and Slave receptacle

protective cover for looseness, connector is dam-
damage, or corrosion. aged.
21 Before Oil level Check diesel engine oil level (check Oil level is below
cold oil level dots on dipstick). required level.
22 Before Fuel prefilter and two step a. Inspect fuel prefilter and two Any fuel leaks.
fuel filter step fuel filter for leaks, loose
or damaged parts.
b. Drain condensation from fuel Diesel engine runs

prefilter. roughly after starting
because condensa-
tion water has col-
1. Open flap (1). lected.
CAUTION
Place collection container under fuel
prefilter and two step fuel filter.
2. Hold small container below

filter cup (3) of fuel prefilter (2).
3. Remove drain plug (4) until

mixture of fuel and condensa-
tion water emerges from drain
plug hole.
4. When only fuel emerges,

screw drain plug (4) back in.
5. Tighten drain plug (4).
2-23
TM 9-6115-668-13
ENGINE COMPARTMENT-
continued
c. Drain condensation from two Diesel engine runs
step fuel filter. roughly after starting
because condensation
1. Hold small container under
water has collected.
right filter cup (5) and left filter
cup (8) of two step fuel filter (9).
2. Remove drain plugs (6, 7) un-
til mixture of fuel and condensa-
tion water emerges from drain
plug holes.
3. When only fuel emerges,
screw drain plugs (6, 7) back in
one after another.
4. Tighten drain plugs (6, 7).
CAUTION
Remove collection container.
5. Close flap (1).
2-24
TM 9-6115-668-13
ENGINE COMPARTMENT-
continued
23 Before Battery charging alternator Check battery charging alternator for Loose, damaged, or
loose, damaged, or missing parts. missing parts.
24 Before V belts Inspect V belts for cracks, fraying and V belt(s) is (are)
looseness. frayed or broken.
25 Before Flame Glowplug System Check that fuel line and cables are Any fuel leak, loose,
firmly attached to both flame glow- damaged, or missing
plugs. fuel lines.
26 Before Heating unit and heat Check that heating unit and heat ex- If box is loose or any
exchanger changer box are firmly attached to damaged, loose or
mounting plate; and check for loose, missing hardware.
missing, or damaged hardware.
27 Before Air hoses Check that air hoses between heating Air hoses are loose or
unit and heat exchanger box, and be- damaged.
tween heat exchanger box and diesel
engine are firmly attached and un-
damaged.
28 Before Air hose Check that air hose above oil hose is Air hoses are loose or
firmly attached to heat exchanger damaged.
housing and undamaged.
29 Before Air pipe inlet Check that air pipe inlet is firmly at- Air pipe inlet points in
tached to heating unit, and points to- the other direction.
ward the terminal box.
30 Before Gas exhaust manifold Check that gas exhaust manifold is Gas exhaust manifold
firmly attached to heating unit, and is is not connected to
properly connected and aligned with gas exhaust inter-
gas exhaust intermediate pipe. mediate pipe.
31 Before Gas exhaust intermediate Check that gas exhaust intermediate Gas exhaust inter-
pipe pipe is firmly attached to base frame. mediate pipe is loose.
32 Before Fuel pipes Check that both fuel pipes are firmly Fuel pipes loose or
attached to heating unit with no leaks. damaged. Any fuel
leak.
2-25
TM 9-6115-668-13
ENGINE COMPARTMENT-
continued
33 Before Oil hoses Check that both oil hoses are firmly Oil hoses are loose or
attached to diesel engine oil sump damaged.
with no leaks.
34 Before Plastic lever Check that plastic lever on heating Plastic lever is not all
unit terminal box is all the way to the the way to the left.
left, and is caged.
35 Before Ground strap Inspect ground strap and ground Ground strap is loose
strap connections to heating unit and or damaged.
base frame.
36 Before Control cable Check that control cable is firmly con- Control cable is loose
nected to connector on terminal box, or damaged.
and is not damaged. Check labeling
of J102.
37 Before Connector X103 Check that connector X103 is prop- Connector is loose or
erly assembled and not damaged. damaged.
Check labeling of X103.
38 Before Connector X106 Check that connector X106 is Jumper is missing.

bridged. Check labeling of X106.
39 Before Cable, glowplug Check that cable is firmly connected Cable is loose or
to glowplug and is undamaged. damaged.
40 Before Cable, temperature switch Check that cable is firmly attached to Cable is loose or
(burner monitor) temperature switch (burner monitor) damaged.
and is undamaged. Check labeling of
X109.
41 Before Cable, temperature switch Check that cable is firmly attached to Cable is loose or
(overtemperature) temperature switch (over-temperature) damaged.
and is undamaged. Check labeling of
X110.
42 Before Switches, temperature (oil) Check that cable is firmly attached to Cable is loose or
temperature switch (oil) and is undamaged.
damaged. Check labeling of X104.
2-26
TM 9-6115-668-13
Table 24 Operator Preventive Maintenance Checks and Services-continued.

ENGINE COMPARTMFNT -
continued
43. Before Air flap Check that air flap moves easily Air flap does not mow
and closes automatically. smoothly.
44. Before Air flap puller magnet Check that cable is firmly at Cable is loose or dam,
tached to air flap puller magnet aged.
and is undamaged. Check label.
ing of J104.
GENERATOR COMPART-
MENT
45. Before Fuel Fill Hose Check that hose is firmly at- Cracked hose, broken
tached to fuel tank and fuel filler clamps or fuel leak.
neck. Check hose clamps.
46. Before Battery Set Check that batteries and connec- Batteries or connec-
tors are secure. tors are missing.
47. Before Air cooling inlet grate Inspect air coling inlet grate for Air cooling inlet grate
looseness, damage, or dirt. is clogged.
High voltage is produced

when this Generator Set
150kW is in operation could re
sult in personal injury or
death.
48. During Front panel door Check condition and operation of Front panel door can-
front panel door. not be opened.
19. During Control cabinet assembly a. Check all indicators and Indicators or controls
controls for damaged or are damaged or miss-
missing parts. ing.
b. Check that designation
plates are firmly attached
and readable.
c. Check that all lamps and in-
dicators operate properly.
Change 1 2-27
TM 9-6115-668-13

No. Interval item to Check/Service Procedure Capable I:
GENERATOR COMPART-
MENT
50. Wing READY TO START IF HEAT- Check that at READY TO START READY TO START IF.
ING IS ON lamp IF HEATING IS ON lamp on con- HEATING IS ON lamp
trol cabinet assembly lights up af- does not light.
ter approximately 13 minutes.
51. During CONTROL CABINET AS- Check that control cabinet as-
SEMBLY plate sembly plate is firmly attached
and readable.
52. During Receptacles Inspect receptacles for loose- Receptacles are

ness or damage. Check that des- loose or damaged.
ignation plates are firmly at-
tached and readable.
53. During Exhaust Check that exhaust is soot free Exhaust is not soot
after approximately 5 minute free.
warmup.
54. During Synchronous generator Check synchronous generator Parts are loose or
for loose or damaged parts. damaged.
55. During Output plate Check that output plate is firmly

atached and readable.
56. During Exciter hood Inspect exciter hood for dirt build- Exciter hood is dirty.
up.
57. During Fuel tank Inspect fuel tank for leaks, loose Any fuel leaks, loose
or damaged parts. or damaged parts.
58. During Fuel tank assembly plate Check that fuel tank assembly
plate is firmly attached and read-
able.
59. During Electrical fuel pump Check that electrical fuel pump is Electrical fuel pump is
firmly attached, and that cable is loose, or control cable
firmly connected to electrical fuel is loose or damaged.
pump. Any fuel leak.
60. During Electrical fuel pump and tank Inspect fuel hose connections to Fuel hose is loose or
hose electrical fuel pump and fuel damaged. Any fuel
tank. leak.
61. During Electrical fuel pump and valve Inspect fuel hose and connec- Fuel hose is loose or
hose tions to electrical fuel pump and damaged. Any fuel
valve. leak.
2-28

No. Interval Item 10 Check/Service Procedure Capable if:
GENERATOR COMPART-
MENT
62. During Air filter and piping Inspect air filter and piping for Piping or connections
loose or damaged connections. are loose.
63. During Dust collector Check dust collector for dust Piping or connections
buildup. Dust collector is filled
with dust.
64. During Cable connection to mainte- Inspect cable connection to Cable is loose or dam-
nance switch maintenance switch. aged.
65. During Battery Set Inspect battery cables and con- Battery cables are
nectors for corrosion, loose, loose, damaged or
damaged or missing parts. missing.
Pages 2 - 30 through 2 - 33 have been deleted.
Change 1 2-29/(2-30 blank)

TM 9-6115-668-13
ENGINE COMPART-
MENT-
continued
81 After Subcurrent filter inspect subcurrent filter for leaks, Class III oil leak.
loose, or damage parts.
82 After Oil cooler and cylinder Check oil cooler and cylinder cooling Class III oil leak.
cooling fins fins for dust buildup or oil leaks.
83 After Scavenge pump Inspect scavenge pump for leaks or Class III oil leak.
loose, damaged, or missing parts. Loose, damaged, or
missing parts.
84 After Supply air duct (cooling air in- Inspect supply air duct for looseness, Supply air duct is
let for diesel engine) damage, or dirt. clogged.
85 After Slave receptacle Inspect slave receptacle, and protec- Slave receptacle
tive cover for looseness, damage, or connector is dam-
corrosion. aged.
86 After Oil level Check diesel engine oil level (check Oil level is below
cold oil level dots on dipstick). required level.
87 After Fuel prefilter and two step Inspect fuel prefilter and two step fuel Any fuel leaks.
fuel filter filter for leaks, loose or damaged
parts.
88 After Battery charging alternator Check battery charging alternator for Loose, damaged, or
loose, damaged, or missing parts. missing parts.
89 After V belts Inspect V belts for cracks, fraying and V belt(s) is (are)
looseness. frayed or broken.
90 After Flame Glowplug System Check that fuel line and cables are Any fuel leak, loose,
firmly attached to both flame glow- damaged, or missing
plugs. fuel lines.
91 After Heating unit and heat Check that heating unit and heat ex- If box is loose or any
exchanger changer box are firmly attached to damaged, loose or
mounting plate; and check for loose, missing hardware.
missing, or damaged hardware.
2-31
TM 9-6115-668-13
ENGINE COMPARTMENT-
continued
92 After Air hoses Check that air hoses between heat- Air hoses are loose or
ing unit and heat exchanger box, and damaged.
between heat exchanger box and
diesel engine are firmly attached and
undamaged.
93 After Air hose Check that air hose above oil hose is Air hose is loose or
firmly attached to heat exchanger damaged.
housing and undamaged.
94 After Air pipe inlet Check that air pipe inlet is firmly at- Air pipe inlet points in
tached to heating unit, and points to- the other direction.
ward the terminal box.
95 After Gas exhaust manifold Check that gas exhaust manifold is Gas exhaust manifold
firmly attached to heating unit, and is is not connected to
properly connected and aligned with gas exhaust inter-
gas exhaust intermediate pipe. mediate pipe.
96 After Gas exhaust intermediate Check that gas exhaust intermediate Gas exhaust inter-
pipe pipe is firmly attached to base frame. mediate pipe is loose.
97 After Fuel pipes Check that both fuel pipes are firmly Fuel pipes loose or
attached to heating unit with no damaged. Any fuel
leaks. leak.
98 After Oil hoses Check that both oil hoses are firmly Oil hoses are loose or
attached to diesel engine oil sump damaged.
with no leaks.
99 After Plastic lever Check that plastic lever on heating Plastic lever is not all
unit terminal box is all the way to the the way to the left.
left, and is caged.
100 After Ground strap Inspect ground strap and ground Ground strap is loose
strap connections to heating unit and or damaged.
base frame.
101 After Control cable Check that control cable is firmly Control cable is loose
connected to connector on terminal or damaged.
box, and is not damaged. Check
labeling of J102.
102 After Connector X103 Check that connector X13 is prop- Connector is loose or
erly assembled and not damaged. damaged.
2-32
TM 9-6115-668-13
Section III. OPERATION UNDER USUAL CONDITIONS
2.3 INITIAL ADJUSTMENTS, CHECKS, AND SELF TEST.
2.3.1 Initial AdjustmentS.
The Generator Set 150 kW requires no initial adjustments.
2.3.2 Checks and self test.
2.3.2.1 Control Cabinet Assembly Lamp Test.
Before operating the unit: perform steps a through d.

During operation of the unit: perform step d.
1. Preparation:
Open flap (1, figure 2-6) and set MASTER SWITCH (10) to ON.
a. Turn PANEL DIMMER switch/potentiometer (8) all the way to the right.
b. The following lamps must light up:
The three front panel lights (2)
BATTERY CHARGING CONTROL (3) and OIL PRESSURE (4)
c. The following meters must be illuminated:
OIL TEMPERATURE (5), OIL PRESSURE (6), and FUEL LEVEL (7)
d. Pressure LAMP TEST pushbutton (9):
All lamps on front panel must light up.
e. If any lamp fails to light, refer to the next higher level of maintenance.
2.3.2.2 Cabinet Light
1. Proceed as follows to test the light installed in the cabinet:

a. Remove the key from the left side of the front panel and using the key turn the four front panel quick-release
fasteners to the right to unlock them.
b. Open the front panel to the right, set the front panel prop to keep the panel open and check that the light installed
in the cabinet lights up.
c. If lamp fails to light, refer to the next higher level of maintenance.
d. Close the front panel and turn the four front panel quick-release fasteners to the left to secure them. Return key
to holder.
e. Close flap (1, figure 2-6).
(2-33 blank)/2-34 Change 1

TM 9-6115-668-13
Figure 2-6 Control Cabinet Assembly Lamp Test.
2-35
TM 9-6115-668-13
2.3.2.3 Replace Diesel Engine Oil.
1. Open flap (1, figure 2-7) and flap (1, figure 2-8).
NOTE
l Prepare a container to collect approximately 5.28 gallons (20 liters)
of used oil.
l Start diesel engine (paragraph 2.5.1) and allow to reach operating
temperature; then shut down diesel engine (paragraph 2.5.2).
l Diesel engine must be on level surface during oil change.
2. Undo velcro strap (2, figure 2-7) and uncoil hose (3); open stopcocks (4, 5) and insert hose (3) into
oil collection container.
3. Use scavenge pump (6) to pump used oil from diesel engine (7) into collection container.
4. Close stopcocks (4, 5), coil up hose (3) and secure with Velcro strap (2).
5. Unscrew oil cap (2, figure 2-8) from oil filler neck (3).
CAUTION
l Refer to paragraph 2.3.3 to determine proper engine oil for operat-

ing conditions.
l Use a cloth to catch any oil overflows.
6. Place funnel in oil filler neck (3) and add new oil to the upper dot marking (5): approximately 5.28
gallons (20 liters).
7. Screw oil cap (2) onto oil filler neck (3).
8. Start diesel engine (paragraph 2.5.1) and allow to reach operating temperature; then shut down en-
gine (paragraph 2.5.2).
9. Check oil level (paragraph 2.3.2.4 or 2.3.2.5) and correct as necessary.
10. Close flap (1).
2-36
TM 9-6115-668-13
2.3.2.4 Check Diesel Engine Oil Level after Engine Shutdown.
Shut down Gen Set 150 kW, paragraph 2.5.2.
NOTE
Diesel engine oil must be checked on level surface.
1. Open flap (1, figure 2-8).

2. Remove dipstick (4) from tube and wipe off with cloth (item 3, Appendix E).
NOTE
1-2 minutes after engine Is shut off, oil level must reach to top line
marking (8) on dipstick.
3. Insert dipstick (4) into tube until it stops: pull out and read oil level.
CAUTION
If oil level comes only to lower line (7), immediately add oil of the same
specification.
4. Insert dipstick (4) back into tube until it stops.

5. Unscrew oil cap (2) from oil filler neck (3).
CAUTION
l Do not mix oils of different specifications.

l Check oil level repeatedly while adding; do
not go above upper line marking (8).
6. Place funnel in oil filler neck (3) and add oil of correct specification for the engine, paragraph 2.3.3.
7. Remove funnel from oil filler neck (3) and screw on oil cap (2).
8. Close flap (1).
2-37
TM 9-6115-668-13
2.3.2.5 Check Diesel Engine Oil Level before starting engine.
Shut down Gen Set 150 kW, paragraph 2.5.2.
NOTE
Diesel engine oil must be checked on level surface.

2. Remove dipstick (4) from tube and wipe off with cloth (item 3, Appendix E).
NOTE
Oil level must come up to upper dot marking (5).
3. Insert dipstick (4) into tube until it stops, then remove and read off oil level.
CAUTION
If the oil level reaches only to lower dot marking (6), immediately add
oil of the same specification.
4. Insert dipstick (4) back into tube until it stops.

5. Unscrew oil cap (2) from oil filler neck (3).
CAUTION
l Do not mix oils of different specifications.
l Check oil level repeatedly while adding; do

not go above upper dot marking (5).
6. Place funnel in oil filler neck (3) and add oil of correct specification for the engine, paragraph 2.3.3.
7. Remove funnel from oil filler neck (3) and screw on cap (2).
8. Close flap (1).
2-38
TM 9-6115-663-13
Figure 2-7 Diesel Engine Oil Removal Maintenance.
Change 1 2-39
TM 9-6115-668-13
Figure 2-8 Diesel Engine oil Level Maintenance.
2-40 Change 1
TM 9-6115-666-13
2.3.3 Engine Oil.
CAUTION
KHD warranty for the diesel engine will be void if oils listed in table 2-5 are not used.
2.3.3.1 Oil Quality.

As an internal combustion engine operates, some of the engine oil used to lubricate the cylinders is also
burned. Temperature stress and fuel combustion products entering the oil also cause deterioration of the
oil, especially its chemical additives, As a result all of the oil must periodically be replaced with fresh oil.
The oil manufacturer provides the only guarantee of the quality grade to which an oil belongs. Oil quality
is partly defined by API classes: CC/SE or CD/SE 1) (paragraph 2.3.3.3).
If the only quality information available is from MIL-specifications, proceed as follows:
MIL-L-2104C, added at the same time as MIL-L-46125A, corresponds to API: CD/SE.
SHPD oils 2, (paragraph 2.3.3.3) are approved individually by the engine manufacturer.
Table 2-5 SHPD Oils Approved for Diesel Engine BF8L513.
Oil Company Brand of Oil
Agip Sigma Turbo
Caltex RPM DELO 450 Oil
Chevron Chevron Delo 450 Motor Oil Multigrade
Esso DIESEL MOTOR OIL 500
Gulf Gulf Turbo Diesel
Valvoline Valvoline Super HDS LD
Veedol Veedol Turbostar
2.3.3.2 Oil Viscosity.
Because the viscosity of an oil changes with temperature, the ambient temperature at the operating loca-
tion of the diesel engine is a critical factor in selecting the viscosity class (SAE class) (figure 2-9).
If SAE 15W-40 is used, occasional temperatures slightly lower than the limit (e.g. down to 5 °F (-15° C))
may impair cold-starting ability but will not cause engine damage
Excessively viscous oil leads to difficulties in starting, which is why temperature during engine starting is
the essential factor in selecting a viscosity for winter operation. The use of multigrade oils eliminates the
need for temperature-related oil changes. Multigrade oils are subject to the same oil change intervals as
single-grade oils.
2-41
TM 9-6115-668-13
* with engine preheating only
Figure 2-9 Viscosity Class (SAE C/ass).
NOTE
> Greater than

< Less than
≥ Greater than or equal to
≤ Less than or equal to
In addition to the possibilities listed in paragraph 2.3.3.1 and 2.3.3.2, it is recommended that SAE
15W-40 (item 1, appendix E) be used when average ambient temperatures are ≤ 32 °F ( ≥ 0 °C), and
SAE 5W-30 (item 2, appendix E) when average temperatures are ≤ 32 °F (≤ 0 °C).
2.3.3.3 Oil Change Intervals.
Since oil deterioration depends on operating conditions, fuel quality, and oil quality, oil change intervals
can vary. Table 2-6 indicates oil change intervals in operating hours (OH). Factors affecting these intervals
include:
l Oil quality
l Sulfur content of the diesel fuel

l Outside temperature (daily average)
NOTE
Use HOURMETER to determine operating hours.
2-42
TM 9-6115-668-13
Table 2-6 Oil change intervals.
Continuous operation at outside temperature

(daily average)
0.5 . . . 1 % <14 °F or >86 °F (≤ 10° C or >30° C)
CD/SE 1) 0.5 . . . 1 % >14 °F or <86 °F (≥ 10° C or <30° C)
<0.5 % >14 °F or <86 °F (≥ 10° C or <30° C)
125 0.5 . . . 1 % <14 °F or >86 °F (≤ 10° C or >30° C)

2)
250 SHPD 0.5 . . . 1 % >14 °F or <86 °F (≥ 10° C or <30° C)
500 <0.5 % >14 °F or <86 °F (≥ 10° C or <30° C)
If a higher grade oil is used after a long period of operation, perform the first change of the higher grade
oil at 20 operating hours. At the same time, change the oil filter as described in chapter 4.
2.3.4 Fuel SUpply.
2.3.4.1 Fuel Quality.
Do not use diesel fuel with a sulfur content greater than 1%. At temperatures below 32 °F (0° C) use only
winter diesel fuel with the appropriate additive or flow improver.
2.3.4.2 Refueling.
The Generator Set 150 kW tank has a capacity of 101.7 gallons (385 liters) of diesel fuel, including re-
serve. It can be filled with the fuel pump, a fueling nozzle, or a canister.
WARNING
The fuel in this Generator Set 150 kW is highly explosive. Do not

smoke or use open flame when performing maintenance. Fire and ex-
plosion could occur, resulting in severe personal injury or death.
CAUTION
The fuel pump must always be delivering diesel fuel during operation;
it will be damaged if it is allowed to run dry.
NOTE
If the LOW FUEL lamp (5, figure 2-10) lights up during operation, re-
2-43
TM 9-6115-668-13
fuel. If refueling is not performed In time, the fuel system will draw In
air and must be bled (table 2-4).
2.3.4.2.1 Refueling with the Fuel Pump.
1. Open flaps (1 and 4, figure 2-10) and turn MASTER SWITCH (9) ON.
2. Uncoil fuel hose (2) from its holder on the tank, and immerse the lower end in the storage tank.
3. Press FUEL TANK PUMP ON illuminated pushbutton switch (7):
Fuel pump delivers diesel fuel (refueling an empty tank takes approximately 18 minutes).
4. After the required amount of diesel fuel has been added, press FUEL TANK PUMP OFF pushbut-
ton switch (8) or wait until fuel tank pump automatically turns off when tank is full.
5. Remove the fuel hose from the storage tank, dry it off, and coil it onto the holder.
2.3.4.2.2 Refueling with a Fueling Nozzle or Canister.
1. Open flap (4, figure 2-10) and turn MASTER SWITCH (9) ON
2. Unscrew tank cap (3).
3. Insert fueling nozzle into the filler opening and begin fuel delivery; or insert a funnel into the filler
opening and fill the tank from a canister.
4. Have a second person monitor and call out the fuel level from the FUEL LEVEL meter (6).
5. Stop delivering fuel when the tank is full, and screw the tank cap back on.
2-44
TM 9-6115-668-13
Figure 2-10 Refueling.
Change 1 2-45
TM 9-6115-668-13
2.3.5 Installation Instructions.

2.3.5.1 Connect Battery Cable.
Below 32 °F (0 °C) the battery sets of two Generator Sets 150kW can be connected in parallel to increase capacity;
below -22 °F (-30 °C) the battery sets must be connected in parallel. The battery cable is used to connect the two sets
a. Connect battery cable as follows:
‘(1) Remove protective cap (1, figure 2-11) from J3 SLAVE RECEPTACLE 24 VOLTS.
(2) Connect battery cable (2) to the J3 SLAVE RECEPTACLE 24 VOLTS of each Generator Set 150 kW.
Figure 2-11 Connect Battery Cable.
2-46
TM 9-6115-668-13
2.3.6 Connecting Control and Power Cables
WARNING
Potential 208 VAC shock hazard. Do not disconnect or connect control or power cables while
Generator Set 1 or 2 is running.
Always install protective covers on control and power cables when cables are
disconnected. Failure to observe this warning could result In severe personal-
Injury or death by electrocution.
The Generator Set 150 kW is connected to the EPP III by one control cable and four power cables. At the EPP III, the
cables are permanently connected to the power distribution unit. At the Generator Set 150 kW, the cables are coupled
to receptacles on the control cabinet assembly.
a. Connect control cable as follows:

(1) Remove protective cap (1, figure 2-1 2) from control cable connector.
(2) Remove protective cap (2) from J9 PARALLEL OPERATION receptacle.
(3) Insert control cable into J9 PARALLEL OPERATION receptacle and tighten threaded coupling.
NOTE
The locking switches for receptacles L1 (ØA), L2 (ØB), L3 (ØC) and N cannot be
closed unless the cable connector threaded couplings have been propperly
tightened.
b. Connect control cables as follows:

(1) Remove protective covers (11). (12), (13), and (14) from power cable connectors L1, L2, L3 and N.
(2) Insert power cable L1 (3, figure 2-12) into L1 (ØA) receptacle (4) and tighten threaded coupling.
(3) Insert power cable L2 (5) into L2 (ØB) receptacle (6) and tighten threaded coupling.
(4) Insert power cable L3 (7) into L3 (ØC) receptacle (8) and tighten threaded coupling.
(5) Insert power cable N (9) into N receptacle (10) and tighten threaded coupling.
Change 1 2-47
TM 9-6116-668-13
Figure 2-12 Connecting Control and Power Cables.
2-48 Change 1
TM 9-6115-668-13
2.4 DECALS AND INSTRUCTION PLATES.
NSN: 6115-1 2-337-8494

ELECTRICAL GENERATOR
150 KW/400 HZ
TKZ: 010.04.0037
SERIAL NO. XXXXXX
TECH. MANUAL: TM 9-6115-668-13
Figure 2-13 Generator Set 150 kW Identification Plate.
X: - - - in.
Y: - - - in.
Z: - - - in.
Figure 2-14 Generator Set 150 kW CG Plate.
OPERATIONAL WEIGHT: 6608 pounds

SHIPPING WEIGHT: 8139 pounds
LENGTH: 124 in.
WIDTH: 79.5 in.
HEIGHT: 79.5 in.
Figure 2-15 Generator Set 150 kW Transportation Data Plate.
2-49
TM 9-6115-668-13
SHORT OPERATING INSTRUCTIONS
EG 150KW / EPP 2 x 150KW / 400HZ, 120/208V
NSN:
Ambient temperature <-30°C.

1. Connect external battery to external starting plug socket.
2. Switch on the cold-start heater - push the HEATING ON button.
NOTE
If HEATING FAILURE lamp lights up, first push
HEATING OFF button, then turn on cold-start heater again.
3. Wait for READY TO START lamp to light up (approx. 25 minutes), then
start the engine.
NOTE
For extended engine service life, always use the cold-start heater
whenever ambient temperature is less than -10 °C.
4. WARNING: Always wear gloves!
During engine start, a second person must pull the actuator lever as far as
it will go.
LECHMOTOREN
Lechmotoren GmbH
Südl. Römerstr. 12-16 * D-86972 Altenstadt/Schongau, Germany
Telephone: +49 (8861) 710-0 * Telex: 59717
Telefax: +49 (8861) 710-180/-181
Figure 2-16 Engine Preheating Plate.
2-50
TM 9-6115-668-13
SHORT OPERATING INSTRUCTIONS
EG 150KW / EPP 2 x 150KW / 400Hz,120/208V

NSN:
Preparation
1. Check all cable connections between EPP and power distribution unit (PDU).
2. Connect EPP to ground.
3. Connect potential equalization cables to PDU and to the load.
4. Connect exhaust hoses.
5. Perform a visual check of the engine and generator.
6. Check oil level and top up to maximum if required.
7. Turn MASTER SWITCH to ON.
8. Perform lamp test.
9. Check fuel level and top up if necessary.
10. Check gauges and meters.
11. Uncoil and connect power supply and control cables.
Starting the generator

Ambient temperature >0 ° C
Turn GLOWPLUGSTART switch to the far right position, and hold (max. 30
seconds) until
engine is running.
Ambient temperature between 0 ° C and -30 ° C

Turn GLOWPLUGSTART switch to center position and hold until GLOWPLUG ON l
amp lights up
(approx. 90 sec.); then turn GLOWPLUGSTART switch to extreme
right position until engine is running.
Function Check
After starting the unit
1. All fault indicators must be OFF.
2. Hourmeter is ON.
3. Oil pressure indication must be within the range of 3 - 5 bar.
30 sec. after the unit is running

1. Check the frequency indication (400 Hz).
2. Check output voltage by using the voltage selector switch.
L1 -N; L2-N; L3-N = 120 V
L1 42; L2-L3; L3-L1 = 208 V
Figure 2-17 Generator Set 150 kW Short Operating Instructions Plate (sheet 1 of 2).
2 - 51
TM 9-6115-668-13
LECHMOTOREN
Lechmotoren GmbH
Südl. Römerstr. 12-16 * D-86972 Altenstadt/Schongau,
Germany
Telephone: +49 (8861) 710-0 * Telex: 59717
Telefax: +49 (8861) 710-180/-181
Switching on Generator Output (AC Circuit)
Press AC CIRCUIT lNTERUPTER ON pushbutton switch.
Parallel Operation (EPP)

1. Start one of the Generator Sets 150 kW and perform Function Check; press
AC CIRCUIT INTERRUPTER ON pushbutton switch.
2. Start second Generator Set 150 kW and perform Function Check.
3. Compare output voltages and frequency values for the two Generator Sets
150 kW.
(max. frequency deviation < 0,2 Hz)
(max. voltage deviation < 2 V)
4. Press SYNCHRONIZATION ON pushbutton switch.
(Generator Sets 150 kW will be automatically synchronized.)
Synchronization of the two Generator Sets 150 kW is complete when AC
CIRCUIT INTERRUPTER ON lamp lights up.
AMPS and KILOWATT meter readings for the two Generator Sets 150 kW
must be almost identical.
(max. KILOWATT difference < 20 kW)
(max. AMPS difference < 40 A)
6. If actual differences exceed the allowable range, press AC CIRCUIT I
NTERRUPTER OFF
pushbutton switch and recheck frequency and voltage settings (item 3) for the
Generator Sets
150 kW.
Power Distribution Unit (PDU)
After switching ON the EPP AC circuit, the PDU will be supplied with
control voltage and 400 Hz voltage.
Perform the lamp test.
If RS is switched ON, output indicators J1, J2, and J3 are on.
If ECS is switched ON, output indicator J4 is on.
Converter Operation
Preparation
1. Connect EPP to ground.
2. Connect all power supply cables and control cables between converter
control cabinet and PDU.
3. See converter operating instructions for subsequent procedures.
Figure 2-17 Generator Set 150 kW Short Instructions P/ate (sheet 2 of 2).
2 - 52
TM 9-6115-668-13
2.5 OPERATING PROCEDURES.
2.51 Operating the Generator Set 150 k.W
WARNING
Do not operate Generator Set 150 kW unless it is properly grounded and all load
teeminals are not shorted. Failure to observe this warning can result in severe
personal Injury or death.
CAUTION
Before starting the Generator Set, note the ambient temperature and refer to
figs. 2-16 and 2-17 as applicable. Do not use Glow Plug/ Start procedures when
temperatures are above 32°F. Use Glow Plug/ Start procedures when tempera-
tures are below 32° F, -0° C and -12° F, - 30° C. Use Engine Pre-start procedures
when temperatures are below -12’ F, -32’ C.
NOTE
Before operating Generator Set 150 kW, all connections must be made to the
PDU. See also 150 kW Short operating Instructions plate (figure 2-17).
If the diesel engine does not run smoothly or emits dense whitish gray-smoke,
set the GLOWPLUG/START rotary switch (19) back to GLOWPLUG and repeat
the glowplug procedure (maximum duration: 3 minutes).
2.5.1.1 Starting the Diesel Engine and Synchronous Generator.

a. Open flap (1, figure 2-18) and turn MASTER SWITCH (21) to ON
b. Turn GLOWPLUG/START rotary switch (19) to START and hold:
Diesel engine must start and begin accelerating within 20 seconds.
BATTERY CHARGING CONTROL and OIL PRESSURE lamps (5 and 7) go out 2-3 seconds after engine starts.
If the diesel engine does not start within 20 seconds, wait approximately 30 seconds and repeat the starting procedure.
c. Troubleshoot using figure 4-9 if the diesel engine does not start.
NOTE
The synchronous generator is activated In approximately 90 seconds.
Change 1 2-53
TM 9-6115-668-13
NOTE
If the diesel engine or the synchronous generator malfunctions during opera-
tion, the main contactor K1 or Generator Set 160 kW will shut down.
d. Read OIL PRESSURE meter (11, figure 2-18): 3 - 5 bars.

e. Troubleshoot using figure 3-4 if oil pressure is too low or no oil pressure is indicated.
f. Read BATTERY CHARGE meter (22): 10 - 66 A.
g. Troubleshoot using figure 4-11 if battery set is not being charged or no charging current is indicated.
h. Read FREQUENCY meter (8): 400.0 ± 0.0.2 Hz if reading is different, set frequency with the FREQUENCY
ADJUST potentiometer (13) and lock in place with locking lever (12).
i. Troubleshoot using figure 3-5 if frequency cannot be adjusted or no frequency is indicated.
j. Set VOLTAGE SELECTOR SWITCH (17) to L1 -L2, then L2-L3, then L3-L1+. and read VOLTAGE meter (6): 208
±2 V. If reading is different, set voltage with the VOLTAGE ADJUST potentiometer (16) and lock in place with
locking lever (15).
k. Troubleshoot using figure 3-6 if voltage cannot be adjusted or no voltage is indicated.
I. Set VOLTAGE SELECTOR SWITCH (17) to L1-N, then L2-N, then L3-N, and check VOLTAGE meter (6): 120 ± 1
V.
m. At temperatures below 32 °F (0 °C), allow the diesel engine to warm up for approximately 10 minutes before
actuating the AC ClRCUIT INTERRUPTER ON illuminated pushbutton switch (14).
2.5.1.2 Switching Voltage to the Control Cabinet Assembly Receptacles.

a. Press AC CIRCUIT INTERRUPTER ON illuminated pushbutton switch (14, figure 2-18):
AC CIRCUIT INTERRUPTOR ON lamp (14) lights up.
Power system (main contactor K1) is turned on.
b. Troubleshoot using figure 3-7 if AC CIRCUIT INTERRUPTER ON lamp does not light up.
NOTE
Maximum difference between current readings: <40 A.
c. Read AMPS L1 (ØA), AMPS L2 (ØB), and AMPS L3 (ØC) meters (2,3, and 4): 0 - 600 A.
d. Troubleshoot using figure 4-15 if currents are not present or are not indicated.
e. Read KILOWATTS meter (22): 0 - 206 kW.
f. Troubleshoot using figure 4-16 if no power is being indicated.
2-54 Change 1
TM 9-6115-668-13
CAUTION
if the fuel tank is ran completly empty, the fuel system will draw in air
and will need to be bled (table 2-4).
g. Add fuel (paragraph 2.3.4) if the LOW FUEL lamp (10) lights up.
CAUTION
Failure to service the air fliter will reduce the power output or cause
the diesel engine to overheat. This may damage cylinders or the diesel
engine itself.
h. If the AIR FILTER lamp (9) lights up, clean or replace the air filter insert (paragraph 4.29) and
empty the dust collector (paragraph 3.4). If the air filter needs replacing, refer to the next higher
level of maintenance.
Faults that will be displayed until the MASTER SWITCH is turned OFF:
OIL PRESSURE: use Chapter 3 to troubleshoot.
BATTERY CHARGING CONTROL: Refer to next higher level of maintenance.
OIL TEMP-CYLINDER HEAD: Refer to next higher level of maintenance.
UNDER/OVER VOLTAGE: Refer to next higher level of maintenance.
GENERATOR OVER TEMPERATURE: Refer to next higher level of maintenance.
UNDER/OVER FREQUENCY: Refer to next higher level of maintenance.
OVERLOAD: Refer to next higher level of maintenance.
REVERSE POWER: Refer to next higher level of maintenance.
2 - 55
TM 9-6115-668-13
Figure 2-18 Operating the Generator Set 150 kW.
2-56
TM 9-6115-668-13
2.5.2 Generator Set 150 kW Shutdown.
Open Flap (1, figure 2-19).
2.5.2.1 Normal Shutdown.

a. Press AC CIRCUIT INTERRUPTER OFF pushbutton switch (3):
Lamp in AC CIRCUIT INTERRUPTER ON illuminated pushbutton switch (2) goes out.
CAUTION
Before shutting down Generator Set 150 kW, allow It to operate for five
minutes with no load applied.
b. Turn MASTER SWITCH to OFF (4). Pull key ¼ to ½ way out from MASTER SWITCH.
c. Perform the Preventive Maintenance Checks and Services (PMCS) listed as “AFTER” in table 2-4.
Figure 2-19 Generator Set 150 kW Shutdown.
2-57
TM 9-6115-668-13
2.6 EMERGENCY PROCEDURES.
2.6.1 EMERGENCY Shutdown.
a. Remove key from MASTER SWITCH (11, figure 2-20).
2.6.2 BATTLE SHORT Operation.
2.6.2.1 Fault indication and Shutdown.
If the BATTLE SHORT switch (9, figure 2-20) is turned on during operation (BATTLE SHORT lamp (10)
lights up), the Generator Set 150 kW will not shut down if the following faults are indicated:
BATTERY CHARGING CONTROL (6),
OIL PRESSURE (7),
OIL TEMP-CYLINDER HEAD (8),
UNDER/OVER VOLTAGE (2),
GENERATOR OVER TEMPERATURE (3).
The Generator Set 150 kW will shut down if the following faults are indicated:
UNDER/OVER FREQUENCY (1),
OVERLOAD (4),
REVERSE POWER (5).
2.6.2.2 Damage to System Components.
If operation continues for long periods despite the presence of suppressed faults, system components
can be damaged or destroyed:
BATTERY CHARGING CONTROL
Insufficient charging can cause deep discharge and damage to the battery set.
OIL PRESSURE
Insufficient oil pressure can damage or destroy the diesel engine.
OIL TEMP-CYLINDER HEAD
The diesel engine can be damaged or destroyed if oil and/or cylinder head temperature is too high.
UNDER/OVER VOLTAGE
Voltages received by load units (ECS and RCS) will be too high or too low.
GENERATOR OVER TEMPERATURE
Overheating of the stator winding can damage or destroy the synchonous generator.
2 - 58
TM 9-6115-655-13
Figure 2-20 BATTLE SHORT Mode.
2-59
TM 9-6115-668-13
2.7 PREPARATION FOR MOVEMENT.
2.7.1 Shut Down Generator Set 150 kW,

Refer to paragraph 25.2
2.7.2 Disconnecting Control Power Cables.
WARNING
Potential 205 VAC shock hazard. Do not disconnect or connect control or power cables while
Generator Set 1 or 2 is running.
Always install protective covers on control and power cables when cables are disconnected.
Failure to observe this warning could result in severe personal injury or death by electrocution.
a. Disconnect control cable as follows:
(1) Unscrew control cable (2, figure 2-21) and pull out of J9 PARALLEL OPERATION receptacle.
(2) Place protective cap (1) on control cable connector.
(3) Place protective cap (3) on J9 PARALLEL OPERATION receptacle.
b. Disconnect power cable as follows:
(1) Unscrew connector (4, figure 2-21) and pull power cable L1 out of receptacle L1 (ØA).
(2) Place protective cover (8) on cable connector.
(3) Unscrew connector (5) and pull power cable L2 out of receptacle L2 (ØB).
(5) Unscrew connector (6) and pull power cable L3 out of receptacle L3 (ØC).
(7) Unscrew connector (7) and pull power cable N out of receptacle N.
2.7.3 Disconnect Battery Cable.
a. Disconnect battery cable as follows:
(1) Pull battery cable (1, figure 2-22) out of SLAVE RECEPTACLE 24 VOLTS on each Generator Set 150 kW.
(2) Place protective cap (2) on J3 SLAVE RECEPTACLE 24 VOLTS.
2.7.4 Disconnect Ground Cable.
a. Disconnect ground cable as follows:
(1) Remove nut (1, figure 2-23), serrated washer (2) washer (3), and detach ground cable (4) and washer (5)
from connector bolt (6).
(2) Install washers (2,3 and 5) and nut (1) onto bolt (6) and tighten nut (1).
2-60 Change 1
TM 9-6116-668-13
Figure 2-21 Disconnecting Control and Power Cables.
Change 1 2-61
TM 9-6116-668-13
Figure 2-22 Disconnect Battery Cable.
Figure 2-23 Disconnect Ground Cab/e.
2-62
TM 9-6115-668-13
Section IV. OPERATION UNDER UNUSUAL CONDITIONS
WARNING
Do not operate Generator Set 150 kW unless it is properly grounded
and ail load terminals are not shorted. Failure to observe this warning
can result in severe personal injury or death.
NOTE
Beforeoperating Generator Set 150 kW, all connections must be made
to the PDU. See also SEA 150 kW Short Operating Instructions plate
(figure 2-17).
2.8 OPERATING THE ENGINE PREHEATING ASSEMBLY.
The Engine Preheating Assembly can be used at 14 °F (-10 °C) or below and must be used at -22 °F (-30
° C) or below.
a. Perform the Preventive Maintenance Checks and Services (PMCS) listed as “Before” in table 2-4.
b. Open flap (1, figure 2-24) Control cabinet assembly controls and indicators are accessible.
c. Set MASTER SWITCH (8) to ON. BATTERY CHARGING CONTROL (2) and OIL PRESSURE (3)
lamps light up.
Troubleshoot using figure 3-1 if BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not
light up.
d. Press HEATING ON illuminated pushbutton switch (6):
Heating unit begins operating, and HEATING ON lamp lights up.
NOTE
The READY TO START IF HEATING IS ON lamp (4) may not light up at
temperatures above 14 ° F (-10 ° C), since the temperature switch moni-
toring the oil temperature may perform a shutdown.
e. The READY TO START IF HEATING IS ON lamp (4) lights up after about 13 minutes.
The diesel engine can be started (the fan motor will continue to run for about 90 seconds).
f. If the HEATING ON lamp lights up before the READY TO START IF HEATING IS ON lamp (4)
lights up, press the HEATING ON illuminated pushbutton switch (6) again.
g. if the diesel engine is started before the READY TO START IF HEATING IS ON lamp lights up,
shut down the heating system with the HEATING OFF pushbutton switch (7).
Troubleshoot using figure 3-2 if the HEATING FAILURE lamp (5) lights up, or if the READY TO START IF
HEATING IS ON lamp does not light up (i.e. the engine preheating assembly is not operating properly).
2 - 63
TM 9-6115-668-13
Figure 2-24 Operating the Engine Preheating Assembly.
2-64
TM 9-6115-668-13
2.9 OPERATING THE FLAME GLOWPLUG SYSTEM (BELOW 32 °F (0 °C)).
a. Perform the Preventive Maintenance Checks and Services (PMCS) listed as “Before” in table 2-4.
b. Open flap (1, figure 2-25): control cabinet assembly controls and indicators are accessible.
NOTE
The MASTER SWITCH (6) is a five position switch:
Position One - Locked and Gen Set 150 kW will not run in this position.
Position Two - Off with the key fully inserted (pushed in); Gen Set 150 kW
will run in this position but cannot be started.
Position Three - Off with the key in the half-way inserted position; this is the
“NORMAL” shut down position.
Position Four - Switch is on with key fully inserted; this is the “NORMAL” start
and run position.
P o s i t i o n F i v e - Switch is on with key inserted half way; this is the

EMERGENCY shut down position.
c. Set MASTER SWITCH (6) to ON (Position Four):

BATTERY CHARGING CONTROL (2) and OIL PRESSURE (3) lamps light up.
d. Troubleshoot using figure 3-1 if BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not
light up.
e. Turn GLOWPLUG/START rotary switch (5) to GLOWPLUG and hold:
GLOWPLUG ON lamp (4) must light up within 90 seconds.
f. Troubleshoot using figure 3-3 if GLOWPLUG ON lamp does not light up.
CAUTION
Do not turn the GLOWPLUG/START rotary switch (5) to the START

position until the GLOWPLUG ON lamp (4) lights.
Release the GLOWPLUG/START rotary switch (5) as soon as the
diesel engine is running under its own power.
g. Turn GLOWPLUG/START rotary switch (5) to START and hold:

Diesel engine must start and begin accelerating within 20 seconds.
BATTERY CHARGING CONTROL and OIL PRESSURE lamps (2, 3) go out 2-3 seconds after en-
gine starts.
If the diesel engine does not start within 20 seconds, wait approximately 30 seconds and repeat the start-
ing procedure. Troubleshoot using figure 4-9 if the diesel engine does not start.
2 - 65
TM 9-6115-668-13
Figure 2-25 Operating the Flame Glowplug System.
2 - 66
TM 9-6116-668-13
2.10 OPERATION IN EXTREME COLD (BELOW -22 °F (-30 °C))

1. Fill tank with winter diesel fuel with appropriate additive or flow improver (paragraph 2.3.4).
2. Use engine oil of the appropriate viscosity class (paragraph 2.3.3).
3. Check generator V belts: winter type is smooth.
If a toothed belt is installed, refer to the next higher level of maintenance to install proper belt.
NOTE
SW also Engine Preheating plate (figure 2-16).
4. Connect battery sets in parallel to start diesel engine (paragraph 2.351).
5. Start engine preheating assembly (paragraph 2.8).
WARNING
Failure to wear gloves when operating actuator, could result in severe personal
injury.
6. Have a second person open flap (1, figure 2-26) and pull the fuel injection pump actuator rod (2) in the direction
of the arrow.
7. Start flame glowplug system (paragraph 2.9).
8. Start diesel engine and release actuator/fuel injection pump linkage (paragraph 2.5.1.1).
9. Allow diesel engine to warm up for approximately 10 minutes.
10. Turn on power system (main contactor K1) (paragraph 2.5.1.2).
Change 1 2-67
TM 9-6115-668-13
Figure 2-26 Fuel Infection Pump Actuator Linkage.
2-68
TM 9-6115-668-13
CHAPTER 3
OPERATOR MAINTENANCE INSTRUCTIONS
Page
Subject Index
Operator Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Section I.
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Section I I. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2
Section III. Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11
3.3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.4 Air Filter Dust Collector Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 12
3-1
TM 9-6115-668-13
Section I. OPERATOR LUBRICATION
3.1 GENERAL.
Refer to appendix F and paragraph 2.3.3.
3-2
TM 9-6115-668-13
Section II. TROUBLESHOOTING
3.2 GENERAL.
The symptom index for the generator set 150 kW lists faults associated with control cabinet assembly
operation. figures 3-1 through 3-7 provide a go/no-go flowchart for each malfunction. Each malfunction
listed includes a reference to the applicable figure that contains a chart to help you determine probable
causes and corrective actions to take. The symptom index cannot list all faults that may occur, or all the
tests, inspections, and corrective actions. If a malfunction is not listed or cannot be corrected by listed
corrective actions, notify next higher level of maintenance for assistance.
SYMPTOM INDEX Troubleshooting

Procedure
BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up. . . . . . . . . . Figure 3-1
HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp

does not light u p. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... Figure 3-2
GLOWPLUG ON lamp does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-3
Oil pressure too low, or no oil pressure indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-4
Generator frequency cannot be adjusted, or no frequency indication . . . . . . . . . . . . . . . . . . . . . Figure 3-5
Generator voltage cannot be adjusted, or no voltage indication . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-6
AC CIRCUIT INTERRUPTER ON lamp does not light up. . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3-7
3-3
TM 9-6115-668-13
SHUT DOWN GENERATOR SET 150 kW

BEFORE REPLACING INDICATOR
LAMPS. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN SEVERE
PERSONAL INJURY OR DEATH.
(PARAGRAPH 4.24)
Figure 3-1 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up.
3-4
TM 9-6115-668-13

BEFORE OPENING CONTROL CABINET
ASSEMBLY. FAILURE TO OBSERVE THIS
NO In control cabinet assembly, is circuit YES

breaker F102 and/or F103 on, and is
HEATING ON illuminated
pushbutton switch pressed?
Turn on circuit breaker F102 NO

and/or F103 and press HEAT- HEATING FAILURE lamp
ING ON illuminated pushbutton on?
switch
Monitor to see whether READY NOTIFY NEXT

TO START IF HEATING IS ON HIGHER LEVEL OF
lamp or FAILURE lamp lights up MAINTENANCE
after approximately 13 minutes
Figure 3-2 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp does not
light up.
3-5
TM 9-6115-668-13

BEFORE REPLACING INDICATOR LAMP.
FAILURE TO OBSERVE THIS WARNING
COULD RESULT IN SEVERE PERSONAL
INJURY OR DEATH.
NO YES
Does GLOWPLUG ON lamp light
up when LAMP TEST pushbutton
switch is pressed?
Replace lamp NOTIFY NEXT

(PARAGRAPH 4.24) HIGHER LEVEL OF
MAINTENANCE
Figure 3-3 GLOWPLUG ON lamp does not light up.
3-6
TM 9-6115-668-13

ASSEMBLY OR CHECKING OIL LEVEL.
INJURY OR DEATH.
(Paragraph 2.3.2.4
F5
(Paragraph 2.3.2.4
or 2.3.2.5) or 2.3.2.3)
Figure 3-4 Oil pressure too low, or no oil pressure indication.
3-7
TM 9-6115-668-13

ASSEMBLY. FAILURE TO OBSERVE THIS
Figure 3-5 Generator frequency cannot be adjusted, or no frequency indication.
3-8
TM 9-6115-668-13

ASSEMBLY, FAILURE TO OBSERVE THIS
Figure 3-6 Generator voltage cannot be adjusted, or no voltage indication.
3-9
TM 9-6115-668-13

BEFORE REPLACING INDICATOR LAMP.
INJURY OR DEATH.
(PARAGRAPH 4.24)
Figure 3-7 AC CIRCUIT INTERRUPTER ON lamp does not light up.
3-10
TM 9-6115-668-13
Section III. MAINTENANCE PROCEDURES
3.3 GENERAL.
Operator maintenance procedures for the Generator Set 150 kW are described in paragraph 3.4.
3-11
TM 9-6115-668-13
3.4 AIR FILTER DUST COLLECTOR MAINTENANCE.
This task covers: a. Removal c. Service

b. Inspection d. Installation
Materials/Parts Equipment Conditions

Reference
Cloth, cleaning Generator Set 150 kW shut
(item 3, appendix E) down, paragraph 2.5.2

2. Undo clamping clips (5) and remove dust collector (2) with cover (4) from air fitter (3).
3. Remove cover (4) from dust collector (2).
1. Inspect for dust visually.
1. Empty dust collector (2).

2. Clean dust collector (2) with a cloth.
1. Place cover (4) on dust collector (2) so that holding tab (6) fits into cutout (7) in dust collector (2).
CAUTION
Note “OBEN á TOP” marking on cover.
2. Place dust collector (2) with cover (4) on air filter (3) so that marking “OBEN á TOP” arrow points up.
3. Secure clamping clips (5).
4. Close flap (1).
3-12
TM 9-6115-668-13
Figure 3-8 Air Filter Assembly Maintenance.
3-13(3-14 blank)
TM 9-6115-668-13
CHAPTER 4
UNIT MAINTENANCE INSTRUCTIONS
Subject Index Page

Diagnostic Equipment (TMDE); and Support Equipment . . . . . . . . . . . . . . . . 4-5
4.1 Common Tools and Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.2 Special Tools, TMDE, and Support Equipment. . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3 RepairParts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Section I I. Service Upon Receipt of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4 Service upon Receipt of Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.5 Installation Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.6 Preliminary Servicing and Adjustment of Equipment. . . . . . . . . . . . . . . . . . . . 4-12
Section III. Unit Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.7 Synchronous Generator Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 14
Section IV. Unit Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . 4-15
4.8 Introduction to Unit PMCS Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Section V. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.9 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 20
Section VI, Radio Interference Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 40
4.10 General Methods used to Attain Proper Suppression. . . . . . . . . . . . . . . . . . . 4 - 40

4.11 Interference Suppression Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 40
Section VII. Maintenanceprocedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 41
4.12 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 41
4.13 Unit Hood Flap Ground Strap Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 43
4.14 Unit Hood Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 45
4.15 Unit Hood - Base Frame Ground Strap Maintenance . . . . . . . . . . . . . . . . . . . 4 - 45
4.16 Supply Air Duct Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 50
4.17 Air Leading Duct Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 51
4-1
TM 9-6115-668-13
Subject Index Page

4.18 Air Cooling Inlet Grate Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 52
4.19 Cover and Case for Connection Panel Maintenance. . . . . . . . . . . . . . . . . . . . 4 - 53

4.20 Twist Grip and Lock Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
4.21 Gas-Cylinder and Prop Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 56
4.22 Flap Mount Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 57
4-23 Light Indicator Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 59
4.24 Bulb in Indicator Lamp Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 62
4.25 Bulb in Illuminated Switch Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
4.26 Replace Bulb in Panel Light H6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 66
4.27 Replace Bulb in Illuminated Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 68
4.28 Replace Bulb in Cabinet Light H7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 70
4.29 Air Fifter Cartridge Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 72
4.30 Oil Filter Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 75
4.31 Subcurrent Filter Cartridge Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 76
4.32 Fuel Prefilter Cartridge Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 78
4.33 Two Step Fuel filter Cartridge Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 80
4.34 Battery Charging Alternator V Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 83
4.35 Battery Charging Alternator V Belt Maintenance. . . . . . . . . . . . . . . . . . . . . . . . 4-84
4.36 Diesel Engine Cylinder Cooling Fins and Oil Cooler Maintenance. . . . . . . . . 4 - 87
4.37 Priming Pump Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 89
4.38 Fuel Lines and Prefilter Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . 4 - 91
4.39 Fuel Lines and Two Step Fuel Filter Assembly Maintenance . . . . . . . . . . . . . 4 - 92
4.40 Fuel Prefilter Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94
4.41 Two Step Fuel Filter Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 96
4.42 Fuel Line Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 99
4.43 Control Cabinet Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104

4.44 Pushbutton Switch and Indicator Assembly Maintenance. . . . . . . . . . . . . . . . 4- 111
4.45 Pushbutton Switch Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 114
4.46 Panel Illumination H6 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 117
4.47 Preheating Resistor R1 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 119

4.48 Battle Short Switch S21 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 121
4.49 Voltage Selector Switch S11 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-123

4.50 Glowplug/Starf Switch S2 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-125
4.51 Master Switch S1 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-126
4.52 Frequency Adjust R4 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-128
4-2
TM 9-6115-668-13
Subject Index Page

4.53 Voltage Adjust R3 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-130
4.54 Panel Dimmer S16/R2 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-132
4.55 Frequency Meter P5 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-135
4.56 Meter Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-137
4.57 Cabinet Illumination H7 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-140
4.58 Door Contact Switch S3 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-141

4.59 Brightness Control N5 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-142
4.60 Transformer Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-144
4.61 DiodeMaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-147
4.62 Diode V3 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-149

4.63 Circuit Breaker Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-152
4.64 True Power Measuring Transformer P4A Maintenance. . . . . . . . . . . . . . . . . . 4-155

4.65 Resistor Rl 00 To R102 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-158
4.66 Contactor Kl Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-161
4.67 Engine Preheating Control Board Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . 4-165
4.68 Circuit Breaker Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-167
4.69 Connector J9 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-171
4.70 J1/120 V 400 Hz Double Connector Receptacle Maintenance. . . . . . . . . . . . 4-173

4.71 J2/24 V Connector Receptacle Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-175
4.72 Service Switch Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-178
4.73 Shunt R11 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-180
4.74 Battery Set Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-181
4.75 Battery Charging Alternator Regulator N6 Maintenance. . . . . . . . . . . . . . . . . 4-184

4.76 EHG Regulator N7 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-185
4.77 Fuel Tank Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-187
4.78 Electrical Fuel Pump Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . 4-191
4.79 Upper Fuel Level Switch Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-193
4.80 Lower Fuel Level Switch Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-195
4.81 Fuel Level Sensor 2R4 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-197
4.82 Silencer Assembly, Left Side Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 200

4.83 Silencer Assembly, Right Side Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 205
4.84 Scavenge Pump Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 210

4.85 Oil Outlet Pipe Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 212
4.86 Oil line Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-213
4.87 Oil Pressure Switch 1S2 and Oil Pressure Sensor 1R2 Maintenance. . . . . . 4 - 214
4-3
TM 9-6115-668-13
4.88 Oil Temperature Switch 1S3 and Oil Temperature Sensor 1R3 Maintenance. 4-215
4.89 Battery Charging Alternator Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-218
4.90 Starter Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 222
4-4
TM 9-6115-668-13
Section I. REPAIR PARTS; TOOLS; SPECIAL TOOLS; TEST, MEASUREMENT AND

DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT
4.1 COMMON TOOLS AND EQUIPMENT.
A list of recommended tools and test equipment required to maintain the Generator Set 150 kW is contained in
Appendix B, SECTION III.
4.2 SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT.
Refer to TM 9-6115-668-23P for Generator Set 150 kW special tools.
4.3 REPAIR PARTS.
Refer to TM 9-6115-668-23P for Generator Set 150 kW repair parts.
4-5
TM 9-6115-668-13
Section II. SERVICE UPON RECEIPT OF EQUIPMENT
4.4 SERVICE UPON RECEIPT OF MATERIEL.
4.4.1 Storage and Transport in Orginal Packaging.
The Generator Set 150 kW is packed in a wooden container (figure 4-1). The container is covered at the
top by rainwater protection film (1). The packing list is located below the plate (2). The container is la-
beled with the necessary logistical identifiers (5).
4.4.1.1 Transport.
The container Is designed for transportation In a horizontal position

only.
a. When transporting with a forklift, insert forks into sockets (6).

b. When transporting with a crane, attach lifting cables as indicated (3).
Do not stand In the operating area of the crane or forklift. Do not

walk under the suspended load.
Move the container slowly so that it remains In the horizontal posi-
tion.
4.4.1.2 Storage.
The container can be stored in the original packaging for up to two years. The unit is packaged in airtight ma-
terials meeting MIL standards. The packaging can be checked al regular intervals using the moisture indicator
(8), as follows:
a. Open protective grill (7).

b. The indicator must be blue in color. If the indicator is entirely or partly pink, proceed as indicated for
30 %, 40 %, and 50 % relative humidity.
c. Close protective grill (7).
4-6
TM 9-6115-668-13
NOTE
The Generator Set 150 kW is packaged with a residual amount of fuel
and with battery terminals detached.
4.4.2 Unpacking Equipment.
4.4.2.1 Unpacking Generator Set 150 kW using a Forklift.
a. Remove cover (1, figure 4-2) and square wooden members (2).
b. Remove one side (wide side).
C. Detach film at points (3). The forklift sockets (1, figure 4-3) are located here.
NOTE
The unit is secured to the bottom of the container with square
wooden members only (no threaded fasteners), and can be lifted
up.
Separate the unit from the container using a forklift.
d. Insert forks, lift unit with packaging, and lower onto a solid surface.
e. Remove all film material from the unit.
f. Prepare the Generator Set 150 kW for start-up as instructed in chapter 2.
4.4.2.2 Unpacking Generator Set 150 kW using a Crane.
a. Remove cover and four sides of the container (figure 4-1).

b. Detach film so the four eyebolts (2, figure 4-3) at the corners are accessible.
c. Suspend the sling assembly from the crane and position the crane approximately above the center
of Generator Set 150 kW as shown in figure 4-3.
d. Insert the four cable hooks of the sling assembly into the lifting rings (2). Lift up the Generator Set
150 kW with the crane and lower it onto a solid surface.
WARNING
Do not stand in the operating area of the crane. Do not walk under
the suspended load.
Move the Generator Set 150 kW slowly so that it remains In the hori-
zontal position.
e. Detach the sling assembly from the Generator Set 150 kW.
4-7
TM 9-6115-668-13
4.4.3 Checking Unpacked Generator Set 150 kW.
a. Inspect the Generator Set 150 kW for damage incurred during shipment. If the Generator Set 150
kW has been damaged, report the damage on SF 364, Report of Discrepancy (ROD).
b. Check the Generator Set 150 kW against the packing list to see if the Generator Set 150 kW is
complete. Report all discrepancies in accordance with the instructions in DA Pam 738-750.
c. Check to see whether the Generator Set 150 kW has been modified.
4.4.4 Deprocessing Unpacked Generator Set 150 kW.

Refer to DA Form 2258, Depreservation Guide for Vehicles and Equipment, packed with the Generator
Set 150 kW. The depreservation guide explains what was done to the Generator Set 150 kW prior to
packaging. It also explains what has to be done before placing the Generator Set 150 kW in operation.
Perform all depreservation actions required by the depreservation guide.
4-8
TM 9-6115-668-13
Figure 4-1 Original Packaging in Container.
4-9
TM 9-6115-668-13
Figure 4-2 Unpacking the Container.
4-10
TM 9-6115-668-13
Figure 4-3 Generator Set 150 kW, Unpacked.
4-11
TM 9-6115-668-13
4.5 INSTALLATION INSTRUCTIONS.
Refer to paragraph 2.3.5
4.6 PRELIMINARY SERVICING AND ADJUSTMENT OF EQUIPMENT.
CAUTION
At temperatures below 32° F (0 ° C), if the batteries are not fully charged
they will be damaged or destroyed.
4.6.1 Batteries.
The batteries in the battery set assembly are maintenance free.

No electrolyte can leak out during proper operation; there is no need to top up with distilled water;
The batteries exhibit very little self-discharge, so there is no need for frequent recharging to make
up for self-discharge losses.
4.6.2 Fuel Tank.
Fill fuel tank (paragraph 2.3.4) with fuel type in accordance with table 4-1. Fuel tank capacity is 101.7 gal-
ions (385 liters).
Table 4-1 Fuel
AMBIENT TEMPERATURE DIESEL FUEL
+20 °F TO +120 °F (-6 °C TO 49 °C) W-F-800 GRADE DF-2, JP4, JP5, OR JP8
0 °F TO +20 °F (-17 °C TO -6 °C) W-F-800 GRADE DF-1, JP4, JP5, OR JP8
-25 °F TO 0 °F (-32 °C TO -17 °C) W-F-800 GRADE DF-1
-25 °F TO 0 °F (-32 °C TO -17 °C) W-F-800 GRADE DF-A
4-12
TM 9-6115-668-13
4.6.3 Lubricating Oil.
Fill diesel engine (paragraph 2.3.3) with lubricating oil in accordance with table 4-2. Lubrication system
capacity is 23.25 quarts (22 liters).
Tab/e 4-2 Lubricating Oil.
NOTE
> Greater than or equal to

< Less than or equal to
AMBIENT TEMPERATURE LUBRICATING OIL
> 32 °F (0 °C) SAE 15 W/40
< 32 °F (0 °C) SAE 5 W/30
4-13
TM 9-6115-668-13
Section III. Unit Lubrication
4.7 SYNCHRONOUS GENERATOR ASSEMBLY.
4.7.1 Lubricate synchronous generator bearings.
a. Open flap (1, figure 4-4).

b. Place grease gun on grease nipple (3) and (4) and inject approximately 1.4 ounces (40 g) bearing
grease (item 4, appendix E) into synchronous generator (2) bearing.
Figure 4-4 Lubricate synchronous generator bearings.
4-14
TM 9-6115-668-13
Section IV. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
4.8 INTRODUCTION TO UNIT PMCS TABLE.
Table 4-3 (PMCS table) has been provided so you can keep your equipment in good operating condition and ready
for its primary mission.
4.8.1 Warnings. Cautions. and Notes. Always observe the WARNINGS, CAUTIONS and NOTES appearing in
your PMCS table. Warnings and cautions appear before applicable procedures. You must observe WARNINGS to
prevent serious injury to yourself and others. You must observe CAUTlONS to prvent your equipment from being
damaged. You must observe NOTES to ensure procedures are performed properly.
4.8.2 Explanation of Table Entries.
4.8.2.1 Item No. Column. Numbers in this column are for reference. When completing DA Form 2404 (Equipment
Inspection and Maintenance Worksheet), include the item number for the check/service indicating a fault. Item num-
bers also appear in the order that you must do checks and services for the intervals listed.
4.8.2.2 Interval Column. This column tells you when you must do the procedure in the procedure column. Perform
procedures such as Monthly or Quarterly at the listed calendar interval. Perform procedures designated by number of
hours when the equipment has been operated for that many hours.
4.8.2.3 Location. Item to be Checked or Serviced Column. This column lists the item to be checked or serviced.
4.8.2.4 Procedure Column. This column gives the procedure for checking or servicing the item listed in the item
to check/service column. You must perform the procedure to know if the generator set 150 kW is ready or available
for its intended mission or operation. You must do the procedure at the time stated in the interval column.
4.8.2.5 Not Fully Mission Capable if: Column. Information in this column tells you what faults will keep your
equipment from being capable of performing its primary mission. If you make checks or services that show faults
listed in this column, do not operate the equipment.
4.8.3 Other Table Entries. Be sure to observe all special information and notes that appear in your table.
4.8.4 Special Instructions. Preventive maintenance is not limited to performing the checks and services listed in
the PMCS table. Refer to figure 4-5 for PMCS routing. Covering unused receptacles, stowing unused accessories,
and other routine procedures such as equipment inventory, cleaning components, and touch-up painting are not
listed in the table. These are things you should do any time you see that they need to be done. If a routine check is
listed in the PMCS table, it is because experience has shown that problems may occur with this item. Take along
the tools and cleaning cloths needed to perform the required checks and services.
4-15
TM 9-6115-668-13
Use the information in the following paragraphs to help you identify problems at any time. Use the following
information to help identify potential problems before and during checks and services.
WARNING
Dry cleaning solvent used to clean parts Is potentially dangerous to
personnel and property. Clean parts In a well-ventilated area. Avoid
inhalation of solvent fumes. Wear goggles and rubber gloves to pro-
tect eyes and skin. Wash exposed skin thoroughly. Do not smoke or
use near open flame or excessive heat. Failure to observe this warn-
ing can cause severe personal injury or death.
CAUTION
Keep cleaning solvents, gasoline and lubricants away from rubber or
soft plastic parts. They will deteriorate material.
a. Keep it clean. Dirt, grease, and oil get in the way and may cover up a serious problem. Use dry cleaning
solvent to clean metal surfaces.
b. Use soap and water to clean rubber or plastic parts and material.
C. Check all bolts, nuts, and screws to make sure they are not loose, missing, bent, or broken. Do not try
to check them with a tool, but look for chipped paint, bare metal, or rust around bolt heads. If you find
one loose, report it to the next higher level of maintenance.
d. Inspect welds for loose or chipped paint, rust, or gaps where parts are welded together. If a broken weld
is found, report it to the next higher level of maintenance.
e. Inspect electrical wires, connectors, terminals, and receptacles for cracked or broken insulation, bare
wires, and loose or broken connectors. Tighten loose connectors. Examine terminals and receptacles for
serviceability. If deficiencies are found, report them to the next higher level of maintenance.
f. Inspect hoses and fluid lines. Look for wear, damage, and leaks. Make sure that clamps and fittings are
tight. Wet spots and stains around a fitting or connector can mean a leak. If a leak comes from a loose
connector, or if something is broken or worn out, report it to the next higher level of maintenance.
4-16
TM 9-6115-668-13
Figure 4-5. Unit PMCS Routing Diagram.
Change 1 4-17
TM 9-6115-668-13
Table 4-3. Unit Preventive Maintenance Checks and Services for Generator Set 150 kW.
Item Item to be Not Fully Mission

No. Interval Checked or Serviced Procedure Capable if:
1 125 Engine Preheating Assembly Check operation. Refer to paragraph Diesel engine cannot
Hours 2.8 be preheated.
2 250 V Belts (Battery Charging a. Check V belt tension and readjust V belts are loose,
Hours/ Alternator) if necessary. Check V belts for dam- frayed, or damaged.
Semi age, and replace defective V belts.
Annual Refer to paragraphs 4.34 and 4.35.
b. Below 23 °F (-5 °C), install

V belts for winter operation. Refer to
paragraph 4.35.
3 250 Engine Oil Change Engine Oil (Refer to para- Class III oil leak.
Hours/ graph 2.3.3.3) for oil change intervals
Semi under unusual conditions.
Annual
4 250 Oil Filter Replace oil filter at every other oil Class III oil leak.
Hours/ change, or at intervals of 250 hours or
Semi less. Refer to paragraph 4.30.
Annual
5 250 Subcurrent Filter Assembly Replace filter cartridge at every other Class III oil leak.
Hours/ oil change, or when subcurrent filter
Semi does not get hot during operation
Annual (250 Hours or less). Refer to para-
graph 4.31.
6 250 Fuel Prefilter and Two Step a. Clean or replace filter cartridges. Diesel engine runs
Hours/ Fuel Filter Assembly Refer to paragraph 4.32 and 4.33. roughly with poor
Semi output or any fuel
Annual leak.
b. Bleed fuel filter after filter insets Any fuel leak.

are cleaned or replaced. Refer to
paragraphs 4.38 and 4.39.
7 1000 Synchronous Generator Lubricate bearings. Refer to para-

Hours/ Assembly graph 4.7. Perform load bank proce-
Annual dures in accordance with paragraph
5.53.
4-18 Change 2
TM 9-6115-668-13
Table 4-3. Unit Preventive Maintenance Checks and Services for Generator Set 150 kW-continued.
Item Item to be Not Fully Mission

No. Interval Checked or Serviced Procedure Capable if:
8 1000 Air Filter Assembly Clean or replace filter cartridge annu- If AIR FILTER lamp
Hours/ ally or when AIR FILTER lamp is on. is on.
Annual Refer to paragraph 4.29.
9 1000 Battery Set Assembly CAUTION Batteries will not hold

Hours/ Do not use a lead acid battery charge.
Annual charger to recharge conventional,
gal battery, or damage to battery
may occur.
Remove and clean battery set assem-

bly. At temperatures below 32 °F
(0° C) or if starting is difficult, check
battery charge. Refer to the next
higher level of maintenance. See
TM 9-6150-200-14.
10 1000 Flame Glowplug System At temperatures below 32 °F (0° C)

Hours/ or if starting is difficult, check opera-
Annual tion of flame glowplug system. Refer
to paragraph 5.30.
11 Semi- EPP III Perform load bank procedures in

annually accordance with paragraph 5.53.
12 1000 Valves Refer to paragraph 5.54 Diesel engine runs

Hours/ roughly with poor out-
Annual put.
13 1000 Cooling Blower Assembly Refer to paragraph 5.55

hours/
Annual
Change 4-19
TM 9-6115-668-13
Section V. TROUBLESHOOTING
4.9 GENERAL
The symptom index for the generator set 150 kW lists faults associated with control cabinet assembly operation. Figures
4-6 through 4-23 provide a go/no-go flowchart of each malfunction. Each malfunction listed includes a reference to the
applicable figure that contains a chart to help you determine probable causes and corrective actions to take. The
symptom index cannot list all faults that may occur, nor all the tests or inspections and corrective actions. If a malfunction
is not listed or cannot be corrected by listed corrective actions, notify next higher level of maintenance for assistance.
WARNING
• Potential 150 kW/208 VAC shock hazard with failure to adhere to this warning.
Contac with this high power could result in death or severe injury. If the
removal of one generator from the EPP III is required. replace it with an extra
generator. Always make sure that two generators are mounted to the EPP IN.
Continued use of the EPP II with only one generator could result in a
catastrophic shock hazard.
• Prior to energizing the equipment the operator must check for exposed
electrical terminals.
• Always install protective covers on control and power cables when cables are
not connected.
• Be sure to observe all warning signs on equipment.
• Potential 208 VAC shock hazard. Do not disconnect or connect control or

power cables while Generator Set 1 or 2 is running.
NOTE
Before performing troubleshooting procedures:
• Ensure that operator level troubleshooting

steps have been performed.
• Be sure you have performed your PMCS.
• Refer to the Wiring Diagram FO-1 and FO-2

as troubleshooting aids.
4-20 Change 1
TM 9-6115-668-13

Procedure
BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up . . . . . . Figure 4-6
HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp

does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-7
GLOWPLUG ON lamp does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-8
Desel engine cannot be started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-9
Oil pressure too low, or no oil pressure indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-10
Battery set is not being charged, or no charging current indication . . . . . . . . . . . . . . . . . Figure 4-11
Generator frequency cannot be adjusted, or no frequency indication .............. Figure 4-12
Generator voltage cannot be adjusted, or no voltage indication ................... Figure 4-13
AC CIRCUIT INTERRUPTER ON lamp does not light up . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-14
No line currents are flowing, or no line current indication . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-15
No power indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-16
BATTERY CHARGING CONTROL lamp lights up during operation . . . . . . . . . . . . . . . . Figure 4-17
OIL PRESSURE lamp lights up during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-18
OIL TEMP-CYLINDER HEAD lamp lights up during operation . . . . . . . . . . . . . . . . . . . . Figure 4-19
UNDER/OVER FREQUENCY lamp lights up during operation . . . . . . . . . . . . . . . . . . . . Figure 4-20
UNDER/OVER VOLTAGE lamp lights up during operation . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-21
GENERATOR OVER TEMPERATURE lamp lights up during operation . . . . . . . . . . . . . Figure 4-22
OVERLOAD lamp lights up during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4-23
4-21
TM 9-6115-668-13
WARNING
SHUT DOWN GENERATOR SET 150 kW BEFORE PER-
FORMING TEST OR INSPECTION OF CONTROL CABINET
ASSEMBLY, DIESEL ENGINE OR BASE FRAME ASSEMBLY.
FAILURE TO OBSERVE THIS WARNING COULD RESULT IN
SEVERE PERSONAL INJURY OR DEATH.
Figure 4-6 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up.
4-22
TM 9-6115-668-13
WARNING
ASSEMBLY OR ENGINE PREHEATING ASSEMBLY. FAIL-
URE TO OBSERVE THIS WARNING COULD RESULT IN
Figure 4-7 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp does
not light up.
4-23
TM 9-6115-668-13
WARNING
ASSEMBLY OR DIESEL ENGINE. FAILURE TO OBSERVE
THIS WARNING COULD RESULT IN SEVERE PERSONAL
INJURY OR DEATH.
Figure 4-8 GLOWPLUG ON lamp does not light up.
4-24
TM 9-6115-668-13
WARNING
ASSEMBLY, DIESEL ENGINE OR BASE FRAME ASSEMBLY.
FAILURE TO OBSERVE THIS WARNING COULD RESULT
IN SEVERE PERSONAL INJURY OR DEATH.
Paragraph 4.37
Paragraph 4.74
Figure 4-9 Diesel engine cannot be started.
4-25
TM 9-6115-668-13
WARNING
INJURY OR DEATH.
Figure 4-10 Oil pressure too low, or no oil pressure indication.
4-26
TM 9-6115-668-13
WARNING
INJURY OR DEATH.
Figure 4-11 Battery set is not being charged, or no charging current indication.
4-27
TM 9-6115-668-13
WARNING
ASSEMBLY. FAILURE TO OBSERVE THIS WARNING
COULD RESULT IN SEVERE PERSONAL INJURY OR
DEATH.
Figure 4-12 Generator frequency cannot be adjusted, or no frequency indication.
4-28
TM 9-6115-668-13
WARNING
DEATH.
Figure 4-13 Generator voltage cannot be adjusted, or no voltage indication.
4-29
TM 9-6115-668-13
WARNING
DEATH.
Figure 4-14 AC CIRCUIT INTERRUPTER ON lamp does not light up.
4-30
TM 9-6115-668-13
WARNING
DEATH.
Figure 4-15 No line currents are flowing, or no line current indication.
4-31
TM 9-6115-668-13
WARNING
DEATH.
Figure 4-16 No power indication.
4-32
TM 9-6115-668-13
WARNING
FORMING TEST OR INSPECTION OF GENERATOR OR
FUEL TANK ASSEMBLY. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN SEVERE PERSONAL IN-
JURY OR DEATH.
(PARAGRAPH 4.34 or 4.35)
Figure 4-17 BATTERY CHARGING CONTROL lamp lights up during operation.
4-33
TM 9-6115-668-13
WARNING
FORMING TEST OR INSPECTION OF DIESEL ENGINE OR
BASE FRAME ASSEMBLY. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN SEVERE PERSONAL IN-
JURY OR DEATH.
(PARAGRAPH 4.30)
(PARAGRAPH 4.31)
Figure 4-18 OIL PRESSURE lamp lights up during operation.
4-34
TM 9-6115-668-13
WARNING
FORMING TEST OR INSPECTION OF UNIT HOOD AS-
SEMBLY, DIESEL ENGINE OR CONTROL CABINET AS-
SEMBLY. FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN SEVERE PERSONAL INJURY OR DEATH.
(PARAGRAPH 4.36)
Figure 4-19 OIL TEMP-CYLINDER HEAD lamp lights up during operation.
4-35
TM 9-6115-668-13
WARNING
FORMING TEST OR INSPECTION OF FUEL TANK AS-
SEMBLY, AIR FILTER ASSEMBLY OR CONTROL CABINET
DEATH.
(PARAGRAPH 2.3.4)
(PARAGRAPH 4.29)
Figure 4-20 UNDER/OVER FREQUENCY lamp lights up during operation.
4-36
TM 9-6115-668-13
WARNING
FORMING TEST OR INSPECTION OF FUEL TANK AS-
SEMBLY, AIR FILTER ASSEMBLY OR CONTROL CABINET
DEATH.
Figure 4-21 UNDER/OVER VOLTAGE lamp lights up during operation.
4-37
TM 9-6115-668-13
WARNING
FORMING TEST OR INSPECTION OF SYNCHRONOUS
GENERATOR OR CONTROL CABINET ASSEMBLY. FAIL-
URE TO OBSERVE THIS WARNING COULD RESULT IN
Figure 4-22 GENERATOR OVER TEMPERATURE lamp lights up during operation.
4-38
TM 9-6115-668-13
WARNING
DEATH.
Figure 4-23 OVERLOAD lamp lights up during operation.
4-39
TM 9-6115-668-13
Section VI. RADIO INTERFERENCE SUPPRESSION
4.10 GENERAL METHODS USED TO ATTAIN PROPER SUPPRESSION.
Suppression is attained by providing a low resistance path to ground for stray currents. The methods
used include shielding the ignition and high-frequency wires, grounding the frame with grounding straps,
and using filtering systems.
4.11 INTERFERENCE SUPPRESSION COMPONENTS.
4.11.1 Primary Suppression Components.
Primary suppression components are those whose primary function is to suppress electromagnetic inter-
ference. The primary suppression components on this Generator Set 150 kW are:
l Rubber HF sealing on front panel doors of Control Cabinet Assembly,

l Rubber HF sealing on connection panel of Control Cabinet Assembly,
l Filter capacitors FK in Control Cabinet Assembly.
4.11.2 Secondary Suppression Components.

Secondary suppression components have electromagnetic interference suppression functions which are
incidental or secondary to their primary function. The secondary suppression components for the Genera-
tor Set 150 kW are the unit hood assembly and the base frame assembly.
4-40
TM 9-6115-668-13
SECTION VII. MAINTENANCE PROCEDURES

4.12 GENERAL
The section will provide authorized unit level maintenance instructions for the Electrical Generator As-
sembly and its components. Each major component will be covered under its own paragraph heading.
Each paragraph will be further divided into specific maintenance tasks, as directed by the Maintenance
Allocation Chart (MAC). These tasks will include inspection, testing, service, adjustment, removal, disas-
sembly, assembly, repair, replacement, and installation, as applicable. Step-by-step instructions and il-
lustrations will guide personnel through each maintenance task.
Potential 150 kW/209 VAC shock hazard with failure to adhere to

this warning. Contact with this high power could result In death or
severe injury. If the removal of one generator from the EPP Ill is re-
quired, replace it with an extra generator if available. lf the EPP III
must be operated with only one generator Installed, insure that ail
cables for the removed generator have the protective caps properly
Installed prior to starting the remaining generator set.
Prior to energizing the equipment the operator must check for ex-
posed electrical terminals.
Always install protective covers on control and power cables when
cables are not connected.
Be sure to observe ail warning signs on equipment.
Potential 208 VAC shock hazard. Do not disconnect and connect
control or power cables while Generator Set 1 or 2 is running.
When working around the engine, remove the ignition key; if neces-
sary, also detach the negative terminal of the battery set.
For safety reasons, work on the Generator Set 150 kW must always
be performed by two persons.
Change 1 4-41
TM 9-6115-668-13
NOTE
The following should generally be performed after any removal/

Installation operation, if applicable:
Functional test
Lamp test
Leak check
Bleeding
Oil pressure check
Oil level Check
Observe all regulations when disposing of oil filters, used oil, and
rags.
4-42
TM 9-6115-668-13
4.13 UNIT HOOD FLAP GROUND STRAP MAINTENANCE.
This task covers: a. Removal b. installation
INITIAL SETUP
Tools Equipment Conditions
General Mechanic’s Tool Kit Reference

(item 2, appendix B) Generator Set 150 kW shut
Automotive Fuel and Electrical System Repair, Tool Kit down, paragraph 2.5.2
(item 3, appendix B)
REMOVAL
WARNING
l Note the removal sequence of attaching hardware to ensure proper

installation sequence.
l Failure to observe this warning could result in severe personal In-
jury or death.
NOTE
This procedure is the same for flaps (3), (4) and (5).

2. Remove nut (6), serrated lock washer (7), washers (8, 9), and grounding strap (10) from screw (11)
on unit hood assembly (1).
3. Remove nut (12), serrated lock washer (13), washers (14, 15), and grounding strap (10) from screw
(16) on flap (2).
INSTALLATION
1. Install washers (14, 15), serrated lock washer (13), and grounding strap (10) on screw (16), and
install nut (12) onto screw (16) on flap (2).
2. Install washers (8, 9), serrated lock washer (7) and grounding strap (10) on screw (11), and install
nut (6) on screw (11) on unit hood assembly (1).
3. Close flap (2).
4-43
TM 9-6115-668-13
Figure 4-24 Unit Hood Flap Ground Strap Maintenance.
4-44
TM 9-9115-668-13
4.14 UNIT HOOD ASSEMBLY MAINTENANCE.
This task covers: a. Removal b. Installation
INITIAL SETUP

Automotive Fuel and Electrical System Repair, Tool Kit down,
(item 3, appendix B) paragraph 2.5.2
Sling/Hoisting Device, Universal
Materials/Parts Personnel Required
Lubricant Two - Three

(item 6, appendix E)
REMOVAL
1 Remove six bolts (25, figure 4-25) six lock washers (26) and six washers (27) from connection
panel case (30).
2. Remove attachment rail (28) and rubber cover (29).
3. Remove ten bolts (22) ten serrated lock washers (23) and ten washers (24) from connection panel
case (30).
4. Remove connection panel case (30) with seal and protection profile out of unit hood (1).
5. Using a 19 mm wrench, loosen six lock nuts (18) six eye bolts (14) six nuts (17) six washers (16),
and six plates (15).
6. Lift six plates (15) out of retainers (13) and fold down six eye bolts (14) six nuts (17) six washers
(16) and six plates (15).
7. Remove nut (6) serrated lock washer (7) washers (9, 10), and ground strap (8) from stud (11) on
base frame (12). Install washer (9, 10), serrated lock washer (7) and nut (6) on stud (11) to prevent
loss of hardware.
8. Open flap (36) and loosen two band clamps (37) on rubber fuel fill hose (38).
This procedure requires a minimum of two personnel

Stay clear of the suspended load. Failure to observe this warning
could result In severe personal injury or death.
Change 1 4-45
TM 9-6115-668-13
CAUTION
Assure ground strap is free and will not snag when removing hood.
9. Secure hoisting device to eye bolts (31 to 34), lift unit hood (1) off base frame assembly (12) and
place on a flat surface.
INSTALLATION
Note the sequence of attaching hardware for installation to ensure

proper grounding. Failure to observe this warning could cause se-
Ensure fuel hose is secure and properly stowed inside the hood prior
to Installation to prevent damage to the hose.
1. Align rubber sealing strip (20) in U-profile on bottom plate.
2. Coat rubber seal (21) on partition wall with assembly lubricant.
3. Insure rubber fuel fill hose (38) and two metal band hose clamps (37) have been installed on fuel
tank inlet.
4. Attach hoisting device to eye bolts (31 to 34), lift up unit hood (1), and position above base frame
assembly (12) so the U-profile on the inside of the unit hood is located above rubber seal (21) on
partition wall.
NOTE
The rubber seal (21) and lnsulating mat on the partition wall must
slide into the U-profile.
5. Lower unit hood (1) until it rests evenly on rubber sealing strip (20) in the U-profile on the base
frame assembly (12), and on the partition wall rubber seal (21). insure fuel filler neck slides down
into rubber fill hose (38).
6. Detach hoisting device from eyebolts (31 to 34).
7. Swing up eye screws (14) with nuts (18). washers (16), and plates (15), and set plates (15) in re-
tainers (13).
8. Tighten nuts (17) and secure with lock nuts (18).
9. Install grounding strap (8) on stud (11) with nut (6), serrated lock washer (7), and washers (9,10).
10. Place case for connection panel (30). with seal, in unit hood (1) and attach to unit hood with ten
bolts (22), ten serrated lock washers (23), and ten washers (24).
11. Align attachment rail (28) and rubber cover (19) on unit hood (1) and secure with six bolts (25), six
serrated lock washers (26), and six washers (27).
12. Open flap (36), tighten the two metal band hose clamps (37).
4-46 Change 1
TM 9-6115-668-13
Figure 4-25. Unit Hood Assembly Maintenance.
Change 1 4-47
TM 9-6115-6685-13
4.15 UNlT HOOD-BASE FRAME GROUND STRAP MAINTENANCE.
INITAL SETUP

(item 3, appendix B
REMOVAL
Note the removal sequence of attaching hardware for installation to

ensure proper grounding. Failure to observe this warning could re-
suit in severe personal injury or death.

2. Remove screw (3), serrated lock washers (4,8), washers (5,7), and grounding strap (6) from unit
hood assembly (1).
3. Remove nut (9). serrated lock washer (10), washers (11, 12), and grounding strap (6) from screw
(13).
INSTALLATION
1. Install serrated lock washer (10), washers (11,12), grounding strap (6) and nut (9) onto screw (13).
2. Install serrated lock washers (4,8), washers (5.7) and grounding strap (6) on screw (3) and thread
screw (3) into unit hood assembly (1).
3. Close flap (2).
4-48
TM 9-6115-668-13
Figure 4-26 Unit Hood-Base Frame Ground Strap Maintenance.
4-49
TM 9-6115-668-13
4.16 SUPPLY AIR DUCT MAINTENANCE.
INITIAL SETUP

REMOVAL
1. Loosen twelve screws (5, figure 4-27), twelve serrated lock washers (6), and twelve washers (7)
from supply air duct (4).
2. Remove supply air duct (4), sealing ring (3), and rubber seal (2) from unit hood assembly (1).
INSTALLATION
1. Place supply air duct (4), sealing ring (3) and rubber seal (2), on unit hood assembly (1).
2. Install twelve screws (5), twelve washers (7) and twelve serrated lock washers (6), on unit hood
assembly (1).
4-50
TM 9-6115-668-13
4.17 AIR LEADING DUCT MAINTENANCE.
INITlAL SETUP

REMOVAL
NOTE
For air leading duct on opposite side, proceed as described here.
1. Remove twelve screws (10, figure 4-27), twelve serrated lock washers (11), and twelve washers
(12) from unit hood assembly (1)
2. Remove air leading duct (9), and sealing ring (8) from unit hood assembly (1).
INSTALLATION
1. Place air leading duct (9), and sealing ring (8) on unit hood (1).
2. Install twelve screws (10), twelve serrated lock washers (11), and twelve washers (12) on unit hood
(1).
4-51
TM 9-6115-668-13
4.18 AIR COOLING INLET GRATE MAINTENANCE.
INITIAL SETUP

REMOVAL
1. Remove eight screws (13, figure 4-27), eight serrated lock washers (14), and eight washers (15)
from unit hood assembly (1).
2. Remove air cooling inlet grate (16), and sealing ring (17) from unit hood assembly (1).
INSTALLATION
1. Place air cooling inlet grate (16), and sealing ring (17) on unit hood assembly (1).
2. Install eight screws (13), eight serrated lock washers (14), and eight washers (15) on unit hood as-
sembly (1).
4-52
TM 9-6115-668-13
4.19 COVER AND CASE FOR CONNECTION PANEL MAINTENANCE.
INITIAL SETUP

REMOVAL
1. Remove six screws (21, figure 4-27), six serrated lock washers (22), six washers (23), attachment
rail (24), and rubber flap (25) from case (26).
2. Remove ten screws (20), ten serrated lock washers (19), and ten washers (18) from the sides and
bottom of case (26).
3. Remove case (26), protection profile (27), and sealing ring (28) from unit hood assembly (1).
INSTALLATION
1. Install case (26), protection profile (27), and sealing ring (28) on unit hood assembly (1).
2. Install ten screws (20), ten serrated lock washers (19), and ten washers (18) into ten holes on the
sides and bottom of case (26).
3. Align rubber flap (25), and attachment rail (24) on case (26), and secure with six screws (21), six
serrated washers (28), and six washers (23) onto hood assembly (1).
4. Install six screws (21), six serrated lock washers (22), and washers (23) on unit hood assembly (1).
4-53
TM 9-6115-668-13
Figure 4-27 Unit Hood Assembly Air Ducts and Air Cooling Inlet Grate Maintenance.
4-54
TM 9-6115-668-13
4.20 TWIST GRIP AND LOCK MAINTENANCE.
INITIAL SETUP

REMOVAL
NOTE
This procedure will be used to remove twist grips and locks from all
flaps.

2. Remove four screws (12) while retaining self-locking nut (18).
3. Remove twist grip (13) from flap (19).
4. Remove lock (16) on flap (19) by removing two screws (17) from flap (19).
5. Loosen set screw (15) and remove pin (14) from lock (16).
INSTALLATION
1. Install twist grip (13) on flap (19) using four screws (12) and four nuts (18).
2. Install pin (14) in lock (16) and secure by tightening set screws (15).
3. Install lock (16) on flap (19) with two screws (17).
4. Close flap (19).
4-55
TM 9-6115-668-13
4.21 GAS-CYLINDER AND PROP MAINTENANCE.
INITIAL SETUP

REMOVAL

2. Remove retaining ring (5) and washer (6) from bolt (4).
3. Remove nut (10) while retaining bolt (7).
4. Remove retaining ring (9) and spacer (8) from bolt (7).
5. Remove prop (11) from bolt (7) and remove gas-cylinder (3) from unit hood assembly (1).
INSTALLATION
1. Install gas-cylinder (3) on unit hood (1) and prop (11) on bolt (7).
2. Install spacer (8) and retaining ring (9) on bolt (7).
3. Install nut (10) onto bolt (7) while holding bolt (7) with a suitable wrench.
4. Close flap (2).
4-56
TM 9-6115-668-13
4.22 FLAP MOUNT MAINTENANCE.
This task covers: a. Removal b. Repair c. Installation
INITIAL SETUP

Driver, Blind Rivet
Materials/Parts
Rivets
Talc, technical grade (item 5, appendix E)
REMOVAL
1. Open flap (2, figure 4-28) and prop open.

2. Remove ground strap (refer to paragraph 4.13).
3. Drill out blind rivets (25) and remove flap (2) with hinge (22), rubber sealing strip (23), and hinge
profile (24) from unit hood assembly (1).
REPAIR
1. Pull hinge (24) off rubber sealing strip (23).

2. Pull damaged rubber sealing strip (23) from hinge (22).
3. Cut identical length of rubber sealing strip (23) from rubber sealing strip stock (P/N
405K0099-00-00.2).
4. Coat rubber sealing strip (23) with talc and set into hinge (22).
5. Slide hinge (24) onto rubber sealing strip (23).
INSTALLATION
1. Install flap (2), with hinge profile (22), rubber sealing strip (23), and hinge (24), on unit hood assem-
bly (1).
2. Install blind rivets (25) into hinge (24) and unit hood (1) using blind rivet driver.
3. Install ground strap (refer to paragraph 4.13).
4. Close flap (2).
4-57
TM 9-6115-668-13
Figure 4-28 Unit Hood Flap Maintenance.
4-58
TM 9-6115-668-13
4.23 LIGHT INDICATOR ASSEMBLY MAINTENANCE.
INITIAL SETUP

Materials/Parts
Cable ties
WARNING
Disconnect the negative battery cable first and then the positive bat-
tery terminal cables. Failure to observe this warning could result in se-
vere personal injury or death.
CAUTION
Tag all cables prior to removal to ensure correct connection of the
cables during installation.
REMOVAL
1. Open flap (2, figure 4-29) on unit hood assembly (1).

2. Open front panel (4) of control cabinet assembly (3) and secure with prop (5).
NOTE
Removal procedure for light indicator assembly H103 (6), H102 (7),
H17 (8), H15 (9), H4 (10), H3 (11), H2 (12) is the same as for light indica-
tor assembly H1 (13), described below.
3. Record labeling and position of cables to bulb holder (21).

4. Disconnect cables from terminals (22, 23) of bulb holder (21).
5. Use a screwdriver to push in lower closure first using your hand to support the bottom of the bulb
holder until they snap in, and take out bulb holder (21) with bulb (17).
6. Loosen screws (19) on base (18).
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TM 9-6115-668-13
7. Unlock lamp cap (14) and housing (15) with sealing ring (16) from front of front panel by turning
counterclockwise.
8. Pull lamp cap (14) and housing (15) with sealing ring (16) out of front of front panel (4) and remove
base (18) from back of front panel (4).
NOTE
The diode holders next to light indicator assembly H2 to H4 (10 to 12)
are to be removed separately.
9. To remove diode holders next to light indicator assembly H2 to H4 (12 to 10), perform steps 1 to 5.
INSTALLATION
CAUTION
Reinstall the same type of bulb holder that was removed.
NOTE
The procedure for removing light indicator assembly H103 (6), H102
(7), H17 (8), H15 (9), H4 (10), H3 (11), H2 (12) is the same as for light indi-
cator assembly H1 (13), described below.
1. Install housing (15), sealing ring (16) and lamp cap (14) into front panel (4) from the front and hold
base (18) against front panel (4) from the rear.
2. Push lamp cap (14), housing (15) and sealing ring (16) into base (18) and turn clockwise to secure
to base (18).
3. Tighten screws (19) on base (18).
4. Clip bulb holder (21) with bulb (17) into base (18).
5. Connect cables to terminals (22, 23) of bulb holder (21), noting correct labeling and position.
NOTE
The diode holders next to light indicator assembly H2 to H4 (10 to 12)
are to be installed separately.
6. To install diode holders next to light indicator assembly H2 to H4 (12 to 10), perform steps 1 to 5.
7. Stow prop (5) and close front panel (4).
8. Close flap (2).
4-60
TM 9-6115-668-13
Figure 4-29 Control Cabinet Assembly, Light Indicator Assembly Maintenance.
4-61
TM 9-6115-668-13
4.24 BULB IN INDICATOR LAMP MAINTENANCE.
INITIAL SETUP

Suitable Bulb Removal Tool (Sec IV, Reference code R, ap-
pendix B)
REMO\/AL
NOTE
This procedure is the same for lamp H1 (9), H2 (7), H3 (6), H4 (5), H15
(4), H17 (8), H102 (3), and H103 (2) (figure 4-30).

2. Remove indicator lamp cap (10) by turning counterclockwise from housing (12).
3. Using a suitable bulb removal tool remove bulb (11) from lamp socket (13) by pushing the bulb in,
then rotate the bulb (11) counter clockwise and pull out.
INSTALLATION
1. Using the suitable bulb tool, install the bulb (11) into lamp socket (13) by pushing the bulb in and
rotating the bulb (11) clockwise.
2. Install indicator lamp cap (10) by screwing onto housing (12) clockwise and tightening firmly.
3. Close flap (1).
4-62
TM 9-6115-668-13
Figure 4-30 Bulb in Indicator Lamps Maintenance.
4-63
TM 9-6115-668-13
4.25 BULB IN ILLUMINATED SWITCH MAINTENANCE.
INITIAL SETUP

Suitable Bulb Removal Tool (Sec IV, Reference code R, ap-
pendix B)
REMOVAL
NOTE
This procedure is the same for lamp H5 (2), H8 (7), H9 (6), H10 (5), H11
(3), H12 (8), H14 (10), H16 (9), and H101 (11) (figure 4-31).

2. Remove collar (12) by unscrewing from lamp housing (15).
3. Remove lens (13) by unscrewing from lamp housing (15).
4. Using a suitable bulb removal tool, push bulb (14) in, turn bulb (14) counterclockwise, and remove
bulb (14) from lamp socket (16).
INSTALLATION
1. Install bulb (14) in lamp socket (16), using the suitable bulb tool, by pushing the bulb (14) in and
rotating the bulb (14) clockwise.
2. Install lens (13) on lamp housing (15).
3. Install collar (12).
4. Close flap (1).
4-64
TM 9-6115-668-13
Figure 4-31 Bulb in Illuminated Switch Maintenance.
4-65
TM 9-6115-668-13
4.26 REPLACE BULB IN PANEL LIGHT H6.
INITIAL SETUP

(item 2, appendix B Generator Set 150 kW shut
(item 3, appendix B
REMOVAL
NOTE
Removal procedure for the three H6 panel lights is identical to this ex-
ample.

2. Remove cover (2) by grasping cover (2) firmly and pulling off lamp base (3).
3. Loosen set screws (6) on terminal, and remove wire (7).
4. Pull lamp socket (5) and bulb (4) to the right and slide off lamp base (3).
5. Push down on bulb (4) in lamp socket (5), turn counterclockwise, and pull out.
INSTALLATION
1. Insert bulb (4) into lamp socket (5).

2. Push down on bulb (4), turn clockwise until it stops, then release.
3. Install bulb (4) with lamp socket (5) in lamp base (3), and push in until seated.
4. Attach cable (7) to terminal and tighten set screw (6).
5. Install cover (2) on lamp base (3) and push to secure.
6. Close flap (1).
4-66
TM 9-6115-668-13
Figure 4-32 Panel Light H6 Maintenance.
4-67
TM 9-6115-668-13
4.27 REPLACE BULB IN ILLUMINATED METER.
INITIAL SETUP

REMOVAL
NOTE
This procedure is the same for illuminated meter P9 (11), P10 (10), P11 (9).
2. Using key (12) open front panel (2) and secure with prop (3).
3. Pull bayonet socket (7) with bulb (6) and insulator (5) out of lamp base (4). Discard insulator (5).
4. Remove bulb (6) by pushing down, turning counterclockwise and pulling out of bayonet socket (7).
INSTALLATION
1. Inset-t bulb (6) into bayonet socket (7), push down and turn counterclockwise.
2. Install new insulator (5) on lamp base (4).
CAUTION
Following installation, make sure the double-contact flat connectors
(8) do not touch to prevent damage by short circuit.
3. Install bulb (6) with bayonet socket (7) into lamp base (4) of meter and push in.
4. Fold away prop (3), close front panel (2) and replace key (12) in holder.
5. Close flap (1).
4-68
TM 9-6115-668-13
Figure 4-33 Illuminated Meter Maintenance.
4-69
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4.28 REPLACE BULB IN CABINET LIGHT H7.
INITIAL SETUP

REMOVAL

2. Open front panel (2) by using key (9) and secure with prop (3).
3. Remove cover (4) from lamp base (5).
4. Push spring contacts (6, 7) apart and remove bulb (8).
INSTALLATION
1. Push spring contacts (6, 7) apart and install bulb (8).

2. Install cover (4) on lamp base (5).
3. Fold away prop (3), close front panel (2), and replace key (9) in holder.
4. Close flap (1).
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TM 9-6115-668-13
Figure 4-34 Cabinet Light Maintenance.
4-71
TM 9-6115-668-13
4.29 AIR FILTER CARTRIDGE MAINTENANCE.
This task covers: a. Removal b. Service c. Installation
INITIAL SETUP

Materials/Parts
Lubricant (item 6, appendix E)

Light-duty detergent, commercial
REMOVAL

2. Swing clamping clip (6) on air filter housing in direction of arrow, and remove dust collector (4) with
cover from air fitter housing (9) of air filter assembly (3).
3. Remove self-locking nut (5) from threaded rod (7) and pull air filter cartridge (6) out of air filter hous-
ing (9).
SERVICE
NOTE
Do not damage the end of the air filter cartridge when cleaning it.
1. To dislodge dust, hold air filter cartridge (6) vertically and tap the end several times against your
hand or a flat, soft surface.
2. Clean air filter cartridge (6) by swishing back and forth in lukewarm water with a commercial light-
duty detergent; rinse in clean water, shake out excess water, and allow to dry thoroughly.
3. Clean air filter dust collector (refer to paragraph 3.4).
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INSTALLATION
NOTE
Before installing the clean air filter cartridge, shine a flashlight
through it to check for damage.
if the air filter cartridge Is damaged, replace it with a new one.
Use a new self-locking nut.
1. install air filter cartridge (6) in air filter housing (9) of air filter assembly (3) and screw self-locking nut
(5) onto threaded rod (7).
CAUTION
Note “OBEN TOP” mark on cover (4) to prevent damage to equip
ment.
2. Install dust collector with cover (4) on air filter housing (9) so that “OBEN TOP” marking faces up-
ward.
3. Swing clamping clip (8) into place.
4. Close flap (2).
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TM 9-6115-668-13
Figure 4-35. Air Filter Cartridge Maintenance.
4-74 Change 1
TM 9-6115-668-13
4.30 OIL FILTER MAINTENANCE.
INITIAL SETUP

Oil filter wrench (item 8, appendix B
Materials/Parts
Oil Filter
REMOVAL
NOTE
Place a drain pan under the oil filter and dispose of waste oil in accor-
dance with local ordnances.
2. Pump out oil with scavenge pump (3) (paragraph 2.3.2.3).

3. Loosen oil filter (5) using oil filter wrench, then unscrew by hand and remove.
4. Clean sealing surface of filter mount on engine.
INSTALLATION
1. Apply a thin coating of oil to rubber seal (6) of the new oil filter (5).
CAUTION
Do not use tools to install the oil filter.
2. Place oil filter (5) on filter mount, thread on by hand until rubber seal (6) contacts sealing surface,
and tighten with both hands.
3. Fill with oil (paragraph 2.3.2.3).
4. Close flap (2).
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4.31 SUBCURRENT FILTER CARTRIDGE MAINTENANCE.
INITIAL SETUP

(item 2, appendix B Generator Set 150 kW shut
(item 3, appendix B
Materials/Parts
Oil Filter Cartridge

2 Sealing rings
REMOVAL
CAUTION
Place a drain pan under the oil filter and dispose of waste oil In accor-
dance with local ordnances.
2. Pump out oil with scavenge pump (3) (paragraph 2.3.2.3).

3. Unscrew drain plug (8) from subcurrent filter assembly (4), remove sealing ring (9), and drain oil
into pan.
4. Remove screw (15) and washer (14).
5. Remove cover (13), spring (12), and sealing ring (11), from filter housing (10). Discard sealing ring
(11).
NOTE
Use a cloth to wipe excess oil from the area.
6. Remove oil filter cartridge (7) from filter housing (10) and discard.
INSTALLATION
1. Install drain plug (8) and new sealing ring (9).

2. Install oil filter cartridge (7) in filter housing (10).
3. Install cover (13), spring (12), and new sealing ring (11), on filter housing (10).
4. Install screw (15), washer (14), and tighten.
5. Fill with proper oil (paragraph 2.3.2.3).
6. Close flap (2).
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Figure 4-36. Oil Filter, Subcurrent Filter Maintenance.
Change 1 4-77
TM 9-6115-668-13
4.32 FUEL PREFILTER CARTRIDGE MAINTENANCE.
INITIAL SETUP
Tools Equipment Condition

Materials/Parts
Sealing rings
Filter insert
Lubricating grease
REMOVAL
The fuel in this generator set 150 kW is highly explosive. Do not

Place a drain pan under the fuel prefilter set to collect fuel.
2. Remove drain plug (11) from filter cup (9) and sealing ring (10) and discard sealing ring(10).
3. Remove bleed screw (5), sealing ring (4) and allow all fuel to flow out of filter cup (9). Discard seal-
ing ring(4).
4. Remove screw (3) and washer (3) from top (6) of fuel prefilter.
NOTE
Hold cup (9) tightly.
5. Remove fitter cup (9), sealing ring (7) and filter insert (8).
6. Empty remaining fuel from filter cup (9) into drain pan.
7. Pull filter insert (8) out of filter cup (9) and discard filter insert (8).
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INSTALLATION
1. Place new sealing ring (10) on drain plug (11) and screw drain plug (11) into filter cup (9)
2. Install new filter insert (8) into filter cup (9).
CAUTION
To prevent leaks, apply a thin coating of lubricating grease to the top
of sealing ring (7), insert Into top (6) of fuel filter, and push firmly In.
3. Align filter cup (9) containing filter insert (8) and new sealing ring (7) below top (6) and secure with
screw (2) and washer (3).
NOTE
Bleed screw (5) must not be tightened prior to bleeding fuel prefilter.
4. Install bleed screw (5) and new sealing ring 4).

5. Bleed fuel prefilter (see paragraph 4.38).
6. Close flap (1).
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4.33 TWO STEP FUEL FILTER CARTRIDGE MAINTENANCE.
INITIAL SETUP

Materials/Parts
Sealing ring
Filter cartridges (one is felt and one is paper)
Lubricating grease
REMOVAL
WARNING
Make sure that there are no open flames in the vicinity, and that fuel
cannot splash onto hot components. Failure to observe this warning
could result in severe personal Injury or death.
CAUTION
Place a drain pan under the two step fuel filter set to collect fuel.
2. Remove drain plugs (12, 22) and sealing rings (13, 23) and discard sealing rings (13, 23).
3. Remove bleed screws (19, 30) and sealing rings (18, 29) and allow all the fuel to flow out of filter
cups (14, 24). Discard sealing rings (18, 29).
NOTE
Remove cups in sequence, holding tightly.
4. Remove screw (21) and washer (20) from top (17) of two step fuel filter.
5. Remove filter cup (14), sealing ring (16), and filter insert (15). Discard sealing ring (16) and filter
insert (15).
6. Empty remaining fuel from filter cups (14) into drain pan.
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7. Remove screw (28), washer (27) from top (17) of two step fuel filter.
8. Remove filter cup (24), sealing ring (26) and filter insert (25). Discard sealing ring (26) and filter in-
sert (25).
9. Empty remaining fuel from filter cup(24) into drain pan.
INSTALLATION
NOTE
Item (15) Is felt filter element and Item (25) Is paper filter element.
1. Place new sealing ring (23) on drain plug (22) and install drain plug (22) in filter cup (24).
2. Place filter insert (25) into filter cup (24).
NOTE
Bleed screws (19) and (30) should not be tightened prior to bleeding
two step fuel filter.
3. To prevent leaks, apply a thin coating of lubricating grease to the tops of new sealing rings (16, 26),
insert into top (17) of two step fuel filter, and push firmly in.
4. Fill filter cup (24) with fuel to within 1 inch (2.5 cm) of rim.
5. Align filter cup (24) with filter insert (25) directly below top (17) and secure with screw (28) and
washer (27).
6. Install bleed screw (30) and new sealing ring (29).
7. Place new sealing ring (13) on drain plug (12) and install filter cup (14).
8. Insert filter insert (15) into filter cup (14).
9. Fill filter cup (14) with fuel to within 1 inch (2.5 cm) of rim.
10. Align filter cup (14) with filter insert (15) directly below top (17) and secure with screw (21) and
washer (20).
11. Install bleed screw (19) and new sealing ring (18).
12. Bleed two step fuel filter set (see paragraph 4.39).
13. Close flap (1).
4-81
TM 9-6115-668-13
Figure 4-37 Fuel Prefilter Cartridge, Two Step Fuel Filter Cartridges Maintenance.
4-82 Change 1
TM 9-6115-668-13
4.34 BATTERY CHARGING ALTERNATOR V BELT
This task covers: a. Service
INITIAL SETUP

(item 3, appendix B
SERVICE
1. Open flaps (1, 2 figure 4-38).

2. Loosen screw (3) on clamping bracket (4) of battery charging alternator (9).
3. Loosen screw (5) on clamping bracket (4).
4. Loosen screw (8) on battery charging alternator bracket.
CAUTION
When using a suitable tensioning device be careful not to bend the

oil line located between the engine block and battery charging al-
ternator.
At correct tension, belt should deflect no more than 0.6 inches (15
mm) when pressed with the thumb at a point between the pulleys.
5. Insert a suitable tensioning device as lever (11) between battery charging alternator (9) and engine
block.
6. Use lever (11) to push battery charging alternator (9) in the direction of the arrow.
7. When V belt tension is correct, tighten screw (3) on clamping bracket (4).
8. Tighten screw (5) on clamping bracket (4).
9. Tighten screw (8) on battery charging alternator bracket.
10. Close flaps (1, 2).
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TM 9-6115-668-13
4.35 BATTERY CHARGING ALTERNATOR V BELT MAINTENANCE.
INITIAL SETUP
General Mechanic’s Tool Kitt Reference

Materials/Parts
V belt, Summer (KHD 02235258)

V belt, Winter (KHD 01162093)
REMOVAL
1. Open flaps (1, 2 figure 4-38).

2. Remove air leading duct (paragraph 4.17) when possible.
NOTE
V belts are a matched set. Always replace both belts.
3. Loosen screw (3) from clamping bracket (4) of battery charging alternator (9).
4. Loosen screw (8) on battery charging alternator bracket.
5. Loosen screw (5).
6. Pivot battery charging alternator (9) upward toward engine block.
7. Remove V belts (7).
INSTALLATION
CAUTION
For amblent temperatures 24.8° F (-4° C) to 86° F (+30° C), use sum-
mer V belt.
For ambient temperatures 23° F (-5° C) to -49° F (45° C), use winter
V belts.
New V belts must be no more than 15% longer or shorter than the
old belts.
Operate V belts for no more than 15 minutes, then retension (para-
graph 4.34).
4-84
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NOTE
Bleed screws (19) and (30) should not be tightened prior to bleeding
two step fuel filter.
1. Install V belts (7) on battery charging alternator pulley (10) and engine pulley (6).
2. Tension V belts (7) (paragraph 4.34).
3. Install air leading duct (paragraph 4.17), if removed.
4-85
TM 9-6115-668-13
Figure 4-38. Battery Charging AIternator of V Belt Malntenance.
4-86 Change 1
TM 9-6115-668-13
4.36 DIESEL ENGINE CYLINDER COOLING FINS AND OIL COOLER MAINTENANCE.
This task covers: a. Inspection b. Service
INITIAL SETUP

INSPECTION
WARNING
To prevent severe personal injury from hot engine, perform this in-
spection only when engine is cold.
1. Open flaps (1, 5, figure 4-39).

2. Check cooling fins (2, 3) for dirt buildup.
3. Check oil cooler (4) for dirt buildup.
SERVICE
1. Clean cylinder cooling fins (2) and oil cooler (4):

a. Loosen deposits (mixture of dust, fuel, and oil) between cooling fins (2, 3) and on oil cooler (4)
with a wire brush.
WARNING
Eye protection must be worn when using compressed air to clean

parts. Failure to observe this warning could result In severe personal
Injury.
b. Blow compressed air from air discharge side to clean out cooling fins.
4-87
TM 9-6115-668-13
Figure 4-39 Diesel Engine Cylinder Cooling Fins and Oil Cooler Maintenance.
4-88
TM 9-6115-668-13
4.37 PRIMING PUMP MAINTENANCE

Sealing rings
CAUTION
Place a container underneath the two step fuel filter set and priming
pump to collect fuel as It emerges.
After disconnecting, plug fuel lines and tie up.
2. Using appropriate wrench hold nipple (7) and remove hollow screw (3) with sealing rings (4, 6) and
fuel supply line (5) from priming pump (10). Discard sealing rings (4, 6).
3. Using appropriate wrench hold nipple (12) and disconnect hose fitting (13) and fuel return line (14)
located on priming pump (10).
4. Remove two nuts (17), serrated lock washers (16) and washers (15) from screws (8).
5. Remove nipple (12) and sealing ring (11) from priming pump (10) and discard sealing ring (11).
6. Remove screws (8), washers (9) and priming pump (10) from angle rail (18).
1. Install priming pump (10), screws (8) and washers (9) on angle rail (18).
2. Install nuts (17), serrated lock washers (16) and washers (15) on screw (8).
3. Install nipple (12) and new sealing ring (11) on priming pump (10).
4. Install fuel return line (14) on nipple (12) and screw on hose fitting (13) and tighten.
5. Install hollow screw (3), fuel supply line (5) and new sealing rings (4, 6) on priming pump (10).
6. Close flap (2).
4-89
TM 9-6115-668-13
Figure 4-40. Priming Pump Assembly Maintenance.
4-90 Change 1
TM 9-6115-668-13
4.38 FUEL LINES AND PREFILTER ASSEMBLY MAINTENANCE.
INITIAL SETUP
Sealing rings Reference

Generator Set 150 kW shut
down, paragraph 2.5.2
REMOVAL
CAUTION
Place collection container under prefilter assembly.
2. Remove bleed screw (3) and sealing rings from prefilter assembly (2) and drain fuel into container.
Discard sealing rings.
SERVICE
1. Unscrew handle (4) by turning to the left.

2. Install bleed screw (3) with new sealing ring three turns into prefilter assembly (2).
3. Pull and push handle (4) of priming pump (5) until fuel emerging from hole in screw threads of bleed
screw (3) contains no bubbles and tighten bleed screw (3).
INSTALLATION
1. Remove collection container under prefilter assembly.

2. Close Flap (1).
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TM 9-6115-668-13
4.39 FUEL LINES AND TWO STEP FUEL FILTER ASSEMBLY MAINTENANCE.
This task covers: a. Removal b. Service C. Installation
INITIAL SETUP
Sealing rings Reference

Generator Set 150 kW shut
down, paragraph 2.5.2
REMOVAL
1. Open flap (1, figure 4-41)
CAUTION
Place collection container under two step fuel filter assembly.
2. Remove bleed screws (6, 7) and sealing rings from two step fuel filter assembly (8) and drain fuel
into container. Discard sealing rings.
SERVICE
1. Unscrew handle (4) by turning to the left.

2. Install bleed screws (6, 7) with new sealing ring three turns into fuel filter assembly (8).
3. Pull and push handle (4) of priming pump (5) until fuel emerging from hole in screw threads of bleed
screws (6, 7) contains no bubbles and tighten bleed screws (6, 7).
INSTALLATION
1. Remove collection container under two step fuel filter assembly.

2. Close Flap (1).
4-92
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Figure 4-41 Diesel Engine Fuel Pipes and Fuel Filter Assembly Maintenance.
4-93
TM 9-6115-668-13
4.40 FUEL PREFILTER ASSEMBLY MAINTENANCE.
INITIAL SETUP

Materials/Parts
Sealing rings
Plastic bag
Rubber bands
WARNING
Before removing, completely drain Fuel Prefilter Assembly and/or

Two Step Fuel Filter Assembly and all fuel lines connected to them.
Make sure there are no open flames in the vicinity while draining
fuel.
Wait until Generator Set 150 kW has cooled down before perform-
ing this task.
NOTE
If fuel lines are not to be reinstalled immediately, bag the ends with
plastic bags and secure with rubber bands.
REMOVAL
1. Remove unit hood assembly (1, figure 4-42) as instructed in paragraph 4.14.
CAUTION
Place a container under heavy duty fuel filter set and priming pump
to catch fuel as it emerges.
4-94
TM 9-6115-668-13
2. Remove condensation drain plug (11), and sealing ring (10) from fuel prefilter assembly (16) and
discard sealing ring (10).
3. Remove bleed screw (9), with sealing ring (8) and drain out fuel completely. Discard sealing ring (8).
NOTE
Install bleed screw (9) and drain plug (11) finger tight for storage only.
4. Install condensation drain plug (11) with sealing ring (10) and bleed screw (9).
5. Remove hollow screw (5), with sealing ring (8), sealing rings (6, 7) and fuel outlet line (4). Discard
sealing rings (6, 7)
6. Remove hollow screw (15), sealing rings (12, 14) and fuel supply line (13). Discard sealing rings
(12, 14)
7. Remove two nuts (21), two serrated lock washers (20) and two washers (19) from two screws (18).
8. Remove two screws (18), two washers (17), and fuel prefilter assembly (16) from angle rail (22).
INSTALLATION
NOTE
If fuel lines have been bagged, remove bags prior to this operation
1. Install fuel prefilter assembly (16) on angle rail (22) and insert two screws (18) with two washers
(17).
2. Secure with two washers (19) and two serrated lock washers (20) and two nuts (21).
NOTE
Use new sealing rings.
3. Install hollow screw (15) with new sealing rings (14, 12) and fuel supply line (13) on fuel prefilter
assembly (16).
4. Install hollow screw (5) with new sealing rings (6, 7) and fuel outlet line (4) on fuel prefilter assembly
(16).
5. Install condensation drain plug (11) with new sealing ring (10).
NOTE
Do not tighten bleed screw (9) with new t-sealing ring (8) until fuel system
is purged.
6. Bleed fuel system as instructed in paragraph 4.38 and 4.39.

7. Install hood assembly (1) as instructed in paragraph 4.14.
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TM 9-6115-668-13
4.41 TWO STEP FUEL FILTER ASSEMBLY MAINTENANCE.
INITIAL SETUP

Materials/Parts
Sealing rings
Plastic bag
Rubber bands
NOTE
If fuel lines are not immediately reinstalled, bag the ends with plastic
bags and secure with rubber bands.
REMOVAL
CAUTION
Place a container under heavy duty fuel filter set and priming pump
to catch fuel as it emerges.
2. Remove condensation drain plugs (30, 31) and sealing rings (29, 32). Discard sealing rings (29,
32).
3. Remove bleed screws (28, 34) with sealing rings (27, 33) and discard sealing rings (27, 33). Drain
out fuel completely.
NOTE
Install bleed screws (27, 34) and condensation plugs (30, 31) finger
tight only
4. Install condensation drain plugs (30, 31) with sealing rings (29, 32) and bleed screws (27, 34).
5. Remove hollow screw (24) with sealing rings (25, 26) and fuel supply line (23). Discard sealing rings
(25, 26).
6. Remove hollow screw (35), sealing rings (36, 37) and fuel return line (38). Discard sealing rings (36,
37).
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7. Remove two nuts (45), two serrated lock washers (46) and two washers (47) from two screws (43)
and pull out one screw (43) with lock washer (42).
8. Remove two step fuel filter (41) from angle rail (22) by holding fuel lines (39, 40), clamps (44) and
screw (43) with washer (42).
1. place two step fuel filter (41) on angle rail (22) by holding fuel lines (39, 40), clamps (44), and screw
(43) with washer (42).
2. Install one screw (43) with washer (42), two washers (47), two serrated lock washers (46) and two
nuts (45) onto two screws (43), lighten nuts (45).
NOTE
Use new sealing rings.
3. Install hollow screw (35), new sealing rings (36, 37) and fuel return line (38) on two step fuel filter
assembly (41).
4. Install hollow screw (24), new sealing rings (25, 26) and fuel inlet line (23) on two step fuel filter as-
sembly (41).
5. Install condensation plugs (30.31) with new sealing rings (29) and (32).
NOTE
Do not tighten bleed screws (27, 34) prior to bleeding the fuel system.
6. Install bleed screws (27, 34) with new sealing rings (28, 33).
7. Bleed fuel system as instructed in paragraph 4.38 and 4.39.
8. Install unit hood assembly (1) as instructed in paragraph 4.14.
4-97
TM 9-6115-668-13
Figure 4-42. Fuel Prefilter, Two Step Fuel Filter Maintenance.
4-98 Change 1
TM 9-6115-668-13
4.42 FUEL LINE ASSEMBLY MAINTENANCE.
INITIAL SETUP

Materials/Parts
Sealing rings
Plastic bag
Rubber bands
Cable ties
(item 10, Appendix E)
REMOVAL
CAUTION
Use a container or rag to clean up fuel leaks
After disconnecting, plug fuel line and tie up.

Place drip pan under fuel lines to catch fuel.
2. Remove nuts (36), serrated lock washers (37), washers (38) and plate (34)
NOTE
If fuel lines are not replaced at once, bag and secure ends.
3. Remove cable ties from fuel lines.
NOTE
Step 4 is used in removal of fuel lines (5), (7), (8), (25) and (32).
4. Hold nipple (30) and remove hollow screw (27),fuel line (25), sealing rings (28, 29) and discard
sealing rings (28, 29).
5. Fuel line (25)
a. Perform step 4 and remove fuel line (25).
b. Remove tapered screw (26) from engine block (41) with fuel line (25).
c. Remove fuel line (25).
6. Fuel line (32)
4-99
TM 9-6115-668-13

7. Fuel supply line (8)
a. Perform step 4 and remove fuel supply line (8).
b. Remove hollow screw (10) from priming pump (9) with sealing rings (11, 12) and discard sealing
rings (11, 12).
c. Remove fuel supply line (8).
8. Fuel line (7)
b. Loosen clamp (6) and remove fuel line (7) from preheating assembly (3).
9. Fuel line (5)
b. Loosen clamp (4) and remove fuel line (5) from preheating assembly (3).
10. Fuel line (16)
a. Drain fuel prefilter assembly (15) as instructed in paragraph 4.38.
b. Remove fuel line (16) from priming pump (9).
c. Remove fuel line (16) from fuel prefilter assembly (15).
d. Remove fuel line (16).
11. Fuel line (20)
a. Remove hollow screw (24) from two step fuel filter set (19) with sealing rings (22, 23) and fuel
line (20). Discard sealing rings (22, 23).
12. Fuel line (13)
a. Drain two step fuel filter set (19) as instructed in paragraph 4.39.
b. Loosen clamps (42) from two step fuel filter set (19).
d. Remove tapered screw (14) with fuel line (13).
e. Remove fuel line (13).
4-100
TM 9-6115-668-13
13. Fuel line (17)

a. Drain two step fuel filter set (19) as instructed in paragraph 4.39.
b. Loosen clamps (42) from two step fuel filter set (19).
d. Remove tapered screw (18) from engine block (41) with fuel line (17).
e. Remove fuel line (17).
INSTALLATION
1. Fuel line (17)

a. Install fuel line (17) on engine block (41).
b. Tighten tapered screw (18).
c. Install hollow screw with new sealing rings and fuel line (17) on two step fuel filter assembly (19).
d. Bleed fuel system as instructed in paragraph 4.39.
2. Fuel line (13)
c. Install hollow screw with new sealing rings and fuel line (13) on two step fuel filter assembly (19).
3. Fuel line (20)
c. Install hollow screw (24) with new sealing rings (22, 23) and fuel line (20) on two step fuel filter
assembly (19).
4. Fuel line (16)
a. Install hollow screw with new sealing rings and fuel line (16) on fuel prefilter assembly (15).
b. Install hollow screw with new sealing rings and fuel line (16) on priming pump (9).
c. Bleed fuel system as instructed in paragraph 4.38.
5. Fuel line (5)
a. Install fuel line (5) on preheating assembly (3) and tighten clamp (4).
b. Install hollow screw with new sealing rings and fuel line (5) on fuel tank (31).
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TM 9-6115-668-13
6. Fuel line (7)

a. Install fuel line (7) on preheating assembly (3) and tighten clamp (6).
b. Install hollow screw with new sealing rings and fuel line (7) on fuel tank (31).
7. Fuel supply line (8)
a. Install hollow screw (10) with new sealing rings (11, 12) and fuel supply line (8) on priming pump
(9).
b. Install hollow screw with new sealing rings and fuel supply line (8) on fuel tank (31).
c. Bleed fuel system as instructed in paragraph 4.38.
8. Fuel line (32)
c. Install hollow screw with new sealing rings and fuel line (32) on fuel tank (31).
9. Fuel line (25)
c. Install hollow screw with new sealing rings and fuel line (25) on fuel tank (31).
10. To install unit hood assembly (1) refer to paragraph 4.14.
4-102
TM 9-6115-668-13
Figure 4-43. Fuel Line Assembly Maintenance.
Change 1 4-103
TM 9-6115-668-13
4.43 CONTROL CABINET ASSEMBLY MAINTENANCE.

(Item 2, appendix B) Generator Set 150 kW shut
Wrench, Shop Manufactured
Sling/Hoisting Device, Universal
Cable ties Two

tery terminal cable. Failure to observe this warning could result in se-
CAUTION
2. Open front panel (3) and secure with prop (4).
3. Remove eighteen bolts (8), eighteen serrated lock washers (7) and eighteen washers (6) from con-
trol cabinet connection panel.
4. Open control cabinet connection panel (5) and support the panel.
5. Remove two nuts (38), two serrated lock washers (37), two washers (36), two screws (34), two
washers (35) and cover (39) from control cabinet assembly (2).
CAUTION
Observe the correct sequence when removing cables and corrugated
hoses and tag the accordingly.
4-104
TM 9-6115-668-13
6. Record labeling and position of cables (70) to load contactor K1 (69).

7. Remove upper covers from busbars and open cable conduit above load contactor K1 (69) and the
one to the right of it.
8. Remove three nuts (74), three serrated lock washers (73), three washers (72), six cables (70), and
three heat sinks (71) from terminals of load contactor K1 (69).
9. Record labeling and position of cables to terminal strip X101 (24) on preheating control board (25).
10. Remove nut (13) from cable union, and pull preheating control cable (14) out of back panel of con-
trol cabinet assembly (2).
NOTE
Hold standoffs (21) while unscrewing nuts (18).
11. Remove two nuts (18), two serrated lock washers (19), and two washers (20)
12. Swing digital isochronous load sharing module N4 (16), cover (17) and attached grounding cable
(15) aside and open cable conduits below and beside speed governor assembly N1 (23).
13. Record labeling and position of cables (10, 12) to terminal strip (22).
14. Disconnect cables (12), unscrew nut (11) from cable union and pull actuator cable (12) out of back
panel of control cabinet assembly (2).
15. Disconnect cables (10), unscrew nut (9) from cable union and pull pickup cable (10) out of back
panel of control cabinet assembly (2).
16. Remove eight screws (33), eight serrated lock washers (32), eight washers (31) and cover (30)
from filter box FK (28).
17. Record labeling and position of cables (27) to input terminal strip (29).
18. Disconnect cables of generator cable harness (27) from input terminal strip (29).
19. Remove locknut (26) from cable union and pull generator cable harness (27) out of back panel of
control cabinet assembly (2).
20. Remove cable 141 (52) from terminal N of control cabinet connection panel (5).
21. Disconnect cables 163 (51) at T1, 164 (50) at T2, 76 (49) at I2 and 77 (48) at K2 from the lower
terminals (47) of connection strip Xl (46).
4-105
TM 9-6115-668-13
WARNING
This procedure requires the aid of two assistants and a sling lifting
device to prevent severe personal Injury.
To prevent Injury from contact with filter box FK, wear gloves when
unscrewing nuts from the corrugated hoses.
22. Remove nut (53) from corrugated hose (81) and remove from cables.
23. Remove nut (64), serrated lock washer (65), washer (66), and generator cable 80 (67) from load
contactor K1 (69).
25. Remove nut (54), serrated lock washer (55), washer (56) and generator cable 78 (57) from load
contactor K1 (69).
27. Remove nut (59), serrated lock washer (60), washer (61) and generator cable 79 (62) from load
contactor K1 (69).
29. Remove nut (45), serrated lock washer (44), washers (41, 43), and grounding strap (42) from
threaded pin (40) on control cabinet unit (2).
30. Remove eight bolts (77) from shock absorbers (76).
31. Place sling around control cabinet assembly (2), being careful that sling is positioned between con-
trol cabinet connection panel (5) and control cabinet (2) and attach to hoisting device.
WARNING
Stay clear of the suspended load.
CAUTION
Care must be taken to ensure cables and cable ends do not snag or
become damaged during lifting.
32. Lift control cabinet assembly (2) gently off base frame (75) with one assistant feeding all cables
through the back of the control cabinet (2).
33. When cables are free of the control panel (2) lift control panel completely off unit and set on a flat
surface or mounting.
4-106
TM 9-6115-668-13
Figure 4-44 Control Cabinet Assembly Maintenance (Sheet 1 of 2).
4-107
TM 9-6115-668-13
Figure 4-44 Control Cabinet Assembly Maintenance (Sheet 2 of 2).
4-108
TM 9-6115-668-13
INSTALLATION
1. Place sling around control cabinet (2) and attach to hoisting device using the same Warnings and
Cautions during the installation.
2. Lift control cabinet (2) and with the aid of assistants place all cables in the back of the control cabi-
net and place on base frame assembly (75).
3. Install eight bolts (77) into shock absorber (76) and screw into base frame assembly (75).
4. Unhook sling from hoisting device and detach from control cabinet (2).
5. Install washer (41, 43), serrated lock washer (44) and grounding strap (42) on threaded pin (40) and
install on nut (45).
CAUTION
Tighten screws at connections to contactor K1 with torque wrench to
the torque value In table (Item G.1, appendix G).
NOTE
Note the correct sequence when Installing the cables and corrugated
hoses by observing the tags Installed on cables during the removal
procedure.
6. Install corrugated hose (78) with cables into back panel of control cabinet assembly (2).
7. Slide nut (63) over cable and screw onto corrugated hose (78).
8. Place generator cable 79 (62), serrated lock washer (60), and washer (61) on bolt and install nut
(59) onto terminal of load contactor K1 (69).
17. Connect cables 77 (48) to K1, 76 (49) to I2, 164 (50) to T2 and 163 (51) to T1 at lower terminals
(47) of connection strip Xl (46).
18. Install cable 141 (52) onto terminal N of control cabinet connection panel (5).
19. Insert generator cable harness (27) into back panel of control cabinet assembly (2), slide nut (26)
over cable and install onto cable union.
20. Connect cables of generator cable harness (27) to input terminal strip (29).
4-109
TM 9-6115-666-13
21. Place cover (30) on filter box FK (28) and install eight washers (31), eight serrated lock washers
(32), and screw eight screws (33) into filter box FK (28).
22. Install pickup cable (10) into back panel of control cabinet assembly (2), slide nut (9) over cable and
install onto cable union, connect cable on terminal strip (22) of speed governor N1 (23).
23. Install actuator cable (12) into back panel of control cabinet assembly (2), slide nut (13) over cable
and install onto cable union, connect cable on terminal strip (22) of speed governor N1 (23).
24. Close cable conduits below and beside speed governor assembly N1 (23) and swing digital isochro-
nous load sharing module N4 (16) back.
25. Install two nuts (18), two serrated lock washers (19), and two washers (20).
26. Install preheating assembly control cable (10) into back panel of control cabinet assembly (2), slide
nut (13) over cable and install onto cable union, connect cable on terminal strip X101 (24) on pre-
heating control board (25).
27. Install three heat sinks (71), six cables (70), three washers (72), three serrated lock washers (73),
and screw three nuts (74) onto terminals of load contactor K1 (69).
28. Install upper covers on busbar and close cable conduit above and beside load contactor K1 (69).
29. Place cover (39) on control cabinet assembly (2) and install two screws (34), two washers (35), two
washers (36), two serrated lock-washers (37), and two nuts (38).
30. Close control cabinet connection panel (5).
31. Secure control cabinet connection panel (5) with eighteen bolts (8), eighteen serrated lockwashers
(7), and eighteen washers (6).
33. For installation of unit hood assembly (1) refer to paragraph 4.14.
4-110
TM 9-6115-668-13
4.44 PUSHBUTTON SWITCH AND INDICATOR ASSEMBLY MAINTENANCE.
INITIAL SETUP

Materials/Parts
Cable ties
WARNING
CAUTION
Tag all cables prior to removal to ensure correct connection of the cables
during Installation.
REMOVAL

NOTE
Procedure for removing pushbutton switch and light Indicator H5/S17
(II), H9/S5 (9), H10/S6 (8), H11/S22 (6), H12/S9 (15), H13/S10 (7), H14/S8
(14), H16/S19 (13), H101/S102 (12) Is the same as for pushbutton
switch and light indicator H8/S4 (10), described below.
3. Light Indicator H8:

a. Record labeling and position of cables to bulb holder (25).
b. Disconnect cables from terminals (26, 28).
c. Use a screwdriver to push in upper and lower closures (24) on bulb holder (25) until they snap
in, and remove bulb holder (25) with bulb (20) from base (21).
4-111
TM 9-6115-668-13
4. Pushbutton Switch S4:

a. Record labeling and position of cables to contact block (30).
b. Disconnect cables from terminals (27, 29).
c. Use a screwdriver to push in upper and lower closures (23) on contact block (30) until they snap
in, and remove contact block (30).
6. Unlock ring (16), colored plate (17), housing (18), and sealing ring (19) on front of front panel by
turning counterclockwise.
7. Pull ring (16) with colored plate (17), housing (18), and sealing ring (19) out of front of front panel
(4) and remove base (21) from back of front panel (4).
INSTALLATION
NOTE
Procedure for installing pushbutton switch and light indicator H5/S17
(11), H9/S5 (9), H10/S6 (8), H11/S22 (6), H12/S9 (15), H13/S10 (7), H14/S8
(14), H16/S19 (13), H101/S102 (12) is the same as for pushbutton
switch and light Indicator H8/S4 (10), described below.
1. Insert ring (16), colored plate (17), housing (18), and sealing ring (19) into front of front panel (4)
and hold base (21) against front panel (4) from behind.
2. Push ring (16) with colored plate (17) and housing (18) with sealing ring (19) into base (21) and turn
clockwise to secure to base (21).
3. Light indicator H8:
a. Clip bulb holder (25) with bulb (20) onto base (21).
b. Reconnect cables to terminals (27, 28) of bulb holder (25), noting correct labeling and position.
4. Pushbutton switch S4:
a. Clip contact block (30) onto base (21).
b. Reconnect cables to terminals (26, 29) of contact block (30), noting correct labeling and position.
7. Close flap (2).
4-112
TM 9-6115-668-13
Figure 4-45 Control Cabinet Assembly, Pushbutton Switch and Indicator Assembly Maintenance.
4-113
TM 9-6115-668-13
4.45 PUSHBUTTON SWITCH MAINTENANCE.
INITIAL SETUP

Materials/Parts
Cable ties
WARNING
CAUTION
REMOVAL

2. Open front panel (4) on control cabinet assembly (3) and secure with prop (5).
NOTE
Removal procedure for pushbutton switch S101 (6), S18 (7), S20 (9) is
the same as for pushbutton switch S7 (8), described below.
3. Record labeling and position of cables to contact block (17).

4. Disconnect cables from terminals (18, 19) of contact block (17).
5. Use a screwdriver to push in upper and lower closures (16) until they snap in, and remove contact
block (17) from base (14).
7. Unlock ring (10) with colored plate (11) and housing (12) with sealing ring (13) on front of front panel
by turning counterclockwise.
4-114
TM 9-6115-668-13
8. Pull ring (10) with colored plate (11) and housing (12), and sealing ring (13) out from front of front
panel (4) and remove base (14) from rear of front panel (4).
INSTALLATION
NOTE
lnstallation procedure for pushbutton switch S101 (6), S18 (7), S20 (9)
is the same as for pushbutton switch S7 (8), described below.
1. Insert housing (12), sealing ring (13), colored plate (11), and ring (10) into front panel (4) from the
front and hold base (14) against front panel (4) from the back.
2. Push housing (12), sealing ring (13), colored plate (11) and ring (10) into base (14) and secure to
base (14) by turning clockwise.
4. Install contact block (17) on base (14).
5. Reconnect cables to terminals (18, 19) of contact block (17), noting correct labeling and position.
7. Close flap (2).
4-115
TM 9-6115-668-13
Figure 4-46 Control Cabinet Assembly, Pushbutton Switch Maintenance.
4-116
TM 9-6115-668-13
4.46 PANEL ILLUMINATION H6 MAINTENANCE.

tery terminal cables. Failure to observe this warning could result In se-

cables during Installation.

3. Remove cover panel (6) from lamp base (11) of panel illumination H6.
4. Disconnect cable from terminal (7) of bayonet socket (8) by loosening set screw.
5. Pull bulb (9) with bayonet socket (8) to the right and out of lamp base (11).
6. Tag and disconnect cables from terminals of lamp base (11).
7. Remove two nuts (14), two serrated lock washers (13), and two washers (12) from front panel (4).
8. Remove two screws (10) and lamp base (11) from front panel (4).
1. Install lamp base (11) with two screws (10) on front panel (4).
2. Install two serrated lock washers (13) and two washers (12) on two screws (10) and thread on two
nuts (14).
3. Connect cables to terminals of lamp base (11).
4. Insert bulb (9) and bayonet socket (8) into lamp base (11) until bulb is seated fully in socket.
5. Connect cable to terminal (7) of bayonet socket (8) by tightening set screw.
6. Install cover panel (6) on lamp base (11) of panel illumination H6.
8. Close flap (2).
4-117
TM 9-6115-668-13
Figure 4-47 Control Cabinet Assembly, Panel Illumination H6 Maintenance.
4-118
TM 9-6115-668-13
4.47 PREHEATING RESISTOR R1 MAINTENANCE.

Materials/Parts
Cable ties


3. Pull cable 48 (6) with flat connector from terminal (7).
4. Loosen nut (8), remove cable 4.
6. Remove two nuts (10), two serrated lock washers (11), and two washers (12).
7. Remove top resistor (13).
8. Remove two standoffs (14), two nuts (15), two serrated lock washers (16), and two washers (17).
11. Remove bottom resistor (20) from studs (21).
4-119
TM 9-6115-668-13
1. Place bottom resistor (20) on studs (21)
Tighten screws and stand offs on studs with torque wrench to the
torque value In table (Item G.2, appendix G).
2. Secure bottom resistor (20) with two washers (17), two serrated lock washers (16), and two nuts
(15).
3. Install cable 23 and tighten nut (18), install cable 4 and tighten nut (19).
4. Install two standoffs (14).
5. Place top resistor (13) on standoffs (14).
6. Secure top resistor (13) with two washers (12), two serrated lock washers (11), and two nuts (10).
7. Install cable 23 and tighten nut (9).
8. Install cable 4 and tighten nut (8).
9. Install cable 48 (6) with flat connector on terminal (7).
11. Close flap (2).
4-120
TM 9-6115-668-13
4.48 BATTLE SHORT SWITCH S21 MAINTENANCE.

Materials/Parts
Cable ties


3. Record labeling and position of cables (22) and disconnect cables (22) from terminals of BATTLE
SHORT switch S21 (26).
4. Remove two screws (25), two serrated lock washers (24), two washers (23) and cable (22) from
BATTLE SHORT switch S21 (26).
5. Remove screws (28) and cap (27) from front panel (4).
6. Pull BATTLE SHORT switch S21 (26) from rear of front panel (4).
1. Install BATTLE SHORT switch S21 (26) from rear of front panel (4).
2. Install cap (27) on front panel (4) with two screws (28).
3. Screw BATTLE SHORT switch S21 (26) and cap (27) together through front panel (4).
4. Install cable (22), two washers (18) and two serrated lock washers (19) on two screws (20).
4-121
TM 9-6115-668-13
5. Connect cable (22) to terminals of BATTLE SHORT switch S21 (26), noting correct labeling and
position.
7. Close flap (2).
4-122
TM 9-6115-668-13
4.49 VOLTAGE SELECTOR SWITCH S11 MAINTENANCE.

Materials/Parts
Adhesive
Cable ties
tery terminal cables. Failureto observethis warning could result in se-


3. Record labeling and position of cables (36) to VOLTAGE SELECTOR SWITCH S11 (34).
4. Disconnect cable (36) from terminals of VOLTAGE SELECTOR SWITCH S11 (34).
5. Loosen screw (29) in switch knob (30) remove switch knob (30) from switch (34).
Do not break off lugs (arrows) from plate when prying out.
6. With a screwdriver, carefully pry dial plate (31) from frame in plate (33).
7. Remove screws (32) and remove plate (33) from front panel (4).
8. Pull VOLTAGE SELECTOR SWITCH S11 (34) with capacitor C2 (35) from front panel (4).
4-123
TM 9-6115-668-13
9. Disconnect capacitor C2 (35) from VOLTAGE SELECTOR SWITCH S11 (34), and retain for re-use.
Connect capacitor C2 (36) to VOLTAGE SELECTOR SWITCH S11 (34)

with adhesive.
1. Push VOLTAGE SELECTOR SWITCH S11 (34) with capacitor C2 (35) from the rear of front panel
(4).
2. install plate (33) using screws (32) on front panel (4).
3. Push dial plate (31) into frame of plate (32) until lugs snap into place.
4. install switch knob (30) onto switch shaft and tighten screw (29).
5. Connect cable (36) to terminals of VOLTAGE SELECTOR SWITCH S11 (34), noting correct label-
ing and position.
7. Close flap (2).
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TM 9-6115-668-13
4.50 GLOWPLUG/START SWITCH S2 MAINTENANCE.
TOOLS Equipment Conditions

Materials/Parts
Cable ties
Tag ail cables prior to removal to ensure correct connection of the


3. Record labeling and position of cables (39) to terminals (40) of GLOWPLUG/START switch S2 (38).
4. Loosen screws (40) and remove cables (39) from GLOWPLUG/START switch S2 (38).
5. Remove nut (37) from GLOWPLUG/START switch S2 (38) and pull GLOWPLUG/START switch S2
(38) from rear of front panel (4).
1. Install GLOWPLUG/START switch S2 (38) through the rear of front panel (4) and install nut (37) on
GLOWPLUG/START switch S2 (38).
2. install cables (39) on terminals of GLOWPLUG/START switch S2 (38), noting correct labeling and
position, and tighten screw (38).
4. Close flap (2).
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TM 9-6115-668-13
4.51 MASTER SWITCH S1 MAINTENANCE.

Materials/Parts
Cable ties


3. Remove key (41) from MASTER SWITCH S1 (43).
4. Record labeling and position of cables (44) to terminals (40) of MASTER SWITCH S1 (43).
5. Loosen screws (45) and remove cables (44) from MASTER SWITCH S1 (43).
6. Remove nut (42) from MASTER SWITCH S1 (43) and pull MASTER SWITCH S1 (43) from front
panel (4).
1. Install MASTER SWITCH S1 (43) through rear of front panel (4) and install nut (42) on MASTER
SWITCH S1 (43).
2. Install cables (44) on terminals of MASTER SWITCH S1 (43), noting correct labeling and position,
and tighten screws (45).
3. Insert key (41) into MASTER SWITCH S1 (43).
5. Close flap (2).
4-126
TM 9-6115-668-13
Figure 4-48 Control Cabinet Assembly, Preheating Resistor R1, BATTLE SHORT Switch S21, VOLTAGE
SELECTOR SWITCH S11 GLOWPLUG/START Switch S2, MASTER SWITCH S1 Maintenance.
4-127
TM 9-6115-668-13
4.52 FREQUENCY ADJUST R4 MAINTENANCE.
This task covers: a. Removal b. Installa-

tion

(item 2, appendix B) Generator Set 150 kW
Automotive Fuel and Electrical System Repair, Tool Kit shut down,
Materials/Parts
Solder
Cable ties


3. Record labeling and position of cables (8) and unsolder cables (8) from terminals (10) of FRE-
QUENCY ADJUST R4 (9) potentiometer.
4. Unsolder resistor R4A (7) from terminals (10) of FREQUENCY ADJUST R4 (9) potentiometer,
5. Loosen socket head screw (16) on rotary knob (15) and remove rotary knob (15) and dial (14) and
stop plate (13).
6. Remove threaded element (12) and remove FREQUENCY ADJUST R4 potentiometer (9) and ser-
rated lock washer (11) from the rear of front panel (4).
4-128
TM 9-6115-668-13
1. Install FREQUENCY ADJUST R4 (9) potentiometer and serrated lock washer (11) on rear of front
panel (4), and install threaded element (12) on FREQUENCY ADJUST R4 (9).
Turn the shaft of FREQUENCY ADJUST R4 potentiometers (9) all

the way counterclockwise.
Rotate dial (14) with rotary knob (15) all the way counterclockwise.
Make sure stop plate (13) is installed in the correct position.
2. Slide stop plate (13) on shaft of FREQUENCY ADJUST R4 (9) potentiometer so the lower tab of
stop plate (13) fits into the hole in front panel (4).
3. Install dial (14) and rotary knob (15) on shaft of FREQUENCY ADJUST R4 potentiometer (9).
4. Secure rotary knob (15) on FREQUENCY ADJUST R4 potentiometer (9) by tightening socket head
screw (16).
5. Noting correct labeling and position, solder cables (8) on terminals (10) of FREQUENCY ADJUST
R4 (9) potentiometer.
6. Solder resistor R4A (7) on terminals (10) of FREQUENCY ADJUST R4 potentiometer (9).
8. Close flap (2).
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TM 9-6115-668-13
4.53 VOLTAGE ADJUST R3 MAINTENANCE.

Materials/Parts
Solder
Cable ties


3. Record labeling and position of cables (25) and unsolder cables (25) from terminals (24) of VOLT-
AGE ADJUST R3 potentiometer (23).
4. Loosen socket head screw (18) on rotary knob (17) and remove rotary knob (17), dial (19) and stop
plate (20).
5. Remove threaded element (21) and remove VOLTAGE ADJUST potentiometer R3 (23) and ser-
rated lock washer (22) from the rear of front panel (4).
4-130
TM 9-6115-668-13
1. Install VOLTAGE ADJUST potentiometer R3 (23) and serrated lock washer (22) on rear of front
panel (4). Install threaded element (21) on VOLTAGE ADJUST potentiometer R3 (23).
Rotate shaft of potentiometers VOLTAGE ADJUST R3 (23) all the

way counterclockwise.
Rotate dial (19) with rotary knob (17) all the way counterclockwise.
Make sure stop plate (20) is installed in the correct position.
2. Slide stop plate (20) onto shaft of VOLTAGE ADJUST potentiometer R3 (23) so that lower tab of
potentiometer (23) fits into hole in front panel (4).
3. Install dial (19) and rotary knob (17) on VOLTAGE ADJUST R3 potentiometer (23).
4. Secure rotary knob (17) onto shaft of VOLTAGE ADJUST R3 potentiometer (23) by tightening
socket head screw (18).
5. Noting correct labeling and position, solder cable (25) to terminals (24) of VOLTAGE ADJUST R3
potentiometer (23).
7. Close flap (2).
4-131
TM 9-6115-668-13
4.54 PANEL DIMMER S16/R2 MAINTENANCE.

Fork-head screwdriver
Materials/Parts
Solder (item 12, appendix E)

Cable ties (item 10, appendix E)

cables during Installation.

3. Record labeling and position of cables (34) and unsolder cables from terminals (32) on PANEL DIM-
MER S16/R2 (31).
4. Remove cover cap (27) from rotary knob (28).
5. Remove slotted nut (26) and rotary knob (28) from shaft of PANEL DIMMER S16/R2 (33).
6. Remove nut (29) and graduated dial (30).
7. Remove PANEL DIMMER S16/R2 (33) and serrated lock washer (31) from the rear of front panel (4).
4-132
TM 9-6115-668-13
1. Install PANEL DIMMER S16/R2 (33) and serrated lock washer (31) through the rear of front panel
(4).
2. Install graduated dial (30) on PANEL DIMMER S16/R2 (33) and secure PANEL DIMMER S16/R2
(33) with nut (29).
Rotateshaft PANEL DIMMER S16/R2 all the way counterclockwise; be-

fore tightening, set pointer of rotary knob to zero on graduated dial
(OFF position of switch S16).
3. Slide rotary knob (28) on PANEL DIMMER S16/R2 (33), set pointer to zero position, and secure
rotary knob (28) with slotted nut (26) on PANEL DIMMER S16/R2 (33).
4. Install cover cap (27) on rotary knob (28) and slotted nut (26).
5. Noting correct labeling and position, solder cables (34) on terminals (32) of PANEL DIMMER
S16/R2 (33)
7. Close flap (2).
4-133
TM 9-6115-668-13
Figure 4-49 Control Cabinet Assembly, FREQUENCY ADJUST R4, VOLTAGE ADJUST R3, PANEL
DIMMER S16/R2 Maintenance.
4-134
TM 9-6115-668-13
4.55 FREQUENCY METER P5 MAINTENANCE.

Materials/Parts
Cable ties


3. Remove cover panel (7) from terminals (9) of FREQUENCY meter P5 (6) by pulling cover panel (7)
outward.
4. Record labeling and position of cables and disconnect cables from terminals (9) of FREQUENCY
meter P5 (6).
5. Loosen screw (12), swing angle piece (11) to the side, and remove bar (10) from housing of FRE-
QUENCY meter P5 (6).
6. Remove FREQUENCY meter P5 (6) from front panel (4).
1. Install FREQUENCY meter (6) on front panel (4).

2. Install bar (10) on housing of FREQUENCY meter P5 (6), swing angle piece (11) over FRE-
QUENCY meter P5 (6) and tighten screw (12).
3. Noting correct labeling and position, connect cables to terminals (9) of FREQUENCY meter P5 (6).
4-135
TM 9-6115-668-13
4. Install cover panel (7) over terminals (9) on FREQUENCY meter P5 (6) by pushing cover panel (7)
in until it is seated properly.
6. Close flap (2).
4-136
TM 9-6115-668-13
4.56 METER MAINTENANCE.

Materials/Parts
Cable ties


The removal procedure for meter - OIL PRESSURE P9 (13), HOUR-

METER P8 (15) and FUEL LEVEL P11 (16) - is the same as described
below.
3. Remove OIL TEMPERATURE meter P10 (14):

a. Record labeling and position of cables (20, 24) and disconnect cables from terminals (21, 23) on
OIL TEMPERATURE meter P10 (14).
b. Remove knurled nuts (17), serrated lock washers (18), retaining bracket (19), and remove from
OIL TEMPERATURE meter P10 (14).
c. Remove OIL TEMPERATURE meter P10 (14) and insulation (22) from panel (4).
4-137
TM 9-6115-668-13
The removal procedure for meter - AMPS L1 P1 (33), AMPS L2 P2 (34),

AMPS L3 P3 (35), VOLTAGE P6 (32), and BATTERY CHARGE P7 (31)
- is the same as described below.
4. Remove KILOWATTS meter P4 (25):

a. Record labeling and position of cables (28) and disconnect cables from terminals (27) on KILO-
WATTS meter P4 (25).
b. Remove threaded rod (30), using hook (29) from housing (26) of KILOWATTS P4 meter (25).
c. Remove KILOWATTS meter P4 (25) from front panel (4).
The Installation procedure for meter - AMPS L1 P1 (33), AMPS L2 P2

(34), AMPS L3 P3 (35) VOLTAGE P6 (32), and BATTERY CHARGE P7
(26) - is the same as described below.
1. Install KILOWATTS meter P4 (25):

a. Install KILOWATTS meter P4 (25) on front panel (4).
b. Install hook (29) and threaded rod (30) on housing (26) of KILOWATTS meter P4 (25) and
tighten threaded rod (30).
c. Noting correct labeling and position, connect cables (28) to terminals (27) on KILOWATTS meter
P4 (25).
The installation procedure for meter - HOURMETER P8 (16), OIL

PRESSURE P9 (14), and FUEL LEVEL P11 (16) - Is the same as de-
scribed below.
2. Install OIL TEMPERATURE meter P10 (14):

a. Install OIL TEMPERATURE meter P10 (14) and insulation (22) on front panel (4).
b. Install retaining bracket (19) on OIL TEMPERATURE meter P10 (14), using serrated lock wash-
ers (18), and knurled nuts (17).
c. Noting correct labeling and position, install cables (20, 24) on terminals (21, 23) of OIL TEM-
PERATURE meter P10 (14).
4. Close flap (2).
4-138
TM 9-6115-668-13
Figure 4-50 Control Cabinet Assembly, Meter Maintenance.
4-139
TM 9-6115-668-13
4.57 CABINET ILLUMINATION H7 MAINTENANCE.

Materials/Parts
Cable ties
tery terminal cables. Failure to observe this warning could result in se

3. Remove cover panel (6) from lamp base (10) of indicator H7.
4. Pull flat connectors (13, 14) with cables off contacts of lamp base (10).
5. Remove nuts (7), serrated lock washers (8), and washers (9).
6. Remove lamp base (10) and bulb (11) from threaded pin (25) on control cabinet assembly (3).
1. Install lamp base (10) on threaded pin (25) on control cabinet assembly (3).
Tighten nuts on threaded pins to the torque value In table

(item G.2, appendix G).
2. Install serrated lock washers (8) washers (9) and nuts (7) on threaded pin (25).
3. Install flat connectors (13, 14) with cables on contacts of lamp bases (10).
4. Install cover panel (6) on lamp base (10) of indicator H7.
6. Close flap (2).
4-140
TM 9-6115-668-13
4.58 DOOR CONTACT SWITCH S3 MAINTENANCE.

Materials/Parts
Cable ties


3. Remove cables (30) from terminals (29) of door contact switch S3 (28).
4. Remove screws (26) and serrated lock washers (27) from door contact switch S3 (28).
5. Remove door contact switch S3 (28) from angle piece (24) on control cabinet assembly (3).
1. Install door contact switch S3 (28) on angle piece (24) on control cabinet assembly (3) using screws
(26) and serrated lock washers (27).
2. Tighten screws (26).
3. Noting correct labeling and position, connect cables to terminals (29) on door contact switch S3
(28).
5. Close flap (2).
4-141
TM 9-6115-668-13
4.59 BRIGHTNESS CONTROL N5 MAINTENANCE.

Materials/Parts
Solder
Cable ties


3. Record labeling and position of cables (16) and disconnect cables (16) from terminals (18) of bright-
ness regulator N5 (17).
4. Remove screws (21), serrated lock washers (20), washers (19), brightness regulator N5 (17), and
clips (22) from the top of retaining bar (23).
1. Install brightness regulator N5 (17) with screws (21), serrated lock washers (20), washers (19) and
clips (22) on top of retaining bar (23) and push in clips (22) at the bottom of bar (23).
2. Noting correct labeling and position, connect cables (16) to terminals (18) of brightness regulator
N5 (17).
4. Close flap (2).
4-142
TM 9-6115-668-13
Figure 4-51 Control Cabinet Assembly, Cabinet Illumination H7, Door Contact Switch S3, Brightness Control
N5 Maintenance.
4-143
TM 9-6115-668-13
4.60 LIGHT INDICATOR ASSEMBLY MAINTENANCE.

Materials/Parts
Cable ties


Removal procedure for transformer T14 (6) is the same as for trans-
former T15 (7) described below.
3. Record labeling and position of cables (8) on upper terminals (9) of transformer T15 (7), loosen
screws (10), and remove cables,
4. Record labeling and position of cables (12) on lower terminals (13) of transformer T15 (7), loosen
screws (11) , and remove cables.
5. Use a screwdriver to push locking element (14) on Transformer T15 (7) in direction of arrow, tilt
transformer T15 (7) upward and remove from mounting bar (16).
4-144
TM 9-6115-668-13
Installation procedure for transformer T14 (6) Is the same as for trans-
former T15 (7), described below.
1. Hook top (15) of transformer T15 (7) into mounting bar (16) and clip into place at the bottom.
2. Noting correct labeling and position, install cables (12) on lower terminals (13) of transformer T15
(7), and tighten screws (11).
3. Noting correct labeling and position. Install cables (8) on upper terminals (9) of transformer T15 (7),
5. Close flap (2).
4-145
TM 9-6115-668-13
Figure 4-52 Control Cabinet Assembly, Auxiliary Contactor with Semiconductor, Auxiliary
Contactor, Transformer Maintenance
4-146
TM 9-6115-668-13
4.61 DIODE MAINTENANCE.

Materials/Parts
Cable ties
during installation.

Removal procedure for diode V1 (46) and Diode V2 (47) is the same as
for diode V15 (31), described below.
3. Record labeling and position of cables (39) on upper terminals (38) of diode V15 (31), loosen
screws (37), and disconnect cables.
4. Record labeling and position of cables (33) on lower terminals (32) of diode V15 (31), loosen
screws (34), and disconnect cables.
5. Use a screwdriver to push locking element (35) on diode V15 (31) in direction of arrow, tilt diode
V15 (31) upward and remove from mounting bar (41).
4-147
TM 9-6115-668-13
Installation procedure for diode V1 (46) and diode V2 (47) Is the same
as for diode V15 (31), described below.
1. Hook diode V15 (31) into top (36) of mounting bar (41) and push in at the bottom.
2. Noting correct labeling and position, install cables (33) on lower terminals (32) of diode V15 (31)
3. Noting correct labeling and position, install cables (39) on upper terminals (38) of diode V15 (31)
5. Close flap (2).
4-148
TM 9-6115-668-13
4.62 DIODE V3 MAINTENANCE.

Materials/Parts
Thermoconductive paste (13, appendix E)

3. Remove screw (13) and disconnect cables (14, 15).
4. Remove Diode V3 (12).
5. Remove screw (11) and cables (10).
6. Remove heat sink (9) from control cabinet by removing screws (6), serrated lockwashers (7), and
washers (8) from outside the back panel.
4-149
TM 9-6115-668-13
1. Install heat sink (9) from the front on the back panel of control cabinet.
2. Install screws (6), serrated lock washers (7), and washers (8) from outside the back panel into the
heat sink (9).
Before securing diode V3 to heat sink, apply thermoconductive paste to

the contact surface.
3. Install diode V3 (12) into heat sink (9).

4. Install cables (14, 15) and (10) and secure with screws (13, 11).
6. Close flap (2).
4-150
TM 9-6115-668-13
Figure 4-53 Diodes, Time Relay, Power Supply Maintenance.
4-151
TM 9-6115-668-13
4.63 CIRCUIT BREAKER MAINTENANCE.
Standard Mechanic’s Metric Tool Set Reference

Standard Electrician’s Metric Tool Set down,
Materials/Parts
Cable ties

3. Open cable conduit (47) and cable conduit (60).
4. Circuit breaker F1 (32):
Removal procedure for circuit breaker F2 (33) is the same as forcircuit

breaker F1 (32), described below.
a. Record labeling and position of cable and disconnect cable (46) from terminal (45) of circuit
breaker F1 (32).
b. Loosen screw (41) at terminal of circuit breaker F1 (32) and screw at terminal of circuit breaker
F2 (33), and remove busbar (31) downward from terminals.
c. Use a screwdriver to push unlocking element (42) on circuit breaker F1 (32) in direction of arrow,
tilt circuit breaker F1 (32) upward and remove from mounting bar (14).
Removal procedure for circuit breaker F4 (34), F5 (35), F6 (36), F7 (37), F8

(38), F9 (39) is the same as for circuit breaker F3 (a), described below.
breaker F3 (8).
b. Loosen screw (10) at terminal of circuit breakers F3 (8) and F4 (34) to F9 (39), and remove bus-
bar (30) downward from terminals.
4-152
TM 9-6115-668-13
c. Use a screwdriver to push unlocking element (11) on circuit breaker F3 (8) in direction of arrow,
tilt circuit breaker F3 (8) upward and remove from mounting bar (14).
Removal procedure for circuit breaker F10/L1 (29), F10/L2 (28), F10/L3
(27) is the same as for circuit breaker F11 (20), described below.
breaker F11 (20).
b. Record labeling and position of cable and disconnect cable (23) from terminal of circuit breaker
F11 (20).
c. Use a screwdriver to push unlocking element (24) on circuit breaker F11 (20) in direction of ar-
row, tilt circuit breaker F11 (20) upward and remove from mounting bar (14).
Installation procedure for circuit breaker F2 (33) is the same as for cir-
cult breaker F1 (32), described below.
a. Hook top (44) of circuit breaker F1 (32) into mounting bar (14) and clip on locking element (43)
at the bottom.
b. Install busbar (31) on terminals of circuit breaker F1 (32) and F2 (33) and tighten screws (41).
c. Install cable (46) to terminal (45) of circuit breaker F1 (32) and tighten screw (40).
2. Circuit Breakers F3 (8):
installation procedure for circuit breaker F4 (34), F5 (35), F6 (36), F7

(37), F8 (38), F9 (39) is the same as for circuit breaker F3 (32), described
below.
a. Hook top (13) of circuit breaker F3 (8) into mounting bar (14) and clip on locking element (12) at
the bottom.
b. Install busbar (30) on terminals of circuit breakers F3 (8) and F4 (34) to F9 (39) and tighten
screws (10).
c. Install cable (6) to terminal (7) of circuit breaker F3 (8).
4-153
TM 9-6115-668-13
a. Hook top (26) of circuit breaker F11 (20) into mounting bar (14) and clip on locking element (25)
at the bottom.
b. Install cables (23) to terminal of circuit breaker F11 (20) and tighten screw (22).
c. Install cable (18) to terminal (19) of circuit breaker F11 (20) and tighten screw (21).
4. Close cable conduit (47) and cable conduit (60).
6. Close flap (2).
4-154
TM 9-6115-668-13
4.64 TRUE POWER MEASURING TRANSFORMER P4A MAINTENANCE.

Materials/Parts
Cable ties
tery terminal cables. Failureto observe this warning could result in se-
Tag ail cables prior to removal to ensure correct connection of the cables

4. Record labeling and position of cables and disconnect cables (51, 52) from terminals (50, 53) of
true power measuring transformer P4A (15).
true power measuring transformer P4A (15).
6. Use a screwdriver to push unlocking element (16) on true power measuring transformer P4A (15) in
direction of arrow, tilt true power measuring transformer P4A (15) upward and remove from mount-
ing bar (14).
4-155
TM 9-6115-668-13
1. Hook true power measuring transformer P4A (15) into top of mounting bar (14) and clip on at the
bottom (16).
2. Noting correct labeling and position, install cables (51, 52) to terminals (50, 53) of true power mea-
suring transformer P4A (15).
3. Noting correct labeling and position, install cables (55,56) to terminals (54, 57) of true power mea-
suring transformer P4A (15).
6. Close flap (2).
4-166
TM 9-6115-668-13
Figure 4-54 Control Cabinet Assembly, Circuit Breaker F1 to F11, Thermistor relay F12, True Power Measuring
Transformer P4A Maintenance.
4-157
TM 9-6115-668-13
4.65 RESISTOR R100 TO R102 MAINTENANCE.

Materials/Parts
Solder (item 12, appendix E)

Thermoconductive paste (item 13, appendix E)

3. Remove speed governor assembly N1 (44) as instructed in paragraph 5.13.
4. Remove resistor R 100 (55):
Removal procedure for resistor R101 and R102 is the same as for resis-
tor R100, described below.
a. Remove mounting plate (58) with resistors R100 (55) to R102 (57) from speed governor assem-
bly N1 (43).
b. Unsolder cable (52) from resistor R100 (55).
c. Remove two screws (49), two serrated lock washers (50), and two washers (51).
d. Remove resistor R100 (55) from mounting plate (58).
4-158
TM 9-6115-668-13
1. Install Resistor R100 (55)
Before Installing each resistor, apply thermoconductlve paste to the

back.
Installation procedure for resistors R101 and R102 Is the same as for
resistor R100, described below.
a. Install resistor R100 (55) on mounting plate (58) using two screws (49), two serrated lock wash-
ers (50), and two washers (51).
b. Solder cable (52) to resistor R100 (55).
2. Install speed governor assembly N1 (43) as instructed in paragraph 5.13.
4. Close flap (2).
4-159
TM 9-6115-668-13
Figure 4-55 Control Cabinet Assembly, Relays K19, K20, Digital lsochronous Load Sharing Module
N4, Speed Governor Assembly N1, Resistor Maintenance.
4-160
TM 9-6115-668-13
4.66 CONTACTOR K1 MAINTENANCE.
This task covers: a. Removal b. Repair c. Installation

(item 2, appendix B) Generator Set 150 kW shut down,
Automotive Fuel and Electrical System Repair, Tool Kit paragraph 2.5.2
Materials/Parts

Double-sided Adhesive Tape

3. Remove eighteen screws (6), eighteen serrated lock washers (7), and eighteen washers (8) from
panel (9).
4. Lower control cabinet connection panel (9) and prop.
5. Remove two nuts (11), two serrated lock washers (12), and two washers (13) from panel (10).
6. Remove two screws (15) two washers (14) and cover panel (10).
7. Record labeling and position of cables (31, 33, 35 and 37 to 39) and sensing cables (32, 34, 36).
8. Remove six nuts (30) and disconnect cables (31, 33, 35 and 37 to 39), six serrated lock washers
(29), six washers (28) and six heat sinks (27) from terminals of load contactor K1 (20).
9. Remove sensing cables (32, 34, 36) from terminals of load contactor K1 (20).
10. Disconnect cables (40) from diode V6 (22) at terminals A1 and A2 by loosening screws (41, 42).
11. Remove four nuts (19), four serrated lock washers (18) and four washers (17).
12. Remove load contactor K1 (20) from bolts (16).
4-161
TM 9-6115-668-13
1. Replace 24 V coil:
a. Record labeling and position of cables to diode V6 (22) at terminals A1 and A2.
b. Disconnect cables (40) from diode V6 (22) at terminals A1 and A2 by loosening screws (41, 42).
c. Push down yellow locking lever (arrow, 21) and pull yoke (23) with coil (24) to the right out of
load contactor K1 (20).
d. Remove defective coil (24) from yoke (23), insert new coil with same specifications, and push
yoke (23) with coil (24) into load contactor K1 (20) until yellow locking lever (21) snaps into
place.
e. Noting correct labeling and position, reconnect cables (40) to diode V6 (22) at terminals Al and
A2 and tighten screws (41, 42).
2. Replace auxiliary contactor:
a. Note correct labeling and position of all cables.
b. Disconnect all cables.
c. Disengage lock (25) by pushing toward front of contactor (26) and lift auxiliary contactor (26)
upward off load contactor K1 (20).
d. Replace auxiliary contactor (26) (with same specifications) on load contactor K1 (20) and push
down until lock (arrow, 25) snaps into place.
e. Noting correct labeling and position, reconnect all cables.
3. Replace diode V6:
a. Record labeling and position of cables (40) to diode V6 (22) at terminals A1 and A2.
b. Disconnect cables (40).
c. Pull Diode V6 (22) off double-sided adhesive tape on load contactor K1 (20).
d. Firmly seat diode V6 (22) on double-sided adhesive tape on load contactor K1 (20).
e. Noting correct labeling and position, reconnect cables (40) to Diode V6 (22) at terminals A1 and
A2 and tighten screws (41, 42)
1. Place load contactor K1 (20) on bolts (16).

2. Install four washers (17), four serrated lock washers (18), and four nuts (19) on bolts (16).
3. Reconnect cables (40) to Diode V6 (22) at terminals A1 and A2 and tighten screws (41, 42).
4. Noting correct labeling and position, install heat sink (27) and sensing cables (32, 34, 36) to termi-
nals of load contactor K1 (20).
5. Noting correct labeling and position, reconnect cables (31, 33, 35 and 37 to 39).
Tighten screws at terminals of contactor K1 with torque wrench to the

value In table (item G.2, appendix G).
4-162
TM 9-6115-668-13
6. Install six serrated lock washers (29), six washers (28), and six nuts (30). Tighten nuts (30).
Secure the left side of cover panel first.
7. Install cover panel (10) on control cabinet assembly (3) using two bolts (15) and two washers (14),
8. Install two washers (13), two serrated lock washers (12), and two nuts (11) on bolt (15), tighten nut
(1).
9. Close control cabinet connector panel (9) and remove props.
10. Install eighteen bolts (6), eighteen serrated lock washers (7) and eighteen washers (8) on control
cabinet assembly (3).
12. Close flap (2).
4-163
TM 9-6115-668-13
Figure 4-56 Control Cabinet Assembly, Contactor K1 Maintenance.
4-164
TM 9-6115-668-13
4.67 ENGINE PREHEATING CONTROL BOARD MAINTENANCE.

Materials/Parts
Cable ties

3. Remove two nuts (8), serrated two lock washers (7), and two washers (6) from two screws (9).
4. Remove cover (11), two screws (9), two washers (10).
5. Open cable conduit next to terminal strip X101 (54).
6. Record labeling and position of cables to terminal strip X101 (54) and disconnect cables.
7. Remove nut (12), serrated lock washer (13), washers (14, 16) and grounding strap (15) from
threaded pin (17). Discard nut (12).
8. Remove four self-locking nuts (55) from bolts (56) on mounting plate (57) and take engine preheat-
ing control board off control cabinet (3). Discard nuts (55).
4-165
TM 9-6115-668-13
Use new self-locking nuts when installing the engine preheating con-
trol board.
1. Place engine preheating control board in control cabinet (3) and install four new self-locking nuts
(55) on bolts (56).
2. Noting correct labeling and position, install cables on terminal strip X101 (54).
Tighten nut on threaded pin with torque wrench to torque values in

table (item G.2, appendix G).
3. Install washer (16), grounding strap (15), washer (14), serrated lock washer (13) and new nut (12)
on threaded pin (17). Torque nut (12)
4. Close cable conduit next to terminal strip X101 (54).
5. Install cover (11) using two screws (9) and two washers (10).
6. Install two washers (6), two serrated lock washers (7) and tighten two nuts (8).
8. Close flap (2).
4-166
TM 9-6115-668-13
4.68 CIRCUIT BREAKER MAINTENANCE.

Materials/Parts
Cable ties
WARNING
CAUTION
1. Circuit breaker F101 (46, figure 4-57):

a. Open flap (2) on unit hood assembly (1).
b. Open front panel (4) of control cabinet assembly (3) and secure with prop (5).
c. Open cable conduit (40) and cable conduit (43).
d. Record labeling and position of cables (44) to upper terminals (45) of circuit breakers F101 (46),
loosen screw (47) and remove cables (44).
e. Record labeling and position of cables (50) to lower terminal (49) of circuit breakers F101 (46),
loosen screws (48) and remove cables (50).
f. Use a screwdriver to push locking element (51) on circuit breaker F101 (46) in direction of arrow,
tilt circuit breaker F101 (46) upward, and remove from mounting bar (53).
4-167
TM 9-6115-668-13
2. Circuit breaker assembly F102 (42) and F103 (41):
NOTE
Removal procedure for circuit breaker assembly F102 (42) is the same
as for circuit breaker F103 (41), described below.
a. Open flap (2, figure 4-57) on unit hood assembly (1).

b. Open front panel (4) of control cabinet assembly (3) and secure with prop (5).
c. Open cable conduit (40) and cable conduit (43).
d. Record labeling and position of cables (18, 20, 32) to upper terminals (19, 21, 31) of circuit
breaker assembly parts (24, 39), loosen screws (22, 34) and remove cables.
e. Record labeling and position of cables (27, 29, 36) to lower terminals (26, 28, 37) of circuit
breaker assembly parts (24, 39), loosen screws (26, 38) and remove cables.
f. Use a screwdriver to push locking element (35) on circuit breaker assembly part (39) in direction
of arrow, tilt circuit breaker assembly parts (24, 39), and remove from mounting bar (53).
g. Separate circuit breaker (39) from auxiliary switch (24):

Lift upper locking clip (23) and lower locking clip (30) with screwdriver.
Pull circuit breaker (39) and auxiliary switch (24) apart.

a. Hook top (52) of circuit breaker F101 (46) into mounting bar (53) and push in at the bottom.
b. Noting correct labeling and position, install cables (50) to lower terminal (49) of circuit breaker
F101 (46) and tighten screw (48).
c. Noting correct labeling and position, install cables (44) to upper terminal (45) of circuit breaker
F101 (46) and tighten screw (47).
d. Close cable conduit (40) and cable conduit (43).
e. Stow prop (5) and close front panel (4).
f. Close flap (2).
4-168
TM 9-6115-668-13
2. Circuit breaker assembly F102 (42) and F103 (41):
NOTE
lnstallation procedure for circuit breaker assembly F102 is the same
as for circuit breaker F103, described below.
a. Assemble circuit breaker assembly parts (39) and auxiliary switch (24) by placing circuit breaker
(39) and auxiliary switch (24) together.
b. Use a screwdriver to push down upper locking clip (23) and lower locking clip (30) until they
snap into place.
c. Hook top (33) of circuit breaker assembly parts (24, 39) into mounting bar (53) and push in at
the bottom.
d. Noting correct labeling and position, install cables (27, 29, 36) to lower terminals (26, 28, 37) of
circuit breaker assembly parts (24, 39).
e. Noting correct labeling and position, install cables (18, 20, 32) to upper terminals (19, 21, 31) of
circuit breaker assembly parts (24, 39).
f. Close cable conduit (40) and cable conduit (43).
g. Stow prop (5) and close front panel (4).
h. Close flap (2).
4-169
TM 9-6115-668-13
Figure 4-57 Control Cabinet Assembly, Engine Preheating Control Board, Circuit Breaker Maintenance.
4-170
TM 9-6115-668-13
4.69 CONNECTOR J9 MAINTENANCE.

Removal Tool
Installation Tool
Materials/Parts
Cable ties
WARNING
CAUTION
panel (9).
5. Remove two nuts (42) and cover (43) from spacer (41).
6. Remove four nuts (11), serrated four lock washers (12), four washers (13).
7. Remove four screws (18) and four washer (17) from control cabinet connection panel (9).
8. Remove connector J9 (15), protective cap (16), and seal (14).
9. Remove protective cap (16) from connector J9 (15).
10. Remove contact bushings:
4-171
TM 9-6115-668-13
CAUTION
Use only removal tool to push out contact bushings.
a. Insert removal tool into contact bushing from the front, and push contact bushing with cable out
of connector J9 (15).
1. Install contact bushings:
CAUTION
Use only installation tool to insert contact bushings.
a. Place installation tool over cable (10) and insert contact bushing into contact carrier of connector
J9 (15) from behind.
2. Screw protective cap (16) on connector J9 (15).
3. Install connector J9 (15), protective cap (16) and seal (14) control cabinet connection panel (9).
4. Install screws (18) and washer (17) on control cabinet connection panel (9).
5. Install washers (13), serrated lock washers (12), and nuts (11) on screws (18).
6. Install cover (43) on spacer (41) and secure using two nuts (42). Tighten nuts (41).
8. To install unit hood assembly refer to paragraph 4.14.
4-172
TM 9-6115-668-13
4.70 J1/120 V 400 HZ DOUBLE CONNECTOR RECEPTACLE MAINTENANCE.
Equipment Conditions
Materials/Parts
Cable ties
WARNING
Disconnect the negative battery cable first and then the positive battery
terminal cables. Failure to observe this warning could result in severe per-
sonal injury or death.
CAUTION
Tag all cables prlor to removal to ensure correct connection of the cables dur-
ing installation.
panel (9).
5. Remove two nuts (42) and cover (43) from spacer (41).
NOTE
Retain varistor R9 for re-use.
6. Remove screws (30) and cables (27, 29) and varistor R9 (28) from terminals of J1/120 V 400 Hz
double receptacle (26).
7. Remove screw (20), cover (19) and seal (21).
8. Remove two nuts (25), two serrated lock washers (24), and two washers (23) from panel (9).
9. Pull J1/120 V 400 Hz double receptacle (26), and two screws (22), out of front of control cabinet
connection panel (9).
4-173
TM 9-6115-668-13
1. Insert J1/120 V 400 Hz double receptacle (26), with two screws (22), into front of control cabinet
connection panel (9).
2. Install two washers (23), two serrated lock washers (24) and two nuts (25) on two screws (22).
Tighten nuts (25).
3. Using screws (30) connect cable (27, 29) and varistor R9 (28) to terminals of J1/120 V 400 Hz
double receptacle (26).
4. Put seal (21) and cover (19) in place and install and tighten screw (20).
5. Install cover (43) on spacer (41) and secure with two nuts (42).
4-174
TM 9-6115-668-13
4.71 J2/24 V CONNECTOR RECEPTACLE MAINTENANCE.

Materials/Parts
Cable ties
WARNING
CAUTION
panel (9).
5. Remove cable (34) and varistor R8 (35) from terminal (32) of J2/24 V connector receptacle (31).
6. Remove nut (37) from J2/24 V connector receptacle (31).
7. Pull J2/24 V connector receptacle (31), and sealing ring (33), out of front of control cabinet connec-
tion panel (9).
8. Remove nut (40), serrated lock washer (39), washer (38), and ground terminal of varistor R8 (35)
from threaded pin (36).
4-175
TM 9-6115-668-13
CAUTION
Tighten nuts on threaded pin with torque wrench to torque values in-
dicated in table (item G.2, appendix G).
1. Install ground terminal of varistor R8 (35), washer (38), serrated lock washer (39), and nut (40) on
threaded pin (36). Torque nut (40).
2. Insert J2/24 V connector receptacle (31) and sealing ring (33) into front of control cabinet connec-
tion panel (9).
3. Install nut (37) onto J2/24 V connector receptacle (31).
4. Connect cable (34) and varistor R8 (32) to terminal (32) of J2/24 V connector receptacle (31).
4-176
TM 9-6115-668-13
Figure 4-58 Control Cabinet Assembly, Connection Panel, Connector Maintenance.
4-177
TM 9-6115-668-13
4.72 SERVICE SWITCH MAINTENANCE.
This task covers: a. Removal b. Instal-

lation

WARNING
CAUTION

2. Remove plug connector 2J6 with cable (35) from service switch (34).
3. Remove service switch (34) from air filter housing (33).
1. install service switch (34) into air filter housing (33).

2. Install plug connector 2J6 with cable (35) on service switch (34).
3. Close flap (3).
4-178
TM 9-6115-668-13
Figure 4-59. Air Filter Assembly, J3 Slave Receptacle 24 V Connector Maintenance.
Change 1 4-179
TM 9-6115-668-13
4.73 SHUNT R11 MAINTENANCE.

(Item 2, appendix B) Generator Set 150 kW shut
tery terminal cables. Failure to observe this warning could result in
severe personal Injury or death.
CAUTION

2. Remove screw (11), spring washer (10), washer (9), and cable 02 (8).
3. Remove screw (7), washer (6), and cable 05 (5).
4. Remove screw (15), spring washer (16), washer (17), and cable 2 (18).
5. Remove screw (12), washer (13), and cable 06 (14).
6. Remove nuts (24), serrated lock washers (23) and washers (22), and screws (19) and remove
shunt R11 (4) from engine block together with washer (20),), and mounting plate (21).
1. Install shunt R11 (4) and mounting plate (21) on engine block using screws (19) and washers (20).
2. Install washers (22), serrated lock washers (23), and nuts (24). Tighten nuts (24).
3. Install cable 6 (14) with screw (12) and washer (13).
4. Install cable 2 (18) with screw (15), spring lock washer (16), and washer (17).
5. Install cable 5 (5) with screw (7) and washer (6).
6. Install cable 02 (8) with screw (11), spring lock washer (10), and washer (9).
7. Close flap (2).
4-180
TM 9-6115-668-13
4.74 BATTERY SET MAINTENANCE.
This task covers: a. Removal b. Test c. Installation

WARNING
Before removing the batteries, disconnect first the negative terminal
and then the positive terminal of the battery set. Failure to observethis
warning could result in severe personal injury or death.
CAUTION

2. Remove terminal cover cap (25).
3. Loosen nut (27) on terminal connector of negative terminal and remove terminal connector with bat-
tery cable (26).
4. Remove terminal cover cap (28).
5. Loosen nut (30) on terminal connector of positive terminal and remove terminal connector with bat-
tery cable (29).
6. Loosen nuts (42) on clamping device (41) and swing clamping device (41) aside.
7. Remove upper part (37) of battery set holder from batteries (38, 39).
8. Remove terminal cover caps (31, 32).
9. Loosen nut (35) at terminal connector of positive terminal of battery (39) and nut (34) at terminal
connector of negative terminal of battery (38) and remove battery cable (33).
10. Grasp batteries (38, 39) individually by lifting handles (36) and lift out of lower part (40) of battery
set holder.
4-181
TM 9-6115-668-13
1. Measure no load voltage Uo:

a. Switch off load resistors of lead battery tester.
b. Apply test probes with correct polarity to terminals (+ and -) of battery (38, 39).
c. Read off no load voltage Uo value displayed on lead battery tester.
NOTE
l if no load voltage Uo < 12.5 V, charge battery with charger vi J3

slave receptacle 24 V Connector.
l if the battery gets very hot during charging, It is defective and must
be replaced.
l When no load voltage Uo > 12.5 V, measure load voltage UB.
2. Measure load voltage UB:

a. On the lead battery tester, activate the number of load resistors required for the particular type
of battery.
b. Apply test probes with correct polarity to terminals (+ and -) of battery (38, 39).
c. Read off load voltage UB value displayed on lead battery tester.
NOTE
l if load voltage UB > 10.0 V, battery is at least 40% charged, and its
high current load capability is sufficient for starting.
l if load voltage UB < 10.0 V, charge battery with charger via J3 slave
receptacle 24 Connector.
1. Using lifting handles (36), insert batteries (38, 39) individually into lower part (40) of battery set
holder.
2. Install terminal connector of battery cable (33) on negative terminal of battery (38) and tighten nut
(34)
3. Install terminal connector of battery cable (33) on positive terminal of battery (39) and tighten nut
(35).
4. Install terminal cover caps (31, 32).
5. Place upper part (37) of battery set holder on batteries (38, 39).
6. Swing clamping device (41) into place, hook into upper part (37) of battery set holder, and tighten
screws (42).
4-182
TM 9-6115-668-13
WARNING
Attach the positive terminal of the battery set first, then the negative
terminal.
7. Install terminal connector of battery cable (26) on positive terminal of battery (38) and tighten nut
(27).
8. Install terminal connector of battery cable (29) on negative terminal of battery (39) and tighten nut
(30) .
9. Install terminal cover caps (31, 32).
10. Close flap (3).
4-183
TM 9-6115-668-13
4.75 BATTERY CHARGING ALTERNATOR REGULATOR N6 MAINTENANCE.

WARNING
CAUTION

2. Remove cable with plug connector 2J5 (45) from battery charging alternator regulator N6 (46).
3. Remove two nuts (49), two serrated lock washers (48), two washers (47), two screws (43), and two
washers (44) and remove battery charging alternator generator regulator N6 (46) from bracket (60).
1. Install battery charging alternator generator regulator N6 (46) on bracket (60), using two screws
(43) two washers (44), two washers (47), two serrated lock washers (48), and two nuts (49).
Tighten nuts (49).
2. Install plug connector 2J5 (45) on battery charging alternator generator regulator N6 (46).
3. Close flap (3).
4-184
TM 9-6115-668-13
4.76 EHG REGULATOR N7 MAINTENANCE.

(Rem 3, appendix B) paragraph 2.5.2
Hylomar
severe personel injury or death.
CAUTION

2. Remove two screws (54) and two washers (55) from plug connector 2J7 (53).
3. Remove plug connector 2J7 (53) with seal (56) from EHG regulator N7 (50).
4. Remove two nuts (59), two washers (57), serrated lock washers (58), two screws (51), two
washers (52), and EHG regulator N7 (50) from bracket (60).
1. Install EHG regulator N7 (50) on bracket (60) using two screws (51), two washers (52), two wash-
ers (57), two serrated lock washers (56), and two nuts (59). Tighten nuts (59).
Apply Hylomar to both sides of seal (56) of plug connector 2J7 (53).
2. Install plug connector 2J7 (53) and rubber seal (56) on EHG regulator N7 (50).
3. Install screws (51), washers (52) Washers (57), serrated lock washers (58), and nuts (59). Tighten
nuts (59).
4. Close flap (3).
4-185
TM 9-6115-668-13
Figure 4-60. Shunt Resistor R11, EHG Regulator N7, Generator Regulator N6, Battery Set Maintenance.
4-186 Change 1
TM 9-6115-668-13
4.77 FUEL TANK MAINTENANCE.

Sealing Rings Two

Plastic Bags (item 21, appendix E)
Rubber Bands (item 22, appendix E)
Hylomar
Loctite 243
Cable ties
The fuel in this Generator Set 150 KW is highly explosive. Do not

smoke or use open flame when performing maintenance. Fire and
explosion could occur, resulting in severe personal injury or death.
Ground fuel tank to a ground source other than the Generator Set
150 KW. Assure that grounding point on the tank is an unpainted
surface.
Drain the fuel tank completely before removing.
During the removal / installation when draining the tank, make sure
there are no open flames or sparks in the vicinity, and keep fuel
from splashing onto hot surfaces.
Wear rubber gloves while draining fuel tank.
4-187
TM 9-6116468-13
CAUTION
To prevent contamination, install plastic bags on all fuel supply and
return lines removed from fuel tank and all ports on the tank and se-
cure the bags with rubber bands.
NOTE
Provide a suitable container to hold the drained fuel, maximum 101.7
gallons (385 liters).
2. Deleted.
3. Insert fuel hose assembly (38) into filler neck (33) of fuel tank (49) slowly until it hits the bottom of
the tank.
4. Loosen damp (53) and remove fuel hose (52) from delivery side of electrical fuel pump (60); leave
fuel hose (52) with clamp (53) on fuel tank (49).
Provide a suitable fuel hose for pumping out the fuel.
5. Connect fuel hose (52) to delivery side of electrical fuel pump (60).
6. Switch on electrical fuel pump (60) with FUEL TANK PROP ON switch on control cabinet assembly.
7. Extract as much fuel as possible, then switch off electrical fuel pump (60) with FUEL TANK PUMP
OFF switch on control cabinet assembly.
NOTE
Provide a suitable container for the remaining fuel.
8. Place a suitable container under bottom plate of base frame (2), remove drain plug (47), and sealing
ring (48). Allow remaining fuel to flow out of fuel tank (49) into container.
Use a new sealing ring.
9. Place a new sealing ring (48) and drain plug (47) on fuel tank (49).
10. Remove electrical fuel pump (60) as instructed in paragraph 4.78.
CAUTION
Tag fuel lines before removing them noting position for proper installation.
11. Remove hollow screw (3), sealing ring (4), fuel return line (5), sealing ring (6), nipple (7), and seal-
ing ring (8). Discard sealing rings (4, 6 and 8).
4-188 Change 1
TM 9-6115-668-13
12. Remove hollow screw (14), sealing ring (13), fuel leakage line (12), sealing ring (11), nipple (10),
and sealing ring (9). Discard sealing rings (9, 11 and 13).
13. Remove hollow screw (15), sealing ring (16), fuel supply line (17), sealing ring (18), immersion tube
adapter (19), and sealing ring (20). Discard sealing rings (16, 18 and 20).
14. Remove hollow screw (26), sealing ring (25), fuel return line (24), sealing ring (23), nipple (22), and
sealing ring (21). Discard sealing rings (21, 23 and 25).
15. Remove hollow screw (27), sealing ring (28), fuel supply line (29), sealing ring (30), immersion tube
adapter (31), and sealing ring (32). Discard sealing rings (28, 30 and 32).
16. Remove air filter as instructed in paragraph 5.27.
17. Remove battery charging alternator regulator N6 as instructed in paragraph 4.75.
18. Remove EHG regulator N7 as instructed in paragraph 4.76.
19. Record labeling and position of cables and disconnect cables from terminal strip 2X50 (10, figure
4-62) and grounding cables (12, 13 and 22).
20. Remove plug connector 2J2 (61, figure 4-61) from electrical fuel pump (60).
21. Remove fuel level sensor (54) as instructed in paragraph 4.81.
22. Remove rubber sealing strip (50) from fuel tank (49).
23. Remove upper fuel level switch (36) and lower fuel level switch (37) as instructed in paragraph 4.79
and 4.80.
24. Remove seven screws (45), seven serrated lock washers (44), and seven washers (43).
25. Remove screw (41), serrated lock washer (40, and washer (39).
26. Place sling around fuel tank (49) and attach to lifting device.
This procedure requires the aid of an assistant. Stay clear of the sus-
pended load. Failure to observe this warning could result in severe
personal injury or death.
27. Lift fuel tank (49) off base frame (2) and place on a flat surface or support blocks.
28. Remove serrated lock washer (42) from base frame (2).
1. Place sling around fuel tank (49) and attach to lifting device.
2. Lift fuel tank (49) off the flat surface or support blocks, and position over base frame (2).
CAUTION
Provide a ground connectton between the fuel tank and the base
frame.
3. Install serrated lock washer (42) on base frame (2).

4. Lower fuel tank (49) onto base frame (2).
5. Remove sling from lifting device and fuel tank (49).
6. Install screw (41), serrated lock washer (40, and washer (39).
4-189
TM 9-6115-668-13
7. Install seven screws (45), seven serrated lock washers (44). and seven washers (43).
NOTE
Apply Hylomar to seating surfaces of fuel level switches (38, 37).
8. Install upper fuel level switch (36) and lower fuel level switch (37) as instructed in paragraph 4.79
and 4.80.
9. Noting correct labeling and position, install cables to terminal strip 2X50, (10, figure 4-62).
10. Install rubber sealing strip (50, figure 4-61) on fuel tank (49).
11. Install fuel level sensors (54) as instructed in paragraph 4.76.
12. Install plug connector 2J2 (61) on electrical fuel pump (60).
13. Install EHG regulator N7 as instructed in paragraph 4.76.
14. Install battery charging alternator regulator N6 as instructed in paragraph 4.75.
15. Install air filter as instructed in paragraph 5.27.
CAUTION
Collect any fuel that leaks out.

Apply Loctite 243 to nipples and immersion tubes when inserting.
Reinstall fuel lines as tagged during removal.
Wall new sealing rings.
16. Install nipple (7) and new sealing ring (8).

17. Install hollow screw (3), new sealing ring (4), fuel return line (5), new sealing ring (6), nipple (10),
and sealing ring (9).
18. Install hollow screw (14), new sealing ring (13), fuel leakage line (12), new sealing ring (11), immer-
sion tube adapter (19), new sealing ring (20).
19. Install hollow screw (15), new sealing ring (16), fuel supply line (17), new sealing ring (18), nipple
(22), new sealing ring (20).
20. Install hollow screw (26), new sealing ring (25), fuel return line (24), new sealing ring (23), immer-
sion tube adapter (31), new sealing ring (32).
21. Install hollow screw (27), new sealing ring (28), fuel supply line (29), new sealing ring (30).
22. Using cable ties bundle fuel lines as shown in figure 4-62.
23. Remove fuel hose from delivery side of fuel pump (60).
24. Slide fuel hose (52) onto delivery side of fuel pump (66) and tighten damp (53).
25. Slowly remove fuel hose (38) out of filler neck (33) and hang on bracket (46).
26. Install electrical fuel pump (60) as instructed in paragraph 4.78.
4-190 Change 1
TM 9-6115-668-13
4.78 ELECTRICAL FUEL PUMP ASSEMBLY MAINTENANCE.


2. Remove plug connector 2J2 (61) from electrical fuel pump (60).
3. Loosen damp (62) and remove fuel hose (38).
4. Loosen clamp (53) and remove fuel hose (52).
5. Remove three nuts (59), three serrated lock washers (58), three washers (57), three screws (55),
three washers (56), and electrical fuel pump (60) from mount.
1. Install electrical fuel pump (60) on mount using three screws (55), three washers (56), three wash-
ers (57), three serrated lock washers (58), and three nuts (59). Tighten nuts (59).
2. Install fuel hose (38) and tighten damp (62).
3. Install fuel hose (52) and tighten damp (53).
4. Install plug connector 2J2 (61) on electrical fuel pump (60).
4-191
TM 9-6115-668-13
Figure 4-61. Fuel Tank Assembly, Electrical Fuel Pump Maintenance.
4-192 Change 1
TM 9-6115-668-13
4.79 UPPER FUEL LEVEL SWITCH MAINTENANCE.

Crimping tool
Materials/Parts
Hylomar
Fish wire 60 inches (1,5 m) in length
Adhesive tape
Cable ties
WARNING
severe personal injury or death.
WARNING

WARNING
Avoid open flame or sparks during this procedure.
4-193
TM 9-6115-668-13
NOTE
If upper switch is to be changed, fuel should be drained to a level below
the half way point of the tank.
2. Drain fuel tank (36) as instructed in paragraph 4.77.

3. Cut cable ties (37, 38) on the fuel and return lines.
4. Tag location of blue cable on terminal strip 2X50 (10), disconnect blue cable from terminal strip
2X50 (10), terminal 16, and cut bushing from blue cable.
5. Remove nut (18) from grounding stud (24) with serrated lock washer (19), washer (20), and cable
lug (21) with grounding cable (11).
6. Remove cable lug (22) with grounding cables (12 to 17), and washer (23) from grounding stud (24).
NOTE
Brown cables (12,13) are from the upper and lower fuel level switches
respectively. Care must be taken to cut only the proper cable when
changing either fuel level switch.
7. Cut off brown cable (12 or 13) from cable lug (22).
8. Remove four screws (3) and upper fuel level switch (2) from fuel tank (36).
9. Remove protective covering (5).
I. Using a fish wire and adhesive tape, install protective covering (5) on cable of upper fuel level
switch (2).
NOTE
Apply Hylomar to seating surface of fuel level switch prior to Installation.
2. Install fuel level switch (2) on fuel tank (36) and secure upper fuel level switch (2) with four screws
(3).
3. Cut all grounding cables (12 or 13 and 14 to 17) from cable lug (22).
4. Install new cable lug (22), 0,16 square inch with 0,2 inch hole (10 mm2 with 5 mm hole), on ground-
ing cables (12 to 17).
5. Install washer (23), cable lug (22) with grounding cables (12 to 17), cable lug (21) wtth grounding
cable (11) on grounding stud (24) and secure with washer (20), serrated lock washer (19), and nut
(18) on grounding stud (24).
6. Install new cable bushing on blue cable and install blue cable into marked space in terminal strip
2X50 (10), terminal 16.
7. Install new cable ties (37, 38) on fuel lines and protective coverings.
8. Reconnect battery as instructed in paragraph 4.74.
4-194
TM 9-6115-668-13
4.80 LOWER FUEL LEVEL SWITCH MAINTENANCE.

Crimping tool
Materials/Parts
Hylomar
Fish wire, 60 inches (1,5 m) in length
Adhesive tape
Cable ties
WARNING
severe personal injury or death.
WARNING
1. Remove unit hood assembly (I, figure 4-62) as instructed in paragraph 4.14.
WARNING
Avoid open flame or sparks during this procedure.
4-195
TM 9-6115-668-13
NOTE
If upper fuel level switch is to be changed, fuel should be drained to
a level below the half way point of the tank.
2. Drain fuel tank (36) as instructed in paragraph 4.77.

3. Cut cable ties (37, 38) on the fuel and return lines.
4. Tag location of blue cable on terminal strip 2X50 (10), disconnect blue cable from terminal strip
2X50 (10), terminal 15, and cut bushing from blue cable.
5. Remove nut (18) from grounding stud (24) with serrated lock washer (19), washer (20), and cable
lug (21) with grounding cable (11).
6. Remove cable lug (22) with grounding cables (12 to 17), and washer (23) from grounding stud (24).
NOTE
Brown cables (12,13) are from the upper and lower fuel level switches
respectively. Care must be taken to cut only the proper cable when
changing either fuel level switch.
7. Cut brown cable (12 or 13) from cable lug (22).

8. Remove four screws (7) and remove fuel level switch (6) from fuel tank (36).
9. Remove protective covering (9) from cable of switch (6).
1. Using a fish wire and adhesive tape install protective covering (9) on cable of lower fuel level switch
(6).
NOTE
Apply Hylomar to seating surface of fuel level switch prior to installation.
2. Cut all grounding cables (12 or 13 and 14 to 17) from cable lug (22).
3. Install new cable lug (22), 0,16 square inch with 0,2 inch hole (10 mm2 with 5 mm hole), on ground-
ing cables (12 to 17).
4. Install fuel level switch (6) and secure with four screws (7).
5. Install washer (23), cable lug (22) with grounding cables (12 to 17), and cable lug (21) with ground-
ing cable (11) on grounding stud (24).
6. Install new cable bushing on blue cable and install blue cable into marked space in terminal strip
2X50 (10), terminal 15.
7. Install new cable ties (37, 38) on fuel lines and protective covering.
8. Reconnect battery as instructed in paragraph 4.74.
4-196
TM 9-6115-668-13
4.81 FUEL LEVEL SENSOR 2R4 MAINTENANCE.

Crimping tool
Materials/Parts
Hylomar
WARNING
tery terminal cables. Failure to observe this warning could result In
WARNING
The fuel in this Generator Set 150 KW Is highly explosive. Do not
plosion could occur, resulting In severe personal Injury or death.
2. Record labeling and position of cables (27, 32) on fuel level sensor 2R4 (26).
3. Remove screws (29, 30), serrated lock washers (28, 31) and cables (27, 32) from fuel level sensor
2R4 (26).
4. Remove four screws (35), four serrated lock washers (34), four washers (33) and fuel level sensor
2R4 (26) out of fuel tank (36) and remove seal (25).
CAUTION
Apply Hylomar to seating surface of fuel level sensor.
1. Install seal (25), fuel level sensor 2R4 (26), four washers (33), four serrated lock washers (34), and
four screws (35) on fuel tank (36).
4-197
TM 9-6615-668-13
2. Noting correct labeling and position, install cable (27), serrated lock washer (28), and screw (29) to
fuel level sensor 2R4 (26), and tighten screw (29).
3. Noting correct labeling and position, install cable (32), serrated lock washer (31), and screw (30) to
fuel level sensor 2R4 (26), and tighten screw (30).
4-198
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Figure 4-62. Fuel level Switch and Sensor Maintenance.
Change 1 4-199
TM 9-6115-668-13
4.82 SILENCER ASSEMBLY, LEFT SIDE MAINTENANCE.

Heat shielding tape (Hesiflex, white, 020.05.003) Three

When Generator Set 150 kW is supported, secure to prevent tip-

ping.
When working on silencer assembly, allow to cool first or wear
gloves.
To work on underside of base frame, support Generator Set 150 kW
on stands.
Provide at least 19.7 inches (50 cm) of working space.
2. Raise Generator Set 150 kW:

a. Attach cables to lifting device and ring bolts (3) on base frame (2) and lift Generator Set 150 kW
onto supports.
3. Remove silencer assembly, left side.
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WARNING
This task requires three persons: some parts weigh up to 66.15

pounds (30 kg).
CAUTION
Using a suitable device support the silencer during removal.
a. Remove four nuts (33) and four serrated lock washers (32) while holding four screws (29).
b. Remove screws (29) from flange and bottom plate of base frame (2).
c. Remove nut (4), serrated lock washer (5), and washer (6).
d. Remove nut (13), serrated lock washer (14), washer (15), and connector pipe (22) and elbow
(28), fasteners (7 to 12, 16 to 21, 23, 24, 26, 27) and seal (30).
e. Remove silencer assembly (25) from base frame (2).
4. Remove connector pipes and brackets:
a. Remove washer (7) and nut (8) from holder (9).
b. Hold screw (27) and remove nut (12), serrated lock washer (11), washer (10), nut (8), and holder
(9).
c. Remove screw (27) and washer (26).
d. Pull elbow (28) off silencer (25).
e. Remove washer (16) and nut (17) from holder (18).
f. Hold screw (24) and remove nut (19)) serrated lock washer (20), washer (21)) nut (17)) and
holder (18).
g. Remove screw (24) and washer (23).
h. Remove endpipe (22) from silencer (25).
5. Remove exhaust pipe with header:
a. Loosen locknuts, turn screws on heat shield above header at turbocharger outlet a few turns,
push angle bracket to one side and loosen heat shield.
b. Remove four nuts (40) and four washers (39).
c. Remove exhaust pipe with header (34) from turbocharger outlet.
d. Remove gasket (35) and discard.
CAUTION
Close off turbocharger outlet with cover.
6. Remove heat shielding tape (37) from exhaust pipe with header (34):
a. Remove clamps (36, 38) from exhaust pipe with header (34) and set aside for re-use.
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b. Unwrap heat shielding tape (37) from exhaust pipe with header (34).
WARNING
This task requires three persons: some parts weigh up to 66.15

pounds (30 kg).
1. Apply heat shielding tape (37) to exhaust pipe with header (34):
a. Wrap heat shielding tape (37) over exhaust pipe with header (34) with overlapping turns, starting
from the header.
b. Secure heat shielding tape (37) with clamps (36, 38).
2. Install exhaust pipe with header (34):
CAUTION
Remove cover from turbocharger outlet.
NOTE
Use new gaskets.
a. Install new gasket (35) on turbocharger outlet and press on exhaust pipe with header (34).
b. Install screws (29) between bottom plate of base frame (2) and exhaust pipe with header (34).
c. Install four washers (39) and four nuts (40) on threaded pins and tighten four nuts (40).
d. Position heat shield and angle bracket over header, and tighten heat shield screws and locknuts.
3. Install connector pipes and brackets:
a. Install endpipe (22) on silencer (25).
b. Install screw (24) and washer (23) through clamp and put holder (18) in place.
c. Install washer (21), serrated lock washer (20), and nut (19). Tighten nut (19).
d. Install elbow (28) onto silencer (25).
e. Install screw (27) and washer (26) through clamp and put holder (9) in place.
f. Install washer (10) and serrated lock washer (11) and nut (12). Tighten nut (12).
4. Install silencer assembly, left side:
a. Install nuts (8, 17) and washers (7, 16) on brackets (9, 18) through holes in bottom plate of base
frame from below.
b. Install washer (6), serrated lock washer (5) and nut (4). Do not tighten nut (4).
c. Install washer (15), serrated lock washer (14), and nut (13). Do not tighten nut (13).
d. Install screws (29) through flange and bottom plate of base frame (2).
e. Install four serrated lock washers (32) and four nuts (33). Tighten nuts (33)
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f . Align exhaust pipe with header (34), gaskets (31, 30), silencer (25), elbow (28), and endpipe
(22), and tighten nuts (33) in a crosswise pattern.
g. Tighten nuts (4, 13).
h . Install unit hood assembly (1) as instructed in paragraph 4.14.
4-203
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Figure 4-63. Silencer Assembly, Left Side Maintenance.
4-204 Change 1
TM 9-6115-668-13
4.83 SILENCER ASSEMBLY, RIGHT SIDE MAINTENANCE.

Materials/Parts
Heat shielding tape (Hesiflex, white, 020.05.0003)

WARNING
tery terminal cables. Failure to observe this warning could result In
WARNING
When Generator Set 150 kW is supported, secure to prevent tipping.

When working on silencer assembly, allow to cool first or wear gloves.
To work on underside of base frame, support Generator Set 150 kW on stands.
Provide at least 19.7 Inches (50 cm) of working space.
2. Raise Generator Set 150 kW:

a. Attach cables to lifting device and ring bolts (3) on base frame (2) and lift Generator Set 150 kW
onto supports.
3. Remove silencer assembly, right side.
WARNING
This task requires three persons: some parts weigh up to 88.2 pounds (40 kg).
4-205
TM 9-6115-668-13
CAUTION
Using a suitable device support the silencer during removal.
a. Remove four nuts (11) and four serrated lock washers (12) while holding four screws (16).
b. Remove four screws (16) from flange and bottom plate of base frame (2).
c. Remove nut (51), serrated lock washer (50), and washer (49).
d. Remove nut (39), serrated lock washer (38), and washer (37).
e. Remove nut (27), serrated lock washer (26), washer (25), and connector pipe (15), elbow (46),
and fasteners (40 to 45, 47, 48, 29 to 36, 17 to 24) and seal (14).
f. Remove silencer assembly (28) from base frame (2)
4. Remove connector pipes and brackets:
a. Remove washer (48) and nut (47) from holder (42).
b. Hold screw (40) and remove nut (45), serrated lock washer (44), washer (43), nut (47) and
holder (42).
c. Remove screw (40) and washer (41).
d. Remove washer (37) and nut (35) from holder (31).
e. Hold screw (29) and remove nut (34), serrated lock washer (33), washer (32), and holder (31)
with nut (35).
f. Remove screw (29) and washer (30).
g. Pull endpipe (46) off silencer (28).
5. Remove exhaust pipe with header:
a. Loosen locknuts, turn screws on heat shield over header at turbocharger outlet a few turns, push
angle bracket to one side and loosen heat shield.
b. Remove nuts (9) and washers (8).
c. Pull exhaust pipe with header (10) and gasket (4) off turbocharger outlet. Discard gasket (4).
d. Remove gasket (13) and discard.
CAUTION
Close off turbocharger outlet with cover.
6. Remove heat shielding tape (6) from exhaust pipe with header (10):
a. Remove clamps (5, 7) from exhaust pipe with header (10) and set aside for re-use.
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TM 9-6115-668-13
b. Unwrap heat shielding tape (6) from exhaust pipe with header (10).
WARNING
This task requires three persons: some parts weigh up to 68.2 pounds
(40 kg).
1. Apply heat shielding tape (6) to exhaust pipe with header (10):
a. Wrap heat shielding tape (6) over exhaust pipe with header (10) with overlapping turns, starting
from the header.
b. Secure heat shielding tape (6) with clamps (5, 7).
2. Install exhaust pipe with header (10):
CAUTION
Remove cover from turbocharger outlet.
NOTE
Use new gaskets.
a. Place new gasket (4) on turbocharger outlet and press on exhaust pipe with header (10).
b. Install new gasket (13) between bottom plate of base frame (2) and exhaust pipe with header
(10).
c. Install four washers (8) and four nuts (9) on threaded pins and tighten four nuts (9).
d. Position heat shield and angle bracket over header, and tighten heat shield screws and locknuts.
3. Install connector pipes and brackets:
a. Install screw (40) and washer (41) through holder on endpipe (46).
b. Install holder (42), nut (47), washer (43), serrated lock washer (44), and nut (45). Tighten nut
(45).
c. Slide endpipe (46) onto silencer (28).
d. Install screw (29) and washer (30) through clamp and put holder (31) in place.
e. Install washer (32), serrated lock washer (33) and nut (34). Tighten nut (34).
f. Slide elbow (15) onto silencer (28).
g. Install screw (17) and washer (18) through clamp and put holder (22) in place.
h. Install washer (21), serrated lock washer (20) and nut (19). Tighten nut (19).
4. Install silencer assembly, right side:
a. Install washers (49, 37, 25) and insert brackets (42, 31, 22) for silencer (28), with fasteners,
through holes in bottom plate of base frame (2) from below.
b. Install washer (37), serrated lock washer (38), and nut (39).
c. Install washer (25), serrated lock washer (26), and nut (27).
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TM 9-6115-668-13
d. Install washer (49), serrated lock washer (50), and nut (51).
e. Install screws (16) through flange and bottom plate of base frame (2).
f. Holding four screws (16), install four serrated lock washers (12) and four nuts (11). Tighten nuts
(11).
g. Align exhaust pipe with header (10), gaskets (13, 14), silencer (28), elbow (15), and endpipe
(46), and tighten nuts (11) in a crosswise pattern.
h. Tighten nuts (51, 39, 27).
4-208
TM 9-6115-668-13
Figure 4-64. Silencer Assembly, Right Side Maintenance.
Change 1 4-209
TM 9-6115-668-13
4.84 SCAVENGE PUMP ASSEMBLY MAINTENANCE.

Sealing ring
Sealing tape
1. Open flap (2, figure 6-65) on unit hood assembly.
Place a container underneath scavenge pump.
2. Remove collar nut (21) from threaded bushing (20) on scavenge pump (6).
3. Undo VELCRO strap and remove oil outlet pipe assembly (21 to 29).
After removal, plug oil line (17) and tie up.
4. Remove collar nut (11) from shutoff valve (18) and remove oil line (17).
5. Remove two nuts (9) with two serrated lock washers (8) and two washers (7).
6. Pull out two screws (4) with two washers (5) and remove scavenge pump (6) with shutoff valve (18)
from holder (10).
7. Using a suitable hold damp scavenge pump (6), unscrew shutoff valve (18) and set aside for re-
use.
8. Unscrew threaded bushing (20) from scavenge pump (6) and remove together with sealing ring
(19). Discard sealing ring (19).
NOTE
Use new sealing ring (19) and new thread sealing taps.
1. Clamp scavenge pump (6), wrap sealing tape around pump-end threads of shutoff valve (18) and
screw in shutoff valve (18).
4-210
TM 9-6115-668-13
2. Insert new sealing ring (19) and screw threaded bushing (20) into scavenge pump (6).
3. Place scavenge pump (6) on holder (10).
4. Install two screws (4) with two washers (5). Tighten screws (4).
5. Install two washers (7), two serrated lock washers (8) and two nuts (9). Tighten nuts (9).
6. Install oil line (17) on shutoff valve (18) and tighten collar nut (11).
7. Install oil outlet pipe assembly (21 to 29) on scavenge pump (6) and tighten collar
nut (21).
8. Coil up oil outlet pipe assembly (21 to 29) and secure with VELCRO strap.
9. Close flap (2).
4-211
TM 9-6115-668-13
4.85 OIL OUTLET PIPE ASSEMBLY MAINTENANCE.

Materials/Parts
Sealing rings
Sealing tape

2. Unscrew collar nut (21), remove VELCRO strap and oil outlet pipe assembly (21 to 29) from scav-
enge pump (6).
3. Using a suitable hold clamp shutoff valve (26), unscrew hose nipple (29) and remove together with
sealing rings (28, 27) from shutoff valve (26). Discard sealing rings (27, 28).
4. Remove hose nipple (23) and remove together with sealing rings (25, 24) and oil line (22) from
shutoff valve (26). Discard sealing rings (25, 24).
1. Using a suitable hold clamp shutoff valve (26), insert new sealing rings (25, 24) into shutoff valve
(26) and screw in hose nipple (23) of oil line (22).
2. Insert new sealing rings (27, 28) into shutoff valve (26) and screw in hose nipple (29).
3. Install oil outlet pipe assembly (21 to 29) on scavenge pump (6) and screw on collar nut (21).
4. Coil up oil outlet pipe assembly (21 to 29) and secure with VELCRO Strap.
5. Close flap (2).
4-212
TM 9-6115-668-13
4.86 OIL LINE ASSEMBLY MAINTENANCE.

Materials/Parts
Sealing rings
Sealing tape
CAUTION
Place a container underneath diesel engine.
2. Pump out oil as instructed in paragraph 2.3.2.3.

3. Unscrew collar nut (11) and remove oil line (17) from shutoff valve (18).
4. Remove hollow screw (15), sealing rings (14, 16) and oil line (17) from adapter (13). Discard sealing
rings.
NOTE
When replacing the engine, remove adapter (13) and replace with a
screw. Set adapter (13) aside for re-use.
1. Install new sealing rings (14, 16) and oil line (17) on hollow screw (15).
2. Install hollow screw into adapter (13).
3. Install oil line (17) on shutoff valve (18) and screw on collar nut (11).
4. Refill with oil as instructed in paragraph 2.3.2.3.
5. Close flap (2).
4-213
TM 9-6115-668-13
4.87 OIL PRESSURE SWITCH 1S2 AND OIL PRESSURE SENSOR 1R2 MAINTENANCE.

Materials/Parts
Sealing rings
WARNING
CAUTION
CAUTION
Place container underneath oil pressure switch 1S2 and oil pressure
sensor 1R2 and collect oil as it emerges.
2. Remove plug connector 1J2 (32) with cable from oil pressure switch lS2 and oil pressure sensor
1R3 (30).
3. Remove oil pressure switch 1S2 and oil pressure sensor 1R2 (30) and sealing ring (31) from engine
block. Discard sealing ring (31).
1. Install new sealing ring (31) on oil pressure switch (30).

2. Install oil pressure switch 1S2 and oil pressure sensor 1R2 (30) into engine block.
3. Install plug connector 1J2 (32) with cable onto oil pressure switch 1S2 and oil pressure sensor 1R2
(30).
4. Close flap (2).
4-214
TM 9-6115-668-13
4.88 OIL TEMPERATURE SWITCH 1S3 AND OIL TEMPERATURE SENSOR 1R3 MAINTENANCE.

Materials/Parts
Sealing rings
WARNING
CAUTION
1. Open flap (2, figure 4-65) on unit hood assembly (1)
CAUTION
Place container underneath oil pressure switch and collect oil as it
emerges.
2. Remove plug connector 1J3 (33) with cable from oil temperature switch 153 and oil temperature
sensor1R3 (35).
3. Remove oil temperature switch 1S3 and oil temperature sensor 1R3 (35) and sealing ring (34) from
engine block.
4. Close flap (2).
NOTE
Use new sealing ring.
1. Install new sealing ring (34) on oil temperature sensor (35).
4-215
TM 9-6115-668-13
2. Install oil temperature switch 1S3 and oil temperature sensor (35) with sealing ring into engine
block.
3. Install plug connector 1J3 (33) with cable on oil temperature switch and oil temperature sensor (35).
4. Close flap (2).
4-216
TM 9-6115-668-13
Figure 4-65. Scavenge Pump Assembly, Oil Outlet Pipe Oil Pressure Switch 1S2 and Oil Pressure Sensor
1R2, Oil Temperature Switch 1S3 and Oil Temperature Sensor 1R3 Maintenance.
Change 1 4-217
TM 9-6115-668-13
4.89 BATTERY CHARGING ALTERNATOR MAINTENANCE.

Hardwood board
1. Open flap (2, figure 4-66) on unit hood assembly.

2. Loosen clamp (15) and remove air hose (16).

3. Remove two screws (17), serrated lock washers (18), and side plate (19) away from cover (11) on
battery charging alternator.
4. Remove screw (3) from bracket (4) by holding nut (not shown).
5. Remove screw (8) and loosen screw (5).
6. Remove V belts (7) from V belt pulleys (6, 10).
7. Support battery charging alternator (9) (pulley down) and remove four nuts (12), four lock washers
(13), and four washers (14).
8. Remove cover (11) by sliding along cable (20).
9. Remove plug (22) by removing locking dip (21) and unplugging.
10. Record labeling and position of cables (27, 31, 35) including those (23 to 25) to the plug (22).
11. Remove nut (30), serrated lock washer (29), washer (28) and cable 02 (27).
4-218
TM 9-6115-668-13
14. Remove flat connectors with three cables (23 to 25) from plug (22), by using a screwdriver and
holding down snap in hook (26).
15. Remove cover (11) from cable (20) by sliding along cable (20).
16. Remove battery charging alternator (9) from diesel engine (2).
TEST
CAUTION
l Do not operate battery charging alternator without battery set

(load) and do not reverse polarity.
l Do not short-circuit terminals of battery charging alternator regu-
lator N6.
NOTE
l Check battery charging alternator after installation, and with diesel

engine at rated speed.
l Battery set must be connected and fully charged.
1. Measure charging voltage:

a. To measure voltage, connect multimeter to terminal B+ of battery charging alternator (9) or to
cable 2 on right side of Shunt R11 (4, figure 4-66), and to ground.
b. Start diesel engine as instructed in paragraph 2.5.1 and read off charging voltage on multimeter
(10):
Reading: 27 - 28.2 V at charging current of 10 - 15 A indicated on BATTERY CHARGE P7.
c. If charging voltage <27 V, replace battery charging alternator regulator N6 as instructed in para-
graph 4.75.
INSTALLATION
1. Install cover (11) on cable (20) by sliding on cable (20).

2. Place battery charging alternator (9) on diesel engine (2) and support.
4-219
TM 9-6115-668-13
NOTE
Before installing in plug, push up snap in hooks (26) of flat connectors.
3. Noting correct labeling and position, install flat connectors with three cables (23 to 25) on plug (22).
4. Noting correct labeling and position, install cable 7 (35), washer (36), serrated lock washer (37), nut
(38), and tighten nut (38).
5. Noting correct labeling and position, install cable 0 (31), washer (32), serrated lock washer (33), nut
(34), and tighten nut (34).
6. Noting correct labeling and position, install cable 02 (27), washer (28), serrated lock washer (29),
nut (30), and tighten nut (30).
7. Install plug (22) by plugging on terminals, and secure with locking clip (21).
8. Install cover (11) on battery charging alternator (9) by sliding along cable (20)
9. Install four lock washers (13), four washers (14) and four nuts (12) on battery charging alternator (9)
and tighten nuts (12).
10. Install V belts (7) on V belt pulleys (6, 10).
11. Install screw (8). Install screw (3) on bracket (4) (not shown).
12. Tension V belt as instructed in paragraph 4.34.
13. Slide plate (19) on cover (11) of battery charging alternator (9), and install two screws (17) and ser-
rated lock washers (18).
14. Install air hose (16) and tighten clamp (15).
15. Connect the negative battery cable first and then the positive battery cable.
4-220
TM 9-6115-668-13
Figure 4-66. Battery Charging Alternator Maintenance.
Change 1 4-221
TM 9-6115-668-13
4.90 STARTER MAINTENANCE.

Cable ties
(item 10, appendix F)

2. Remove screw (9), serrated lock washer (8), washer (7), clamp (6), molded part (5) with sealing ring
(4), from positive cable (3).
3. Remove nut (19), serrated lock washer (18), washer (17), and cable (3) from stud (16).
4. Remove nut (25), serrated lock washer (24), washer (23), and cables (21, 22), from stud (20).
5. Remove nut (29), serrated lock washer (28), washer (27), and cable (11) from stud (26) on starter
terminal board (15).
Provide support for the starter. Failure to observe this warning could
result in severe personal injury.
6. Remove three nuts (12), serrated lock washer (13), and washers (14).
7. Remove starter (10) from flange of diesel engine (2).
4-222
TM 9-6115-668-13
Provide support for the starter.
1. Install starter (10) on flange of diesel engine (2) using three serrated lock washers (13), three wash-
ers (14), and three nuts (12). lighten nuts (12).
2. Install screw (9), serrated lock washer (8), washer (7), clamp (6), positive cable (3), molded part (5),
and sealing ring (4) on starter (10). Tighten screw (9).
3. Install cable (11), washer (27), serrated lock washer (28), on stud (26) on starter terminal board
(15), and install nut (29). Tighten nut (29).
4. Install cables (22, 21), washer (23), serrated lock washer (24), on stud (20) on starter terminal
board (15), and install nut (25). Tighten nut (25).
5. Install cable (3), washer (17), serrated lock washer (18), on stud (16) on starter terminal board (15),
and install nut (19). Tighten nut (19).
6. Connect the negative battery cable first and then the positive battery cable.
4-223
TM 9-6115-668-13
Figure 4-67. Generator, Starter Maintenance.
4-224 Change 1
TM 9-6115-668-13
CHAPTER 5
DIRECT SUPPORT MAINTENANCE INSTRUCTIONS
Subject Index Page

Diagnostic Equipment (TMDE); and Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.1 Common Took and Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.2 Special Tools, TMDE, and Support Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Repair Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Section II. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Section Ill. Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
5.5 GeneraI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
5.6 Auxiliary Contactor With Semiconductor Device Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . 5 - 9 7
5.7 Auxiliary Contactor Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99
5.8 Time Relay K3, K10, K13, K17, K25, K26 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-102
5.9 Power Supply NT2 24 VN Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-108
5.10 Thermistor Relay F12 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-110
5.11 Digital lsochronous Load Sharing Module N4 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-112
5.12 Relay K19 And K20 With Relay Socket And Contact Bushings Maintenance. . . . . . . . . . . . 5-115
5.13 Speed Governor Assembly N1 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-117
5.14 Voltage Regulator N2 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-121
5.15 Safety Device N3 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-126
5.16 Fitter Box FK Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-136
5.17 Current Transformer Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-138
5.18 Auxiliary Contactor K109 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-142
5.19 Diode Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-143
5.20 Time Relay Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-145
5.21 Power Supply NT2 24 VN Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-150
5.22 Miniature Relay Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-153
5.23 Power Relay K101, K102 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-155
5.24 Connector Receptade L1 to L3 and N Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-158
5-1
TM 9-6115-668-13
5.25 Interlock Switch Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 160

5.26 J3 Slave Receptacle 24 Volts Connector Maintenance. . . . . . . . . . . . . . . . . . 5 - 163
5.27 Air Filter Housing And Piping Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 165
5.28 Subcurrent Filter Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 168

5.29 Subcurrent Filter Oil Lines Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 170
5.30 Flame Glowplug System Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 173
5.31 Engine Preheating Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 177
5.32 Burner Monitoring Temperature Switch Maintenance. . . . . . . . . . . . . . . . . . . . 5 - 180
5.33 Glowplug Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 181
5.34 Over-temperature Switch Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 182

5.35 Preheating Assembly Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-184
5.36 Air Flap Puller Magnet Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 187
5.37 Electric Oil Pump Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 188
5.38 Air-Oil Heat Exchanger Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 190
5.39 Oil Hose Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 193
5.40 Oil Temperature Switch Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 195

5.41 Actuator Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 198
5.42 Actuator Cable Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 201
5.43 Pick-up Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 203
5.44 Pick-up Cable Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 205
5.45 EHG Temperature Sensor Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 208
5.46 Generator Wiring Harness Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 211

5.47 Diesel Engine And Synchronous Generator Maintenance. . . . . . . . . . . . . . . . 5 - 214
5.48 Diesel Engine Shock Absorbers Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . 5-218
5.49 Synchronous Generator Shock Absorbers Maintenance. . . . . . . . . . . . . . . . . 5 - 220
5.50 Diesel Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 225
5.51 Synchronous Generator Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 230
5.52 Clutch Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 233
5-2
TM 9-6115-668-13
Section I. REPAIR PARTS; TOOLS; SPECIAL TOOLS; TEST, MEASUREMENT

AND
DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT
5.1 COMMON TOOLS AND EQUIPMENT.
A list of recommended tools and test equipment required to maintain the Generator Set 150 kW is con-
tained in Appendix B, SECTION III.
5.2 SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT.
Refer to TM 9-6115-668-23P for Generator Set 150 kW special tools.

5.3 REPAIR PARTS.
Refer to TM 9-6115-668-23P for Generator Set 150 kW repair parts.
5-3
TM 9-6115-668-13
Section II. TROUBLESHOOTING
5.4 GENERAL.
The symptom index for the generator set 150 kW lists faults associated with control cabinet assembly
operation. Figures 5-1 through 5-18 provide a go/no-go flowchart of each malfunction. Each malfunction
listed includes a reference to the applicable figure that contains a chart to help you determine probable
causes and corrective actions to take. The symptom index cannot list all faults that may occur, nor all the
tests or inspections and corrective actions. If a malfunction is not listed or cannot be corrected by listed
corrective actions, notify next higher level of maintenance for assistance.
WARNING
Potential 150 kw shock hazard with failure to adhere to this

warning. Contact with this high power could result in death
or severe injury. if the removal of one generator from the EPP
III is required, replace it with an extra generator. Always
make sure that two generators are mounted to the EPP III.
Continued use of the EPP Ill with only one generator could
result in a catastrophic shock hazard.
Do not operate one of the EPP-III generators when the other
generator is dismounted.
Prior to energizing the equipment the operator must check
for exposed electrical terminals.
Always install protective covers on control and power cables
when cables are not connected.
Be sure to observe all warning signs on equipment.
WARNING
Any wire indicated with a “0” is a ground wire. Disconnecting any “0”
indicated wire will lose the ground to the rest of the circuit.
5-4
TM 9-6115-668-13
NOTE
l Before using this table, ensure that unit level troubleshooting

steps have been performed.
l Refer to the Wiring Diagram FO-1 and Engine Preheating Assem-
bly Diagram FO-2 as troubleshooting aids.
l 24 VDC operating voltage:Depending on the operating state of the
Generator Set 150 kW and the charging state of the battery set, the
24 VDC operating voltage can fluctuate between 22.8 VDC and 28.2
VDC: The higher value (28.2 VDC) occurs when the battery set is
charged and is being buffered by the generator. The lower value
(22.8 VDC) occurs when the battery set is discharged and the gen-
erator is idle. The voltage may drop below this value at tempera-
tures below 32 oF (0 oC), and/or at high currents (e.g. during start-
ing).
5-5
TM 9-6115-668-13

Procedure
BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up. . . . . . . . . . . . . Figure 5-1
HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON

lamp does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-2
GLOWPLUG ON lamp does not light up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-3
Diesel engine cannot be started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-4
Oil pressure too low, or no oil pressure indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-5
Battery set is not being charged, or no charging current indication . . . . . . . . . . . . . . . . . . . . . . . Figure 5-6
Generator frequency cannot be adjusted, or no frequency indication . . . . . . . . . . . . . . . . . . . . . Figure 5-7
Generator voltage cannot be adjusted, or no voltage indication . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-8
AC CIRCUIT INTERRUPTER ON lamp does not light up. . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-9
No line currents are flowing, or no line current indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-10
No power indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-11
BATTERY CHARGING CONTROL lamp lights up during operation . . . . . . . . . . . . . . . . . . . Figure 5-12
OIL PRESSURE lamp lights up during operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-13
OIL TEMP-CYLINDER HEAD lamp lights up during operation. . . . . . . . . . . . . . . . . . . . . . . Figure 5-14
UNDER/OVER FREQUENCY lamp lights up during operation. . . . . . . . . . . . . . . . . . . . . . . . Figure 5-15
UNDER/OVER VOLTAGE lamp lights up during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-16
GENERATOR OVER TEMPERATURE lamp lights up during operation . . . . . . . . . . . . . . . . . Figure 5-17
OVERLOAD lamp lights up during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 5-18
5-6
TM 9-6115-668-13
WARNING
DANGEROUS VOLTAGE EXISTS ON LIVE CIRCUITS. AL-
WAYS OBSERVE SAFETY PRECAUTIONS AND NEVER
WORK ALONE. FAILURE TO OBSERVE THIS WARNING
DEATH.
(PARAGRAPH 4.74)
(PARAGRAPH 5.16)
Figure 5-1 BATTERY CHARGING CONTROL and OIL PRESSURE lamps do not light up (sheet 1 of 7).
5-7
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 4.63)
5-8
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 4.63)
(PARAGRAPH 4.56)
(PARAGRAPH 4.54)
5-9
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 4.89)
(PARAGRAPH 4.75)
5-10
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 5.16)
(PARAGRAPH 4.23)
5-11
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 4.87)
(PARAGRAPH 5.16)
5-12
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 4.23)
5-13
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 5.33)
(PARAGRAPH 4.65)
(PARAGRAPH 5.20)
(PARAGRAPH 5.34)
(PARAGRAPH 5.20)
not light up (sheet 1 of 7).
5-14
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 5.32)
(PARAGRAPH 5.20)
(PARAGRAPH 5.20)
(PARAGRAPH 4.45)
(PARAGRAPH 5.20)
not light up (sheet 2 of 7).
5-15
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 4.68)
Figure 5-2 HEATING FAILURE lamp lights up or READY TO START IF HEATING IS ON lamp does notlight
up (sheet 3 of 7).
5-16
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 4.68)
(PARAGRAPH 4.45)
(PARAGRAPH 4.44)
light up (sheet 4 of 7).
5-17
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 5.20)
(PARAGRAPH 5.23)
5-18
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 5.20)
(PARAGRAPH 5.19)
5-19
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 5.18)
(PARAGRAPH 4.44)
5-20
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 4.50)
(PARAGRAPH 4.47)
Figure 5-3 GLOWPLUG ON lamp does not light up (sheet 1 of 4).
5-21
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 5.16)
5-22
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 5.30)
(PARAGRAPH 5.30)
5-23
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 4.47)
(PARAGRAPH 4.23)
Figure 5-3 GLOWPLUG ON lamp does not Iight up (sheet 4 of 4).
5-24
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 4.74)
(PARAGRAPH 4.63)
Figure 5-4 Diesel engine cannot be started (sheet 1 of 10).
5-25
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 5.6)
(PARAGRAPH 4.23)
5-26
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 5.6)
(PARAGRAPH 4.50)
5-27
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 4.61)
(PARAGRAPH 5.7)
5-28
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 4.61)
(PARAGRAPH 5.6) or K28 (PARAGRAPH 5.7)
5-29
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 5.16)
5-30
TM 9-6115-668-13
WARNING
DEATH.
5-31
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 5.7)
(PARAGRAPH 4.65)
5-32
TM 9-6115-668-13
WARNING
DEATH.
PARAGRAPH 5.6)
(PARAGRAPH 5.43)
(PARAGRAPH 5.42)
(PARAGRAPH 5.13)
5-33
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 5.41)
(PARAGRAPH 5.42)
5-34
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 4.63)
(PARAGRAPH 4.87)
Figure 5-5 Oil pressure too low, or no oil pressure indication (sheet 1 of 3).
5-35
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 5.16)
(PARAGRAPH 4.56)
5-36
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 4.54)
(PARAGRAPH 4.27)
5-37
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 4.73)
(PARAGRAPH 4.89)
Figure 5-6 Battery set is not being charged, or no charging current indication (sheet 1 of 2).
5-38
TM 9-6115-668-13
WARNING
WORK ALONE. FAILURE TO OBSERVE THIS WARNlNG
DEATH.
(PARAGRAPH 4.73)
(PARAGRAPH 5.16)
(PARAGRAPH 4.56)
Figure 5-6 Battery set is not being charged, or no charging current indication (sheet 2 of 2).
5-39
TM 9-6115-668-13
WARNING
WORK ALONE. FAlLURE TO OBSERVE THIS WARNING
DEATH.
(PARAGRAPH 4.52)
Figure 5-7 Generator frequency cannot be adjusted, or no frequency indication (sheet 1 of 5).
5-40
TM 9-6115-668-13
WARNING
DEATH.
(PARAGRAPH 4.52)
(PARAGRAPH 5.13)
5-41
TM 9-6115-668-13
WARNING
DEATH.
5-42
TM 9-6115-666-l 3

DEATH.
I 1
NO Measure voltage at YES

- FiO/U(Output) and I : _
120 f 1 VAC?
w t
Replace FIO NO Measure voltage at YES
(PARAGRAPH 4.63) - FlOll/(Output) and I : -
L 120 f I VAC?
v t
NO YES
Replace Fl 0 Measure voltage at
(PARAGRAPH 4.63) FlOMl(Output) and I : -
120 f I VAC?
L
v
t
Replace FiO
(PARAGRAPH 4.63) - T14/4and 1 :
120 f 1 VAC?
Repair or Replace YES

Measure voltage at
Ti4/12and I :
120 f 1 VAC?
v v
Repair or Replace Continue on

cable ‘145” page 5
5-43
TM 9-6115-666-13

DEATH.
Replace T14
(PARAGRAPH 4.60)
Figure 5-7 Generator frequency cannot be adjusted, or no frequency Indication (sheet 5 of 5).
5-44
TM 9-6115-666-13

WAYS OBSERVE SAFEI?’ PRECAUTIONS AND NEVER
DEATH.

- F9(lnput) and I :
24 VDC?
t v
Repair or Replace NO Measure vottage at YES

cable ” 14’ - F9(lnput) and N2/oV, 0:
24 VDC?
v v
Repair or Replace NO YES

Measure voltage at
cable ‘0” Fg(Output) and N2/oV, o: -
24 VDC?
v v
Replace F9 NO Measure voltage at YES

(PARAGRAPH 4.63) K&2,4 and N2JOV, 0:
24 VDC?
Repair or Replace Measure voltage at YES

- KS/l, 3 and N2/OV, 0: -
24 VDC?
Continue on Continue on
pew 2 pew 4
Figure 5-8 Generator voltage cannot be adjusted, or no voltage lndicatlon (sheet 1 of 7).
5-45
TM9-6116-666-13
WAHNING
DEATH.

- F7(lnput) and K3/A2: _
24 VDC?
t t
Repair or Replace NO Measure voltage at YES
cables ” 14” and “0” - F7(Output) and K3/A2: -
24 VDC?
* t
NO YES
Replace F7 Measure voltage at
(PARAGRAPH 4.63) IQ72 and K3lA2:
24 VDC?
v t

cable “4 I” m W71 and K3lA2:
24 VDC?

cable ‘39’ page 3
Figure 5-8 Generator voltage cannot be adjusted, or no voltage indication (sheet 2 of 7).
5-45
TM 9-6115-668-l 3

DEATH.
NO t=24s YES
r
_ K3: green and amber _
LEDs light up?
Check swrtching time Measure voltage at YES

K3/10 and K6lA2:
(PARAGRAPH 5.8 24 VDC?
NO YES
Repair or Replace Measure voltage at
cables ‘40” and “0” K3/15 and KBiA2:
24 VDC?
-
v v
I -
paragraph 5.8 K5j72 and KS/A21
d 24 VDC?
t v
Repair or Replace
cable “44”
paragraph 5-7 page 4
5 - 47
DEATH.

- Kf3lA 1 and K6lA2: -
24 VDC?

Measure voltage at
cable “46” - K6lt. 3 and N2/OV, 0: -
24 VDC?
* v
NO YES
Replace K6 Measure voltage at
(PARAGRAPH 5.7) 7 N2/+ and N2/OV, 0: -
24 VDC?
v , v
NO YES
cable ‘43” N2/J and N2/K.
At idle: <IO VDC? At rated
load: 10 - 20 VDC?
Adjust or Repair N2 Measure voltage at

YES
(PARAGRAPH 5. 14) Xl/J2 and Xi/+@.
At idle: <IO VDC? At rated -
load: 10 - 20 VDC?
v v

cables “76” and “77’ page 5
5-48
TM 9-6116-666-13

DEATH.
NO Measure voltage at
r-l N2/U and I :
,.,=c;ure voltage at YES

N2Nand I :
120 f 1 VAC?
v v
cable “79” N2/W and I :
120 f 1 VAC?
v v

cable “80” _ Tl5/4andTt5/12: -
208 f2 VAC?
v 7
cables ‘I144” and ” 145” Tt5/5 and T15/9: -
18 f0.2 VAC?
paragraph 4.60
page 6
5 - 49
TM96115666-13
DANGEROUS VOLTAGE EXISTS ON UVE CIRCUITS. AL-

DEATH.
NO Measure voltage at
T 15/s and N2JO:
r-l
18 3~0.2 VAC?
Repair or Replace Measure voiiage at YES

NP/UH and N2/0:
18 f0.2 VAC?

Repair or Replace
cable ‘191” SttltOand 1 :
120 f 1 VAC?
v v
Measure voltage at
cable ‘144” - Sll/iO and Sli/12: -
120 f 1 VAC?

cable “141” Slli6and Sll/12:
.^_ .,.^^
1 Repaimip,‘z?,‘!ace 1 1 CozntiIe,on 1
Figure 5% Generator voltage cannot be adjusted, or no voltage indication (sheet 6 of 7’).
5-50
TM 9-6115-666-13

DEATH.

1 Sl1/2 and Sl1/12:
120 f 1 VAC?
‘I v
Repair or Replace NO Set VOLTAGE SELECTOR YES
cable ” 148” SWITCH to Ll-N, l2-N and L3-N,
and measure voltage at Stl/l and
S11/3: 120 f 1 VAC?
v v
Replace S Ii /C2 Set VOLTAGE SELECTOR

NO YES
(PARAGRAPH 4.49) SWITCH to L3-Ll, l2-L3 and
Ll -l2. and measure voltage at
Sllfl and SliI3: 206 f2 VAC?
w v
NO YES
Replace S 1l/C2 Measure voltage at
(PARAGRAPH 4.49)
rI P6:
206 f2 VAC?
I
Repair or Replace
cables “ 136” and ‘I137” (PARAGRAPH 4.56)
I
5-51
TM9611566813

DEATH.
NO 1 Measure voltage at 1 YES
Measure voltage at YES

paragraph 5.8 - K13l15 and Kt4/A2, Vg: _
24 VDC?
Repair or Replace NO Measure voftage at YES

cable ‘73” - K13it8 and Kt4iA2, Vs: _
24 VDC?
v v
Check switching time Continue on

(12 s) of K13 page 2
(PARAGRAPH 5.8) *
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not light up (sheet 1 of 11).
5 - 52
TM 9-6115-666-13

DEATH.

- 57/t and K14lA2, V9: _
24 VDC?
v w

cable ‘67” - S7i2 and Kt4jA2, V9:
24 VDC?
7 v
NO YES
Replace S7 Measure voltage at
(PARAGRAPH 4.45) SSl3, Ki4lt and Kt4lA2, -
V9: 24 VDC?
* v *
Repair or Replace NO Press S8 and measure YES

cable “66” voltage at S8/4 and
K14lA2, V9: 24 VDC?

(PARAGRAPH 4.44) - K16/22 and Ki4lA2, V9: _
24 VDC?

cable “65” page 3
5 - 53
TM 9-6115-666-l 3

DEATH.
NO Measure voitage at YES

- K16121, K1412 and
K14fA2. V9: 24 VDC?
v v
Replace K16
(PARAGRAPH 4.55) - S12/13 and K14iA.2. V9:
24 VDC?
w v
NO YES
Repair or Replace Press S 12 and measure
cable “64” - voltage at 512114 and -
Kt4lA2, V9: 24 VDC?
paragraph 5.25
paragraph 5.25
v v
Replace S 13 Continue on
(PARAGRAPH 5.25) page 4
5 - 54
TM 9-6115-668-13

DEATH.

- St4113 and Kl4/A2, V9: _
24 VDC?
7 7
NO Press 514 and measure YES
Repair or Replace
cable ” 176” - voltage at S 14/l 4 and -
K 14lA2. V9: 24 VDC?
w 7
NO YES
Replace S 14 Measure voltage at
(PARAGRAPH 5.25) S15/13 and K14lA2. V9: -
24 VDC?
7 7
NO Press S 15 and measure YES

- voltage at S15/14 and -
Kt4iA2. V9: 24 VDC?
paragraph 5.25
paragraph 5.25
7 7
Repair or Replace
page 5
5 - 55
TM 9-6115666-13

DEATH.

- K27l21 and K14/A2, V9: _
24 VDC?
7 7
Replace K27
(PARAGRAPH 5.7) - K21/3t and Kl4fA2. V9:
24 VDC?
v 7
NO YES
cable “63” K21/32 and Kl4/A2. V9: -
24 VDC?
7 7
Replace K2 1 NO Measure voltage at YES

(PARAGRAPH 5.6) Kl2i62 and K14lA2. V9:
24 VDC?

- K12i61 and K14/A2, V9: -
24 VDC?
7 7
Replace Kl2 Continue on

(PARAGRAPH 5.6) Page 6
Figure 5-9 AC CIRCUIT INTERRUPTER ON lamp does not iight up (sheet 5 of 11).
5-56
TM 9-6115-666-13

DEATH.

- K14lAt. V9 and K14fA2, _
VQ: 24 VDC?
w 7
Repair or Replace Replace Kl 41V9
cable ” 196 (PARAGRAPH 5.6)
5 - 57
DEATH.
NO Measure voitage at YES

K12/t?l end .L :
24 VDC?
v v
Repair or Replace
cable “43” - K12/61 and KllA2, V6:
24 VDC?
‘I v
v v
Replace Kl2 NO Measure voltage at YES
(PARAGRAPH 5.6) - K21121 and Ki/A2, V6: -
24 VDC?
v v

cable “71” - K21/22andKt/A2,V6: _
24 VDC?
v v
Replace K2 1 Continue on
5-58
TM g-6115-668-1 3
WAHNING
DEATH.

K1414 and Kl/A2, V6: _
24 VDC?
T v
Repair or Replace
cable “70” - Ki4/3 and KI/IU, V6:
24 VDC?
v v
NO YES
(PARAGRAPH 5.6) - R16. Kl/Ol and KlIA2, V6: -
24 VDC?
v-v

cable “72” RlG(Output) and Kt/AZ, V6: -
24 VDC?
r- 1 Replace R 16
in Control Cabinet
Assembly
NO
paragraph 4.66
5-59
TM 9-6115-666-13

DEATH.

Ktl2and I :
120 f 1 VAC?
v v
Check Synchronous
generator. Refer to Klf4 and I :
DMWR 9-6115-666 120 f 1 VAC?
v v
1
NO YES
Check Synchronous Measure voltage at
generator. Refer to KltBand I :
DMWR 9-6115-666 120 f 1 VAC?
v v
Check Synchronous NO Measure voltage at YES

generator. Refer to Ktll, 13. I5 end I:
DMWR g-6115-666 120 f 1 VAC?
I I
page 10
paragraph 4.66
5 - 60
TM 9-6115-668-13

DEATH.

K12/71 end I : -
13 - 27.5 VDC?
‘I w

cable ‘94’ - K12/71 andHt4/X2: -
13 - 27.5 VDC?
v v
NO YES
cable ‘0” Kl2172 and H14/X2: -
13 - 27.5 VDC?
v *
Replace Ki2 NO Measure voltage at YES

(PARAGRAPH 5.6) - K14/5and Hi4/X2: -
13 - 27.5 VDC?
v v
Replace Kt 4 Continue on
5 - 61
TM 9-6115-666-13

DEATH.
NO I
Measure voltage at I YES
- H14lX5andH14lX2: -
13 - 27.5 VDC?
v v
Repair or Replace Replace H 14(S8)

cable ” 102” (PARAGRAPH 4.44)
5 - 62
TM 9-6115-666-13

DEATH.
NO YES
AC CIRCUIT INTER-
- RUPTER ON tamp -
lights up?
‘ITT
Refer to
Figure 5-9 Ki/l and I : -
120 +l VAC?
w 7
Repair or Replace No Measure voltage at connector YES

Ki - receptacles Li (DA) and N: -
(PARAGRAPH 4.66) 120 k 1 VAC?
t w v
Repair or Replace
cables “114” and “141”
paragraph 4.66
page 2
Figure 5-10 No line currents are flowing, or no line current indication (sheet 1 of 5).
5-63
DEATH.
NO YES
Measure voltage at
- Kll5and I :
120 f 1 VAC?
.
v v
NO YES
Repair or Replace Measure voltage at connector
Kl - receptacles L3((3C) and N: -
(PARAGRAPH 4.66) 120 f 1 VAC?
w v
Repair or Replace
cable ” 116” RS/r5:
0 - 7.5 VAC (0 - 600 A)?
+ v
Check EPP Ill. Refer to YES
Measure voltage at
TM 9-6115-669-13&P - RSf-rS:
,
0 - 7.5 VAC (0 - 600 A)?
YES
Meesure voltage at
TM 9-6115-669-13&P
R7/T7:
0 - 7.5 VAC (0 - 600 A)?
v v
Check EPP III. Refer to Continue on

TM 9-6115-669-13&P page 3
5-64
TM 9-6115-666-13

DEATH.
YES AMPS Li @A) NO

meter indicates
line current?
r
v
NO YES
Continue on Measure voltage at
page 4 - T8 (secondary winding): -
I
0 - X.X VAC (0 - 600 A)?
7 v
NO YES
Replace T8 Measure voltage at
(PARAGRAPH 5.17) T8/1 and P4a/l:
0 -X.X VAC (0 - 600 A)?
w 7
Measure voltage at
cable “156” - PI (Input) and P4afl: -
0 -X.X VAC (0 - 600 A)?
7 7
Check P4a, cable “129” and Replace P 1

Pl Repair or Replace (PARAGRAPH 4.56)
defective component (PARA-
GRAPHS 4.64, or 4.56)
I
5 - 65
TM 9-6115666-13

DEATH.
YES AMPS I2 (OB) NO
- meter indicates ll
1’
line current?
7 ‘1 7
NO YES
Continue on Measure voltage at
paw 5 - T9 (secondary winding): i
0 - X.X VAC (0 - 666 A)?
v v
NO YES
Replace T9 Measure voltage at
(PARAGRAPH 5.17) T9/1 and P4aJ4: -
0 - X.X VAC (0 - 600 A)?
v
r
Measure voltage at
r
w
- P2 (Input) and P4a/4:
0 - X.X VAC (0 - 600 A)?
1
I
1
Repair or Replace
cable”l30”
I
1 fl
NO
I
oq
Measure current I
YES
Check P4a. cable “131” and P2.

Repatr or Replace defective paragraph 4.56
component (PARAGRAPHS 4.64,

or 4.56)
Figure 5-10 No line currents are f/owing, or no line current indication (sheet 4 of 5).
5 - 66
TM g-6116-668-13

DEATH.
YES AMPS L3 (DC) NO

meter indicates
line current?
.
v 7
NO YES
Check overload Measure voltage at
cutout - TIO (secondary winding): -
Refer to Figure 5-18 0 - X.X VAC (0 - 600 A)?
7 7
NO YES
Replace Tl 0 Measure voltage at
(PARAGRAPH 5.17) TiO/i and P4a/7
0 - X.X VAC (0 - 600 A)?
v v
Measure voltage at
cable I(168” - P3 (Input) and P4af7 -
0-X.XVAC(O-600A)?
YES
Repair or Replace Measure current
0- 1 A(O-600A)?
‘I
Check P4a, cable “133” and

P3. Repair or Replace
defective component
(PARAGRAPHS 4.64, or 456)
I Replace P3
(PARAGRAPH 4.56)
5 - 67
TM 9-6115-666-13

DEATH.
NO
NO YES
I Measure voltage at I
P4a/2 and I :
120 f 1 VAC?
v 7
Repair or Replace
cable ” 144” P4aJ5 and I :
120 f 1 VAC?

Repair or Replace
cable ” 145 P4al8 and I :
120 f 1 VAC?
* 7
Measure voltage at
cable ” 146” - P4aJi3and P4aj14: -
208 f2 VAC?
7
I I I
page 2
Figure 5-11 No power indication (sheet 1 of 2).
5-68
TM 9-6115-666-13

DEATH.
P4a: Disconnect P4 from P4a/41

NO YES
and 144. and connect 1
1 .kOhm resistor.
Measure voltage at P4al4 1 and
P4a/44: 0 - 5 VDC (0 - 200 kW)?
P4a NO P4a: Disconnect resistor and con- YES

(PARAGRAPH 4.64) I nect P4 to P4eJ41 and 144. I
Measure voltage at P4/+ and PU-:
fl 0-XXVDC(O-2OOkW)? n
Replace P4
(PARAGRAPH 4.56)
f-l
Figure 5-11 No power indication (sheet 2 of 2).
5 - 69
TM 9-6115-666-13

DEATH.
NO YES
V belt can be pressed
r
in a maximum of
0.6 in. (15 mm)?
7
YES
Retension V belt Cables “7”. * 19” and “20
(PARAGRAPH 4.34) between N6/2J5 and
1G3/2J3 OK?
paragraph 4.35
Repair or Replace wiring Switch on BATTLE SHORT

NO YES
harness, cables “7”, “19” or switch and start up Gen Set
“20” 150 kW:
P7 indicates 10 - 15 ADC
charging current?
f-l Refer to
Figure 5-4 Figure 5-6
Figure 5-12 BATTERY CHARGING CONTROL lamp lights up during operation.
5 - 70
TM 9-6115-668-13

DEATH.
NO YES
I Scavenge pump and oil I
Tighten or replace NO Oil pump, air/oil heat ex- YES

scavenge pump changer, and oil hoses of
and oil hoses engine preheating assembly
(PARAGRAPH 4.84; 4.85 are tight and not leaking?
Tighten or replace electrical- NO lS2(1R2) and YES

oil pump, air/oil heat ex- - associated circuit -
changer, and oil hoses. elements OK?
(PARAGRAPH 5.37 to 5.39)
7 , v
Refer to Check diesel engine

Figure 5-5 crankshaft bearing play.
Refer to
DMWR 9-2815-261
Figure S-13 OIL PRESSURE lamp lights up during operation.
5-71
TM 9-6115-668-13

DEATH.
NO
OIL
--. .--- .-.utlt*-- I1
I tMrtliHI
YES
I
I I meter I
1 1 inredrange? 1 1
NO YES
Continue on EHG:
page 3 fan rotating
at correct speed?
Check EHG. Refer to NO Turbocharger YES

DMWR g-2815-261 - clean on the compressor -
side?
YES
Clean turbo charger. Delivery volumes for fuel in-
- jection pump and injectors -
DMWR g-2815-261 OK?
Check fuel injection

system. Refer to page 2
DMWR 9-2815-261
Figure 5-14 OIL TEMP-CYLINDER HEAD lamp lights up during operation (sheet 1 of 3).
5-72
TM 9-6115-668-13

DEATH.
YES NO
Pull cable of
I I
lR3llS3:
H4 goes out?
v v
YES NO
Replace 1R3/iS3 Pull cable of
(PARAGRAPH 4.88) Is3
H4 goes out?
7 v
YES NO
Replace IS5 Disconnect cable from
(PARAGRAPH 5.45) - FK/S(lnput):
H4 goes out?
v v
YES Disconnect cable from NO
Repair or Replace
wiring harness, cable “9” FK/S(Output):
H4 goes out?
v v
-
Disconnect cable from
paragraph 5.16
v v

cable ” 9” page 3
Figure 5-14 OIL TEMP-CYLINDER HEAD lamp lights up during operation (sheet 2 of 3).
5 - 73
TM96116-666-13

DEATH.
- H4tX2:
H4 goes out?
w v
Repair or Replace Replace 520
cable “7 (PARAGRAPH 4.45)
Figure 5-14 OIL TEMP-CYLINDER HEAD lamps lights up during operation (sheet 3 of 3).
5 - 74
TM 9-6115-668-13

DEATH.
NO Press UNDER/OVER FRE- YES

QUENCY illuminated pushbutton
h
switch: UNDER/OVER
FREQUENCY indicator goes out?
Continue on NO K7/44: Disconnect cable “57

page 3 and connect to one another. YES
i - Switch on BATTLE SHORT switch -
and start up Gen Set 150 kW:
Gen Set 150 kW runs?
vvv
NO YES
Refer to OIL PRESSURE indicator off,
- Figure 5-4 OIL PRESSURE gauge -
indicates 3 -5 bar?
v v
Refer to NO
BATTERY CHARGING
YES
Figure 5-13 CONTROL indicator off,
-
BATTERY CHARGE meter
indicates 10 - 60 A?
Refer to Continue on
Figure 5-12 page 2
Figure 5-15 UNDER/OVER FREQUENCY lamp lights up during operation (sheet 1 of 6).
5-75
TM 9-6115-668-13

DEATH.
FREQUENCY YES
Figure 5-14
meter indicates
400 f0.2 Hz?
Figure 5-7 page 3
5 - 76
TM9-6116-666-13

DEATH.
NO YES
Measure voltage at
- N3/U, UR, R and N3/MP: -
120 f 1 VAC?
. v v
NO YES
cables ‘78” and ” 141” - NW, S and N3/MP:
120 f 1 VAC?
v v
Measure voltage at
cable ‘79’ - N3# and N3/MP:
120 f 1 VAC?
NO
Repair or Replace
cables ‘43” and ‘0” K26115and K7lA2: -
24 VDC?
page 4
5 - 77
TM 9-6115-666-13

DEATH.
NO YES
Measure voltage at
K26/18 and K7JA2: -
24 VDC?
v v
Check swrtchrng time NO Measure voltage at YES

(6 s) of K26 - NJ/RKf(lnput) and -
(PARAGRAPH 5.8) K7iA2: 24 VDC?
v v
NO YES
Repair or Replace Measure voitage at
cable ” 138” - NJ/RKf(Output) and -
K7lA2: 24 VDC?
A
v v
Adjust or Repare NO Measure voltage at YES
N3 K7lAt and K7fA2: -
(PARAGRAPH 5.15) 24 VDC?

cable “4g’ - K7/13 and K7lA2:
El 24 VDC?

cable “4 1” page 5
5 - 78
TM 9-6115-666-13

DEATH.
NO YES
I Measure voltage at I
- K7114and K7lA.2: -
24 VDC?
v v
Replace K7
(PARAGRAPH 5.7) S4/1 and K7lA2:
24 VDC?
h
NO YES
S4/2 and K7lA2:
24 VDC?
paragraph 4.44
v
Repair or Replace
cables “4 1” and “0” K7/44 and K5lA2:
24 VDC?
‘I
Replace K7 Continue on
(PARAGRAPH 5.7) Page 6
5-79
TM 9-6115-666-13

DEATH.
NO YES
Measure voltage at
- K7lAl and K7/AZ: -
24 VDC?
‘I v
NO YES
cable “49” - K7/23 and HBlX2:
13 - 27.5 VDC?
t v
NO YES
cables “94” and “0” K71’24 and H8/X2: -
13 - 27.5 VDC?
v ‘I

(PARAGRAPH 5.7)
paragraph 4.44
5 - 80
TM 9-6115-668-l 3

DEATH.
NO Press UNDER/OVER VOLT- YES

AGE illuminated pushbutton
switch: UNDER/OVER VOLT-
AGE indicator goes out?
v v
Continue on NO Switch on BATTLE SHORT switch

page 3 and start up Gen Set 156 kW: YES
- OIL PRESSURE indicator off, -
OIL PRESSURE gauge indicates
3 -5 bar?
f-l
v
Refer to BATTERY CHARGING YES

Figure 5- 13 CONTROL indicator off,
BATTERY CHARGE meter
indicates 10 - 60 A?
Figure 5-13
Refer to
page 2
Figure 5- 14
Figure 5-16 UNDER/OVER VOLTAGE lamp lights up during operation (sheet 1 of 6).
5 - 81
TM 9-6115-668-13

DEATH.
NO YES
I GENERATOR OVER I
TEMPERATURE
indicator off?
v r v
NO VOLTAGE meter indicates YES
Refer to
Figure 5-17 120 f 1 VAC or
208 dz2 VAC?
Figure 5-17
page 3
5-82
TM g-6115-666-1 3
DANGEROUS VOLTAGE EXISTS ON LIVE CIRCUITS. AL.

DEATH.
l-l
NO YES
Measure voltage at
N3/U, UR, R and NJ/MP:
120 f 1 VAC?
Repair or Replace YES

Measure voltage at
- N3FJ and NSIMP: r
120 f 1 VAC?
Reoair or Reolace
YES
oltage at
SS/tS and KS/AZ: --

cables “4 I ” and “*“’ page 4
Figure 5-76 UNDER/OVER VOLTAGE iamp lights up during operation (sheet 3 of 6).
5-63
TM 9-6116-666-13

DEATH.
NO YES
Measure voltage at
- K26/18 and K8&?: -
24 VDC?
v v
Check switching time NO Measure voltage at YES
(6 s) of K26
- N3/AKU(lnput) and
(PARAGRAPH 5.8) K8JA2: 24 VDC?
v
Repair or Replace
cable ‘138
Ir NO
-
Measure voftage at
N3/AKU(Output) and
K8A2: 24 VDC?
-
YES
paragraph 4.66
Repair or Replace
cable “54”
page 5
5-54
TM 9-6115-666-l 3

DEATH.
NO YES
Measure voltage at
- K8/14 and U8lA.2: -
24 VDC?
Replace K8 mm voltaae at I YES

(PARAGRAPH 5.7)
I
cables “58” and “0” K8/44 and K5/A2:
I i 24 VDC?
I I
A-F--l
Replace K8 Continue on
paragraph 5.7 I
I
page 6
I
5 - 65
TM g-6115-668-1 3

DEATH.
NO YES
Measure voltage at
K8/Al and KBiA2: -
24 VDC?
t v
NO YES
cable “54” - K8123 and H9lX.2:
13 - 27.5 VDC?
v v
NO YES
Repaw or Replace Measure voltage at
cables “94” and “0” K8124 and H9iXZ:
13 - 27.5 VDC?
paragraph 5.7
paragraph 4.44
5 - 86
TM 9-6115-668-13
DANGEROUS VOLTAGE EXISTS ON LIVE CIRCUITS. AL.

DEATH.
YES NO
I Synchronous generator
YES & NO
paragraph 5.15
1
Check EPP Ill. YES NO
Ft2: Disconnect cables from
Refer to Ti and T2, and measure resis-
TM 9-6115-669-13&P tance at cables “163” and “164”:
>350 Q/68 “F (20 ‘C)?
Check Synchronous
generator. Refer to
DMWR g-6115-668
I YES F12: Jumper between
Tl and T2.
Start Gen Set 150 kW.
Gen Set 150 kW shuts down?
NO
paragraph 5.10 page 2
Figure 5-17 GENERATOR OVER TEMPERATURE lamp lights up during operation (sheet 1 of 4).
5 - 87
TM 9-6115-668-13

DEATH.
NO YES
Measure voltage at
FlZIAi and IA2:
24 VDC?
v v
Repair or Replace
cables ‘41” and ‘0” - Ft2/98and K9IA2: -
24 VDC?
w v

cables ” 138” and “0” F12197 and K9lA2
FtPflt and T2 shorted: 0 VDC?
FtZ/Tl and T2 open: 24 VDC?
‘I v
Replace Ft2 Measure voltage at

(PARAGRAPH 5.10)
page 4
Figure S-17 GENERATOR OVER TEMPERATURE lamp lights up during operation (sheet 2 of 4).
5 - 88
TM 9-6115-666-13

WAYS OBSERVE SAFEI-Y PRECAUTIONS AND NEVER
DEATH.
NO YES
Measure voltage at
Kg/i 3 and KQ/A2:
24 VDC?
,
v *
Repair or Replace No Measure voltage at K9/14 and YES

cable ‘4 1” - KQlA2 (Fl2/Tl and /T2 open): -
24 VDC?
v v
NO YES
Replace KQ Measure voltage at S6/i and
(PARAGRAPH 5.7) - KQ/A2 (Fl2/rl and IT2 open): -
- 24 ‘/DC?
v v
Repair or Replace NO Measure voltage at S6/2 and YES
cable “52” KQ/A2 (Fi21Tl and /T2 open):
YES
Repare or Replace Cable “56” from
S6l2 to Fl2/97
paragraph 4.44 OK?

cable “56” page 4
I
Figure 5-l 7 GENERATOR OVER TEMPERATURE lamp lights up during operation (sheet 3 of 4).
5 - 89
TM 9-6115-666-13

DEATH.
NO YES
Measure voltage at
KQt23 and HlOlX2:
13 - 27.5 VDC?
v v
Repair or Replace NO Measure voltage at K9t24 and

YES
cables ‘94” and “0 HlO/X2
F 12/r 1 and /r2 shorted: 0 VDC?
F12/Tl and /T2 open: 13 - 27.5 VDC?
v v
Replace KQ NO Measure vottage at YES

(PARAGRAPH 5.7) - HiO/X5 and HlO/X2:
13 - 27.5 VDC?
Repair or Replace
Repair or Replace
HfO(S6)
(PARAGRAPH 4.44)
Figure 5-17 GENERATOR OVER TEMPERATURE lamp lights up during operation (sheet 4 of 4).
5-w
TM 9-6115-668-13

DEATH.
NO Press OVERLOAD tlluminated YES

pushbutton switch:
-
OVERLOAD indicator
goes out?
I Continue on
page 4
NO
-
Screw protective covers onto con-
nector receptacles Lt (CA), I2
(DB), L3 (CC) and N schrauben.
Press AC CIRCUIT INTERRUPTER .
YES
1
ON Illuminated pushbutton switch:
AC CIRCUIT INTERRUPTER ON
indicator lights up?
v
- Refer to Connect load simulator to connector
Figure 5-9 NO receptacles Lt (CA), L2 (OB),
YES
L3 (CC) and N, and set line currents
to 400 A. AMPS Ll (GA), AMPS L2
1
(CB) and AMPS L3 (OC) meters
indicate 400 A?
v
Refer to NO YES
Overload cutout
Figure 5-10 at line currents
2572 A?
w v
Continue on Check EPP Ill.

page 2 Refer to
TM 9-6115-669-13&P
Figure 5-18 OVERLOAD lamp lights up during operation (sheet 1 of 4).
5 - 91
TM 9-6116-666-13

DEATH.
NO YES
I Line currents 400 A.
- Measure voltage at -
R5lT5: 5 VAC?
mawure voltage at
paragraph 5.17 N3/J 5vAc?
and N3/JR:
I w . v
Replace R6 or T6 NO Measure voltage at YES
(PARAGRAPH 5.17) N3/J and NJ/JS: -
5 VAC?
Repam or Replace NO Measure voltage YES

cable ” 123” at R7K7:
5 VAC?
paragraph 5.17 page3
5-92
TM 9-6115-668-13

DEATH.
paragraph.15
paragraph 5.6
5-93
TM 9-6115-668-13

DEATH.
paragraph 4.44
paragraph 4.45
paragraph 5.6
5-94
TM 9-6115-668-13
Section III. MAINTENANCE PROCEDURES
5.5 GENERAL.
This section will provide authorized direct support level maintenance instructions for the Generator Set
150 kW and its components. Each major component will be covered under its own paragraph heading.
Each paragraph will be further divided into specific maintenance tasks, as directed by the Maintenance
Allocation Chart (MAC). These tasks will include inspection, testing, service, adjustment, removal, disas-
sembly, assembly, repair, replacement, and installation, as applicable. Step by step instructions and spot
illustrations will guide personnel through each maintenance task.
WARNING
• Potential 150 kw shock hazard with failure to adhere to this warn-

ing. Contact with this high power could result In death or severe
injury. if the removal of one generator from the EPP iii Is required,
replace it with an extra generator. Always make sure that two gen-
erators are mounted to the EPP Ill. Continued use of the EPP III with
only one generator could result in a catastrophic shock hazard.
• Do not operate one of the EPP-III generators when the other gener-
ator Is dismounted.
• Prior to energizing the equipment the operator must check for ex-
posed electrical terminals.
• Always install protective covers on control and power cables
when cables are not connected.
• Be sure to observe ail warning signs on equipment.
WARNING
• Disconnect the negative battery terminal cable if task Involves

electrical connections.
• Remove the ignition key while working around the engine.
• For safety reasons, work on the GEN SET 150 kW must always be
performed by two persons.
• A notice will indicate when three persons are required for a particu-
lar task.
5-95
TM 9-6115-666-13
NOTE
• The following should generally be performed after any removal/Installation operation,

if applicable:
Functional test
Lamp test
Sealing check
Bleeding
Oil pressure check
Oil level check
• Observe all regulations when disposing of oil filters, used oil, and rags.
5-96
TM 9-6115-668-13
5.6 AUXILIARY CONTACTOR WITH SEMICONDUCTOR DEVICE MAINTENANCE.

Materials/Parts
Cable ties
WARNING
CAUTION

REMOVAL
NOTE
Removal procedure or auxiliary contactor with semiconductor device
K2 (35)/V13 (29), K4 (39)/V14 (40), K11 (49)/V7 (44), K12 (50)/V8 (45), K14
(59)/V9 (46), K21 (57)/V12 (58), K23 (52)/V10 (59), K24 (46)/V11 (60) is the
same as for auxiliary contactor K2 (35) with semiconductor device V13
(29), described below.
3. Record labeling and position of cables (26) to auxiliary contactor K2 (35) and cable (34) to semicon-
ductor
device V13 (29) at upper terminals (27), loosen screws (28), and remove cables (34) and (26).
4 . Record labeling and position of cables (23) to auxiliary contractor K2 (35) and cable (33) to semi-
conductor device V13 (29) at lower terminals (30) of auxiliary contractor K2 (35), loosen screws
(31), and remove cables (32) and (33).
5-97
TM 9-6715-668-13
5. Use a screwdriver to push locking element (28) on auxiliary contractor K2 (35) in direction of arrow,
tilt auxiliary contractor K2 (35) upward and remove from mounting bar (38).
6. Unlock semiconductor device V13 (29) by pushing in direction of arrow, and remove fromauxiliary
contractor K2 (35).
NOTE
Installation procedure for auxiliary contractor with semiconductor de-
vice K2 (35)/V13 (29), K4 (39)/V14 (40), K11 (49)/V7 (44), K12 (50)/V8 (45),
K14 (59)/V9 (46), K21 (57)/V12 (58), K23 (52)/V10 (59), K24 (53)/V11 (60)
Is the same as forauxiliary contractorK2 (27) with semiconductor de-
vice V13 (29) described below.
1. Hook top (37) of auxiliary contractor K2 (35) into mounting bar (38) and clip in at the bottom.
2. Install semiconductor device V13 (29) on auxiliary contractorK2 (35) and clip into place.
CAUTION
Make sure polarity is correct when semiconductor device Is con-

nected.
3. Noting correct labeling and position, install cables (32) and cable (33) of semiconductor device V13
(29) to terminals (30) of auxiliary contractor K2 (35), and tighten screws (31).
4. Noting correct labeling and position, install cables (26) and cable (34) of semiconductor device V13
(29) to terminals (27) of auxiliary contractor K2 (35), and tighten screws (28).
6. Close flap (2).
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TM 9-6115-668-13
5.7 AUXILIARY CONTACTOR MAINTENANCE.

Materials/Parts
Cable ties
WARNING
CAUTION

NOTE
Removal procedure for auxiliary contractor K5 (41), K6 (42), K7 (43),
K8 (47), K9 (48), K15 (54), K16 (55), K18 (56), K27 (61) is the same as for
auxiliary contractor K28 (20), described below.
3. Record labeling and position of cables (17) to upper terminals (18) of auxiliary contractor K28 (20),
loosen screws (19), and remove cables (17).
4. Record labeling and position of cables (23) to lower terminals (22) of auxiliary contractor K28 (20),
loosen screws (21), and remove cables (23).
5. Use a screwdriver to push locking element (24) on auxiliary contractor K28 (20) in direction of arrow,
tilt auxiliary contractor K28 (20) upward and remove from mounting bar (38).
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TM 9-6115-668-13
NOTE
Installation procedure for auxiliary contractor K5 (41), K6 (42), K7 (43),
K8 (47), K9 (48), K15 (54), K16 (55), K18 (56), K27 (61) is the same as for
auxillary contractor K28 (20), described below.
1 . Hook top (25) of auxiliary contractor K28 (20) into mounting bar (38) and clip into place at the bot-
tom.
2 . Noting correct labeling and position. Install cables (23) in lower terminals (22) of auxiliary contractor
K28 (20), and tighten screws (21).
3. Noting correct labeling and position, install cables (17) to upper terminals (18) of auxiliary contractor
K28 (20), and tighten screws (19).
5. Close flap (2).
5-100
TM 9-6115-668-13
Figure 5-19 Control Cabinet Assembly, Auxiliary Contactor with Semiconductor, Auxiliary Contactor,
Transformer, Maintenance.
5-101
TM 9-6115-668-13
5.8 TIME RELAY K3, K10, K13, K17, K25, K26 MAINTENANCE.
This task covers: a. Removal c. Adjustment

b. Testing d. Installation

Watch, stop
Materials/Parts
Cable ties
WARNING
tery terminal cables. Failureto observe this warning could result in se-
CAUTION
REMOVAL

NOTE
The removal procedure for time relay K3 (40), K10 (42), K13 (43), K17
(45), K25 (44) Is the same as for time relay K26 (19), described below.
3. Record labeling and position of cables (26) to upper terminals (25) of time relay K26 (19), loosen
screws (24), and disconnect cables (26).
4. Record labeling and position of cables (29) to upper terminals (28) of time relay K26 (19), loosen
screws (27), and disconnect cables (29).
5-102
TM 9-6115-668-13
5. Record labeling and position of cables (22) to lower terminals (23) of time relay K26 (19), loosen
screws and disconnect cables (22).
6. Record labeling and position of cables (20) to lower terminals (21) of time relay K26 (19), loosen
screws and disconnect cables (20).
7. Use a screwdriver to push locking element (18) on time relay K26 (19) in direction of arrow, tilt time
relay K26 (19) upward, and remove from mounting bar (30).
CAUTION
Before TESTING, check settings of time relays under ADJUSTMENT,
and correct if necessary.
1. Time relay K3 (40):

a. Start up Generator Set 150 kW as instructed in paragraph 2.5.1.
b. Check that green LED lights up while 24 V input voltage is applied.
c. Check that amber LED is activated after time1 = 24 seconds has elapsed, and lights up while
input voltage is applied.
d. Connect multimeter between terminals 15 and 18 and check that 24 V voltage drops to zero af-
ter time1 = 24 seconds has elapsed.
e. Perform Generator Set 150 kW shut down, paragraph 2.5.2.

c. Check that amber LED is activated after time1 = 30 seconds has elapsed, and lights up while
input voltage is applied.
d. Pull cable with plug 1J2/1 off oil pressure switch 1S2. Connect plug 1J2/1 to ground and check
that diesel engine shuts down,
e. Once diesel engine has shut down, reconnect cable with plug 1J2/1 to oil pressure switch 1S2.
f. Start diesel engine as instructed in paragraph 2.5.1.
g. Perform Generator Set 150 kW shut down, paragraph 2.5.2.

c. Use a screwdriver to push AC CIRCUIT INTERRUPTER ON illuminated pushbutton switch
S8/H14 and check that AC CIRCUIT INTERRUPTER ON illuminated pushbutton switch S8/H14
lights up and relay K1 is energized.
d. Perform Generator Set 150 kW shut down, paragraph 2.5.2.
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TM 9-6115-666-13

b. Check that green LED lights up, while 24 V input voltage is applied.
c. Apply +24 V (with respect to A2) on relay terminal Al and check that AC CIRCUIT INTER-
RUPTER ON illuminated pushbutton switch S8/H14 lights up and relay K1 is energized.
5. Check function of time relay K25 (44):
c. Check contacts D-H of plug J9 and check that amber LED lights up for time2 = 0.5 after
time1 = 0.5 seconds has elapsed, and AC CIRCUIT INTERRUPTER ON illuminated pushbutton
switch S8/H14 is off.

c. Check that amber LED is activated after 6 seconds, and stays illuminated while input voltage is
applied.
d. Connect multimeter between terminals 15 and 18, and check that 24 V voltage drops to zero
after time1 = 6 seconds has elapsed.
7. Perfrom Generator Set 150 kW shut down, paragraph 2.5.2.
CAUTION
Check jumpers on terminals, and remove, insert, or reconfigure as

necessary.
1 . Set Time relay K26 (19) to a 6-seconds switching time:

a. On front of time relay K26 (19), use TIME DIP switches (1) to set a 10-seconds time window as
indicated in figure 5-20.
b. On front of Time relay K26 (19) use knob (3) to set a multiplication factor of .6.
2. Set time relay K3 (40) to switching time of 24 seconds:

a. On front of time relay K3 (40) use TIME DIP switches (1) to set a 30-seconds time window as
b. On front of time relay K3 (5-200) use knob (3) to set a multiplication factor of .8.
5-104
TM 9-6115-668-13
a. On front of time relay K10 (5-202) use TIME DIP switches (1) to set a 30-seconds time window
as indicated in Figure 5-20.
b. On front of time relay K10 (42) use knob (3) to set a multiplication factor of 1.

a. On front of time relay K13 (43) use TIME DIP switches (1) to set a 30-seconds time window as
b. On front of time relay K13 (43) use knob (3) to set a multiplication factor of .4.
Figure 5-20 Time Relays K3, K10, K13 and K26
5-105
TM 9-6115-668-13
5. Set time relay (Wipe Relay) K17 (23) to switching time of 0.5 seconds:
a. Insert jumper Y1-Y2 into lower row of terminal as shown in figure 5-21.
Figure 5-21 Time Relay k17
6. Set time relay K25 (44) to switching time t1 = 0.5 seconds and pulse time t2 = 0.5 seconds:
a. Insert jumper Y1 -Y2-Y3 (1) into upper row of terminal as shown in figure 5-22.
b. Set switching time t1:
On front of time relay K25 (44), use TIME DIP switches (2) to set a 1 -seconds time
window as indicated in figure 5-22.
On front of time relay K25 (44), use rotary knob (4) to set a multiplication factor of .5.
c. Set pulse time t2:
On front of time relay K25 (44), use TIME DIP switches (5) to set a 1 -seconds time
window as indicated in figure 5-22.
On front of time relay K25 (44), use knob (6) to set a multiplication factor of .5.
5-106
TM 9-6115-668-13
Figure 5-22 Time Relay K25
1. Hook top (17) of time relay K26 (19) into mounting bar (30) and push in at the bottom.
2. Noting correct labeling and position, install cables (20) on lower terminals (21) of time relay K26
(19), and tighten screws.
3. Noting correct labeling and position, install cables (22) on lower terminals (23) of time relay K26
(19), and tighten screws.
4. Noting correct labeling and position, install cables (29) on upper terminals (28) of time relay K26
5. Noting correct labeling and position, install cables (26) on upper terminals (25) of time relay K26
7. Close flap (2).
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TM 9-6115-668-13
5.9 POWER SUPPLY NT2 24 V MAINTENANCE.

WARNING
CAUTION
REMOVAL

NOTE
Removal procedure for all power supply components NT2 24 V is
the same as for time relay K26, described below.
3. Remove time relay K26 (19) as instructed in paragraph 5.8.

4. Push the closures on power supply component (16) apart in direction of arrow, and pull power sup-
ply component (16) out of time relay K26 (19).
NOTE
Installation procedure for all power supply components NT2 24 V
is the same as for time relay K26, described below.
1. Insert power supply component (16) in timing relay K26 (19).

2. Install timing relay K26 (19) as instructed in paragraph 5.8.
4. Close flap (2).
5-108
TM 9-6115-668-13
Figure 5-23 Diodes, Time Relay, Power Supply Maintenance.
5-109
TM 9-6115-668-13
5.10 THERMISTOR RELAY F12 MAINTENANCE.

(item 3, appendix B) paragraph 25.2
Materials/Parts
Cable ties
WARNING
CAUTION

thermistor relay F12 (17).
5. Use a screwdriver to push unlocking element on thermistor relay F12 (17) downward, tilt thermistor
relay F12 (17) upward and remove from mounting bar (14).
1. Hook thermistor relay F12 (17) into top of mounting bar (14) and clip in at the bottom.
2. Noting labeling and position of cables install cables (49, 58) to terminals (48, 59) of thermistor relay
F12 (17).
5. Close flap (2).
5-110
TM 9-6115-668-13
Figure 5-24 Control Cabinet Assembly, Circuit Breaker F1 to F11, Thermistor relay F12, True Power
Measure Transformer P4A Maintenance.
5-111
TM 9-6115-668-13
5.11 DIGITAL ISOCHRONOUS LOAD SHARING MODULE N4 MAINTENANCE.
This task covers: a. Removal b. Adjustment c. Installation

Load Bank (item 19, appendix B)
Materials/Parts
Cable ties
WARNING
CAUTION

3. Using a suitable wrench to hold standoffs (35), remove two nuts (32), two serrated lock washers
(33), and two washers (34), from standoffs (35).
4. Remove nut (22), serrated lock washer (23), washer (24), voltage compensation line (21), and
washer (25).
5. Cut cable ties at cable tie holder (26) and remove cables.
6. Remove knurled nuts (29, 30) on N4 (36) and housing cover (31).
7. Record labeling and position of cables and disconnect cables from terminals of N4 (36).
8. Using a suitable wrench to hold standoff (37), remove screws (40), serrated lock washers (39), and
washers (38), from standoff (37).
9. While holding standoff with a suitable wrench, remove screw (28) serrated lock washer (27), and
cable tie holder (26).
10. Remove digital isochronous load sharing module N4 (36) from standoffs (35,37).
5-112
TM 9-6115-668-13
NOTE
The EPP Ill must be operating In order to adjust digital isochronous load sharing
module N4; see TM 9-6115-669-13&P
1. Connect load bank to generator set and perform procedures in paragraph 5.53.
2. Open digital isochronous load sharing module N4 (36) as instructed under REMOVAL, step 7.
3. Preset potentiometers as follows (figure 5-25):
RPLVL to position 5
FP OFF to position 5
FP ON to position 5
LOAD PULSE to position 12
LS GAIN to position 5
DROOP to position 7 (fully counterclockwise)
PM GAIN to position do (factory preset)
not
adjust
4. Connect multimeter to TP 1 (+) and TP 2 (-); (Measurement range 10 V-, R; > 10 Mn).
5. Start up Generator Set 150 kW as instructed in paragraph 2.5.1.
Set output parameters: P = 150 kW, IL = 520 A, cos cp = 0.8.
6. Adjust settings:
a. Use CT CAL potentiometer to set voltage on multimeter 7.5 V-.
b. Use LS GAIN potentiometer to set voltage on multimeter to 5.5 V.
c. Switch on Generator Set 150 kW No. 2 and set up parallel operation with Generator Set 150 kW No.1.
d. When Generator Set 150kW is running with rising and falling rpm, turn LOAD PULSE potentiometer counter-
clockwise until a stable condition is achieved and the rotation speed no longer changes even if the control
linkage between speed control device and fuel injection pump is tapped.
e. When rotation speed is constant, allow Generator Sets 150 kW No. 1 and No. 2 to run in test mode.
7. Shut down Generator Set 150 kW No. 1 and No. 2 as instructed in paragraph 2.5.2.
8. Disconnect mutimeter from TP 1 (+) and TP 2 (-).
9. Close digital isochronous load sharing module N4 (36) as instructed under INSTALLATION, step 4.
10. Disconnect load bank from Generator Set 150 kW.
Change 1 5-113
TM 9-6115-668-13
Figure 5-25 Digital lsochronous Load Sharing Module N4, Location of Potentiometers and Test Points.
NOTE
Perform the ADJUSTMENT procedure when installing a new digital isochrono-
us load sharing module N4 (34).
1. Place digital isochronous load sharing module N4 (36) on standoffs (35.37).

2. install two nuts (32), two serrated lock washers (33) and two washers (34) on standoffs (35) while holding standoff
(35) with a suitable wrench.
3. install cables to terminals of digital isochronous load sharing module N4 (36). Note correct labeling and position.
4. Install housing cover (31) on module (36) and tighten nuts (29, 30).
5. Install washer (25), line (21), washer (24), serrated lock washer (23), and nut (22) on threaded pin.
6. Install cable tie holder (26) with screw (28) and serrated lock washer (27), while holding standoff with a suitable
wrench; arrange cables and secure with cable ties.
7. Install two serrated lock washers (39), two washers (38), and two screws (40) on two standoffs (37) while holding
standoffs (37) with a suitable wrench.
8. Stow prop (5) and dose front panel (4).
9. Close flap (2).
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TM 9-6115-668-13
5.12 RELAY K19 AND K20 WITH RELAY SOCKET AND CONTACT BUSHINGS MAINTENANCE.

Removal Tool, small
Installation Tool, small
Materials/Parts
Cable ties
WARNING
CAUTION

3. Remove digital isochronous load sharing module N4 (36) as instructed in paragraph 5.11.
NOTE
Removal procedure for relay K20 is the same as for relay K19, de-
scribed below.
4. Remove relay K19 (7):

a. Remove two screws (20), two serrated lock washers (19), and two washers (18) from two
threaded elements (17).
5-115
TM 9-6115-668-13
b. Pull relay K19 (7) out of relay socket (16).

5. Remove relay socket (16) with contact bushings:
a. Remove nut (9), serrated lock washer (10), and washer (11) from standoff (8).
b. Remove relay board (15) with relay K20 (6) from standoff (8).
c. Remove nut (12), serrated lock washer (13) and washer (14) from threaded element (17).
d. Remove threaded element (17) and relay socket (16) from relay board (15).
CAUTION
Use only removal tool to push out contact bushings.
6. Remove contact bushings:

7. Insert removal tool from the front into contact bushing and push contact bushing with cable out of
relay socket (16).
CAUTION
Use only installation tool to Insert contact bushings.
1. Slide installation tool over contact bushing and push contact bushing with cable into relay socket
(16).
2. Insert relay socket (16) into relay board (15).
3. Install two washers (11), two serrated lock washers (10), and two nuts (9) on two standoffs (8).
4. Insert relay K19 (7) into relay socket (16).
5. Install two screws (20)) two serrated lock washers (19), and two washers (18).
6. Install digital isochronous load sharing module N4 (36) as instructed in paragraph 5.11.
8. Close flap (2).
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TM 9-6115-668-13
5.13 SPEED GOVERNOR ASSEMBLY N1 MAINTENANCE.

This task covers: a. Removal b. Adjustment c. installation
General Mechanics Tool Kit Reference

Automotive Fuel and Electrical System Repair, Tool Kit down
Load bank (item 19, appendix B)
XY-printer
Cable ties
WARNING
Disconnect the negative battery cable first and then the positive battery termi-
nal cables. Failure to observe this warning could result in severe personal injury
or death.
Tag all cables prior to removal to ensure correct connection of the cables during
installation.

NOTE
Speed governor assembly N1 (43) Is located behind digital isochronous load
sharing module N4 (33).
3. Remove two nuts (32), two serrated Iock washers (32) and two washers (34) from two standoffs (35), while holding
standoffs (35).
4. Swing digital isochronous load sharing module N4 (36) to one side.
5. Record labeling and position of cables (42) and remove cables (42) from terminals (44) of speed governor
assembly N1 (43).
6 . Remove resistor R10 (41) from speed governor assembly N1 (43) and set aside for re-use.
7. Remove cables (54) for resistors R100 to R102 from connection strip (53).
5-117
TM 9-6115-668-13
8. Remove two screws (45), two serrated lock washers (46), and two washers (47) from two standoffs (48).
9. Remove speed governor assembly N1 (43) with mounting plate (51) and resistors R100 to R102 (55 to 57) from
standoffs (48).
2. Remove cover panel over socket terminals L1 to L3 and N in control cabinet as instructed in paragraph 5.24.
3. Connect X/Y-printer to threaded pin of terminals L1, L2, L3 and N.
4. Preset potentiometers as follows (figure 5-26):
LIM to position 11
INT to position 11
DER to position 11
ACT to position 12
DROOP to position 7 (full counterclockwise)
GAIN to position 9
5. Start up Generator Set 150 kW as instructed in paragraph 2.5.1.

6. Adjust settings:
a. Rotate FREQUENCY ADJUST potentiometer R4 all the way clockwise and lock control knob with lever.
b. Use SPD IN potentiometer to set frequency on FREQUENCY meter P5 to 416 Hz.
c. Use FREQUENCY ADJUST potentiometer R4 to set frequency on FREQUENCY meter P5 to 400Hz, and
lock control knob with lever.
d. Rotate ACT potentiometer clockwise, until unit begins to vibrate (if necessary, tap control linkage between
speed control device and fuel injection pump).
e. Rotate ACT potentiometer counterclockwise until a stable condition is achieved, and unit does not begin to
vibrate even if the control linkage is tapped (potentiometer pointer between 2 and 3).
f. Rotate GAIN potentiometer clockwise, until unit begins to vibrate (if necessary, tap control linkage between
speed control device and fuel injection pump).
g. Rotate GAIN potentiometer counterclockwise, until a stable condition is achieved, and unit does not begin
to vibrate even if the control linkage is tapped (potentiometer pointer between 10 and 11).
h. Switch load on and off, and use INT and DER potentiometers to optimize control characteristics based on
curves recorded with X/Y-printer.
7. Shut down Generator Set 150 kW No. 1 AND No.2 as instructed in paragraph 2.5.2.
8. Disconnect X/Y-printer from threaded pins of terminals L1, L2, L3 and N.
9. Install cover panel above socket terminals L1 to L3 and N in control cabinet as instructed in paragraph 5.24.
10. Disconnect load bank from Generator Set 150 kW.
5-118 Change 1
TM 9-6115-668-13
Figure 5-26 Speed Governor Assembly N1, Location of Potentiometers.
NOTE
Perform the ADJUSTMENT procedure when installing a new speed

governor assembly N1 (34).
1. Install speed governor assembly N1 (43) with mounting plate (51) and resistors R100 to R101 (50
to 57) on standoff (48) on back panel of control cabinet (3).
2. Install two screws (45) with two serrated lock washers (46) and two washers (47).
3. Connect cables (54) for resistors R100 to R102 (55 to 57) to connection strip (53).
4. Connect resistor R10 (41) to speed governor assembly N1 (43).
5. Noting correct labeling and position, reconnect cables to terminals (44) of speed governor assembly
N1 (43).
6. Swing digital isochronous load sharing module N4 (36) over speed governor assembly N1 (43).
7. Install two serrated lock washers (33) and two washers (34) and screw on two nuts (32) while hold-
ing standoffs (35).
9. Close flap (2).
5-119
TM 9-6115-668-13
Figure 5-27 Control Cabinet Assembly, Relays K19, K20, Digital lsochronous Load Sharing Module N4,
Speed Governor Assembly N1, Resistor Maintenance.
5-120
TM 9-6115-668-13
5.14 VOLTAGE REGULATOR N2 MAINTENANCE.

This task covers: a. Removal b. Repair c. Adjustment d. Installation

XY-printer (item 16, appendix B)
Cable ties
WARNING
or death.
CAUTION
Tag ail cables prior to removal to ensure correct connection of the cables during
installation.

CAUTION
Do not use excessive force to remove circuit boards. Note the position of circuit
boards during removal for correct positioning during installation.
3. Removing circuit boards (16 to 19) from voltage regulator N2 (6):

a. Removing four screws (II), four serrated lock washers (12), four washers (13), two angle pieces (14), and
front panel (15) from voltage regulator housing (10).
b. Remove circuit boards (16 to 19) from voltage regulator housing (10):
5-121
TM 9-6115-668-13
Voltage Sensing Transformer TT1309-./03 (16)

Averaging Circuit TT1311-./01 (17)
Linear Regulator TT1310-./01 (18)
Equal Power Distribution TT1315-./01 (19)
4. Remove complete voltage regulator N2 (6):

a. Record labeling and position of cables and remove cables from terminals (9) on voltage regulator N2 (6).
b. Remove two nuts (8) and remove voltage regulator N2 (6) from bolts (7). Discard nuts (8).
Perform ADJUSTMENT procedure after replacing parts.
1. If a circuit board is defective:

a. Remove defective circuit board (16 to 19) from voltage regulator housing (10) and insert new circuit board.
2. If transistors are defective (3 x 2N3773, mounted on housing):
a. Remove all circuit boards (16 to 19) from voltage regulator housing (IO).
b. Replace voltage regulator housing (10) and reinsert circuit boards (16 to 19).
1. Adjust equal power distribution TT1310-./01:

a. Use potentiometers (figure 5-28) to adjust power distribution:
Ref. full clockwise (maximum 18 turns), then 9 turns back
Gain full clockwise (maximum 18 turns), then 9 turns back.
Offs. do not adjust (factory preset).
2. Adjust linear regulator TT1310-./01 :
a. Connect load bank to generator set and perform procedures in paragraph 5.53.
b. Remove cover panel socket terminals L1 to L3 and N in control cabinet as instructed in paragraphs 5.24.
c. Connect X/Y-printer to threaded pins of terminals L1, L2, L3 and N.
d. Preset potentiometers (figure 5-28).
Gain full counterclockwise (maximum 18 turns), then 9 turns back.
e. Start up Generator Set 150 kW as instructed in paragraph 2.5.1.

f. Optimize control characteristics:
Gain while switching load OFF and ON, observe excursion printed on X/Y-printer and adjust for
minimum amplitude..
g. Shut down Generator Set 150 kW as instructed in paragraph 2.5.2
5-122 Change 1
TM 9-6115-668-13
h. Disconnect X/Y-printer from threaded pins of terminals L1, L2, L3 and N.

i. Install cover over socket terminals L1 to L3 and N in control cabinet as instructed in paragraph
5.24.
j. Disconnect load bank from Generator Set 150 kW.
Figure 5-28 Voltage Regulator N2, Location of Circuit Boards and Potentiometers.
3. Adjust averaging circuit TT1311-./01:

a. Connect multimeter to terminals of VOLTAGE meter P6 (measurement range 300 V ~, Ri > 10
M ) .
b. Start up Generator Set 150 kW as instructed in paragraph 2.5.1.
5-123
TM 9-6115-668-13
c. Set averaging:
Rotate VOLTAGE ADJUST potentiometer R3 ail the way clockwise (10) and lock control knob
with lever Use Volt. adj. potentiometer to set voltage on multimeter to 230 V.
Use VOLTAGE ADJUST potentiometer R3 to set voltage on multimeter to 208 V, and lock con-
trol knob with lever.
d. Shut down Generator Set 150 kW as instructed in paragraph 2.5.2.

e. Remove connectors of multimeter from terminals of VOLTAGE meter P6.
CAUTION
Note position of boards when removed to ensure correct positioning
1. Install boards into voltage regulator N2 (6):

a. insert boards into voltage regulator housing (10):
Voltage Sensing Transformer TT1309-./03 (16)

Averaging Circuit TT1311-./01 (17)
Linear Regulator TT1310-./01 (18)
Equal Power Distribution TT1315-./01 (19)
b. Install front panel (15) and two angle pieces (14) on voltage regulator housing (10).
c. Install two screws (11), two serrated lock washers (12) and two washers (13) on voltage regula-
tor housing (10).
2. Install complete voltage regulator N2 (6):
NOTE
Use new self-locking nuts (6) when installing voltage regulator N2.
a. Place voltage regulator N2 (6) on bolts (7) and install new nuts (8). Tighten nuts (8).
b. Noting correct labeling and position, install cables to terminals (9) of voltage regulator N2 (6).
4. Close flap (2).
5-124
TM 9-6115-668-13
Figure 5-29 Control Cabinet Assembly Voltage Regulator N2 Maintenance.
5-125
TM 9-6115-668-13
5.15 SAFETY DEVICE N3 MAINTENANCE.
This task covers: a. Removal c. Adjustment

b. Repair d. Installation

X/Y-printer (item 16, appendix B)
Materials/Parts
Cable ties
WARNING
CAUTION
REMOVAL

CAUTION
Do not useexcessive force to removecircuit boards. Note the position
of circuit boards during removal for correct positioning during instal-
lation.
3. Remove circuit boards from safety device N3 (6):

a. Remove four screws (11), four serrated lock washers (12) and four washers (13), two angle
pieces (14) and front panel (15) from housing (10).
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TM 9-6115-668-13
b. Pull circuit board (16 to 19) out of voltage regulator housing (10):
Synchronizing Relay TT1308-.01 (16)
Voltage Sensing Transformers TT1309-./02 (17)
Voltage/Frequency Error Detection TT1314-./01 (18)
Overcurrent/Rev. Power Detection TT1313-./01 (19)
4. Remove complete safety device N3 (6):
a. Record labeling and position of cables and disconnect cables from terminals (9) of safety device N3 (6).
b. Remove nuts (8) and safety device N3 (6) from bolts (7). Discard nuts (8).
CAUTION
Perform ADJUSTMENT procedure after replacing parts.
1. Remove defective circuit board (16 to 19) out of safety device housing (10) and insert new board.
1. Adjust Overcurrent/Rev. Power Detection TT1313-./01 :

a. Connect load bank to generator set and perform procedures in paragraph 5.53.
b. Remove cover over socket terminals L1 to L3 and N in control cabinet as instructed in paragraph 5.24.
c. Connect X/Y-printer to threaded pins of terminals L1, L2, L3 and N.
d. On relay K12 (50, figure 5-19), attach a jumper between terminals 21 and 22.
e. Preset potentiometers (figure 5-30).
lmax Rotate all the way clockwise (maximum 18 turns)
Delay I Rotate all the way counterclockwise (maximum 18 turns)
PRmax Rotate all the clockwise (maximum 18 turns)
Delay P Rotate all the way counterclockwise (maximum 18 turns)
Offs. Do not adjust (factory preset)
f. Start up Generator Set 150 kW as instructed in paragraph 2.5.1.
g. Adjust overload:
Increase inductive load at load bank to et current to 1.1 times rated value: IL = 572 A.
Slowly rotate imax potentiometer counterclockwise until OVERLOAD indicator H13 lights up on front panel
of control cabinet.
Turn delay I potentiometer four turns clockwise.
Reduce load at load bank and push OVERLOAD illuminated pushbutton switch S10 on front
Change 1 5-127
TM 9-6115-668-13
panel of control cabinet:

OVERLOAD indicator must go out.
h. Shut down Generator Set 150 kW as instructed in paragraph 2.5.2.
i. On Relay K12, remove jumper between terminals 21 and 22.
j. Start up Generator Set 150 kW as instructed in paragraph 2.5.1 and check settings.
Increase loads only for short periods.
k. Check trip times:

Increase load at load bank to set current to 1.2 times rated value IL = 628 A.
Trip time of load circuit must be <2.5 seconds.
Increase load at load bank to set current to 1.8 times rated value IL = 936 A.
Trip time of load circuit must be <1.5 seconds.
5-128
TM 9-6115-668-13
Figure 5-30 Voltage Regulator N2, Location of Circuit Boards and Potentiometers.
I. Shut down Generator Set 150 kW as instructed in paragraph 2.5.2.

m. Disconnect load bank from Generator Set 150 kW.
n. Disconnect X/Y-printer from threaded pins of terminals L1, L2, L3, and N.
o. Install cover over socket terminals L1 to L3 and N in control cabinet as instructed in paragraph
5.24.
p. Adjust reverse power for Generator Set 150 kW No. 1:
5-129
TM 9-6115-668-13
NOTE
To adjust reverse power for Generator Set 150 kW No. 1 and Generator
Set 150 kW No. 2, the EPP III must be running, since Generator Set 150
kW No. 1 and Generator Set 150 kW No. 2 must beoperating in parallel
mode. See TM 9-6115-669-13&P.
q. Start up Generator Set 150 kW No. 1 and Generator Set 150 kW No. 2 as instructed in para-
graph 2.5.1 and operate in parallel mode with no load.
On Generator Set 150 kW No. 2, turn FREQUENCY ADJUST potentiometer (R4) clockwise,
until KILOWATTS meter (P4) displays 30 kW. Lock control knob with lever.
On Generator Set 150 kW No. 1, turn PRmax potentiometer counterclockwise until REVERSE
POWER ON indicator (H11) lights up. Contactor K1 de-energizes and AC CIRCUIT INTER-
RUPTER ON indicator goes out (H14). Press REVERSE POWER illuminated pushbutton switch
(S22):
REVERSE POWER indicator (H11) goes out.
On Generator Set 150 kW No. 2, use FREQUENCY ADJUST potentiometer (R4) to set a fre-
quency of 399.8 Hz or 400.2 Hz on FREQUENCY meter (P5). Lock control knob with lever. On
Generator Set 150 kW No. 1, push PARALLEL OPERATION ON illuminated pushbutton switch
(S9). PARALLEL OPERATION ON indicator (H12) lights up during automatic synchronization of
Generator Set 150 kW No. 1 and Generator Set 150 kW No. 2.
On Generator Set 150 kW No. 2, turn FREQUENCY ADJUST potentiometer (R4) clockwise until
KILOWATTS meter (P4) displays 30 kW (adjustment point check).
Lock control knob with lever.
On Generator Set 150 kW No. 1, REVERSE POWER indicator (H11). Contactor K1 de-ener-
gizes and ACCIRCUIT INTERRUPTER ON indicator (H14) goes out. Press REVERSE POWER
illuminated pushbutton switch (S22): REVERSE POWER indicator (H11) goes out.
quency of 399.8 Hz or 400.2 Hz on FREQUENCY meter (P5).
On Generator Set 150 kW No. 1, press PARALLEL OPERATION ON illuminated pushbutton
switch (S9). PARALLEL OPERATION ON indicator (H12) lights up during automatic synchro-
nization of Generator
Set 150 kW No. 1 and Generator Set 150 kW No. 2.
5-130
TM 9-6115-668-13
r. Adjust reverse power for Generator Set 150 kW No. 2:

On Generator Set 150 kW No. 1, turn FREQUENCY ADJUST potentiometer (R4) clockwise until
KILOWATTS meter (P4) displays 30 kW. Lock control knob with lever.
On Generator Set 150 kW No. 2, turn PRmax potentiometer counterclockwise, until indicator
REVERSE POWER ON (H11) lights up. Contactor K1 de-energizes and AC CIRCUIT INTER-
RUPTER indicator ON (H14) goes out.
Press REVERSE POWER (S22) illuminated pushbutton switch:
REVERSE POWER indicator goes out.
quency of 399.8 Hz or
400.2 Hz on FREQUENCY meter (P5).
On Generator Set 150 kW No. 2, press PARALLEL OPERATION ON illuminated pushbutton
switch (S9). PARALLEL OPERATION ON indicator (H12) lights up during automatic synchro-
nization of Generator Set 150 kW No. 1 and Generator Set 150 kW No. 2.
2. Adjust Voltage/Frequency Error Detection TT1314-./01 :
a. On relay K5 (41, figure 5-19), disconnect cable from terminal 1.
b. Connect multimeter to terminals of VOLTAGE meter (P6) (measurement range 300 V~Ri > 10
M ).
c. Preset potentiometers (figure 5-30).
Umax Turn all the way clockwise (maximum 18 turns)

Umin Turn all the way counterclockwise (maximum 18 turns)
fmax Turn all the way clockwise (maximum 18 turns)
fmin Turn all the way counterclockwise (maximum 18 turns)
d. Start up Generator Set 150 kW as instructed in paragraph 2.5.1.
e. Adjust overvoltage:
Start up Generator Set 150 kW as instructed in paragraph 2.5.1.
Turn VOLTAGE ADJUST potentiometer (R3) all the way clockwise (10). Lock control knob with
lever. Use Volt.adj. potentiometer (figure 5-28) to set voltage on multimeter to 240 V.
Turn VOLTAGE ADJUST potentiometer (R3) counterclockwise to set voltage on multimeter to
239.2 V. Lock control knob with lever.
Turn Umax potentiometer counterclockwise until UNDER/OVER VOLTAGE indicator (H9) lights
up.
Turn VOLTAGE ADJUST potentiometer (R3) five turns counterclockwise. Lock control knob with
lever.
Press UNDER/OVER VOLTAGE illuminated pushbutton switch (S5). UNDER/OVER VOLTAGE
indicator (H9) goes out.
Shut down Generator Set 150 kW as instructed in paragraph 2.5.2.
On relay K5, connect cable to terminal 1.
Turn VOLTAGE ADJUST potentiometer (R3) clockwise and check that UNDER/OVER VOLT-
AGE indicator (H9) lights up and Generator Set 150 kW shuts down.
5-131
TM 9-6115-668-13
f. Adjust undervoltage:
On relay K5 (41, figure 5-19), disconnect cable from terminal 1,
Start up Generator Set 150 kW as instructed in paragraph 2.51.
Turn VOLTAGE ADJUST potentiometer (R3) all the way counterclockwise (0). Lock control knob
with lever.
Use Volt. adj. potentiometer (figure 5-28) to set voltage on multimeter to 175 V.
Turn VOLTAGE ADJUST potentiometer (R3) five turns clockwise. Lock control knob with lever.
Turn Umin potentiometer clockwise until UNDER/OVER VOLTAGE indicator (H9) lights up.
Turn VOLTAGE ADJUST potentiometer (R3) five turns clockwise. Lock control knob with lever.
Press UNDER/OVER VOLTAGE illuminated pushbutton switch (S5); UNDER/OVER VOLTAGE
indicator (H9) goes out.
Turn VOLTAGE ADJUST potentiometer (R3) counterclockwise and check that UNDER/OVER
VOLTAGE indicator (H9) lights up and Generator Set 150 kW shuts down.
g. Adjust setpoint:
Turn VOLTAGE ADJUST potentiometer (R3) all the way clockwise (10). Lock control knob with
lever.
Use Volt. adj. potentiometer (figure 5-28) to set voltage on multimeter to 230 V.
Turn VOLTAGE ADJUST potentiometer (R3) counterclockwise and set voltage to 208 V.
Disconnect connectors of multimeter from terminals of VOLTAGE meter (P6).
h. Adjust over-frequency:
On relay K5 (34, figure 5-19), disconnect cable from terminal 1.
Turn FREQUENCY ADJUST potentiometer (R4) all the way clockwise (10). Lock control knob
with lever. Use SPD IN potentiometer of speed governor assembly N1 (figure 5-28) to set a fre-
quency of 435 Hz on
FREQUENCY meter (P5).
Use FREQUENCY ADJUST potentiometer (R4) to set a frequency of 430 Hz on FREQUENCY
meter (P5).
Turn fmax potentiometer (figure 5-30) counterclockwise until UNDER/OVER FREQUENCY (H8)
indicator lights up.
On relay K5, disconnect cable from terminal 1.
Turn FREQUENCY ADJUST potentiometer (R4) five turns counterclockwise. Lock control knob
with lever.
i. Press UNDER/OVER FREQUENCY illuminated pushbutton switch (S4): UNDER/OVER FRE-
QUENCY indicator (H8) goes out.
5-132
TM 9-6115-668-13
Turn FREQUENCY ADJUST potentiometer (R3) counterclockwise and press UNDER/OVER

VOLTAGE
illuminated pushbutton switch (S4): UNDER/OVER VOLTAGE indicator (H8) goes out.
j. Adjust underfrequency:
On relay K5 (41, figure 5-19), disconnect cable from terminal 1.
Start up Generator Set 150 kW as instructed in paragraph 2.51.
Turn FREQUENCY ADJUST potentiometer (R4) all the way counterclockwise (0). Lock control
knob with lever.
Use SPD IN potentiometer of speed governor assembly N1 (figure 5-28) to set a frequency of
365 Hz on
FREQUENCY meter (P5).
meter (P5).
Turn fmin potentiometer clockwise until UNDER/OVER FREQUENCY indicator (H8) lights up.
Turn FREQUENCY ADJUST potentiometer (R4) five turns clockwise. Lock control knob with
lever.
Press UNDER/OVER FREQUENCY illuminated pushbutton switch (S4): UNDER/OVER FRE-
QUENCY indicator (S4) goes out.
Turn FREQUENCY ADJUST potentiometer (R4) counterclockwise and check that UNDER/
OVER FREQUENCY (H8) indicator lights up and Generator Set 150 kW shuts down.
Turn FREQUENCY ADJUST potentiometer (R4) clockwise and press UNDER/OVER FRE-
QUENCY illuminated pushbutton switch (H8): UNDER/OVER FREQUENCY indicator (H8) goes
out.
k. Adjust setpoint:
Turn FREQUENCY ADJUST potentiometer (R4) all the way clockwise (10). Lock control knob
with lever.
Use SPD IN potentiometer of speed governor assembly N1 (figure 5-28) to set a frequency of
416 Hz on FREQUENCY meter (P5).
meter (P5).
5-133
TM 9-6115-668-13
CAUTION
Do not use excessive force when installing circuit boards. Note cor-
rect position of circuit boards during removal to ensure correct posi-
tioning during installation.
1. Install circuit boards in voltage regulator N2 (6):

a. Insert circuit boards into voltage regulator housing (10):
Synchronizing Relay TT1308-./01 (16)

Voltage Sensing Transformers TT1309-./02 (17)
Voltage/Frequency Error Detection TT1314-./01 (18)
Overcurrent/Rev. Power Detection TT1313-./01 (19)
b. Install front panel (15) and two angle pieces (14) on voltage regulator housing (10).
c. Install four screws (11), four serrated lock washers (12), and four washers (13) on voltage regu-
lator housing (10).
2. Install complete safety device N3 (6):
NOTE
Use new self-locking nuts when installing safety device N3.
a. Install safety device N3 (6) on bolts (7) using new nuts (8).
b. Noting correct labeling and position, install cables on terminals (9).
4. Close flap (2).
5-134
TM 9-6115-668-13
Figure 5-31 Control Cabinet Assembly, Safety Device N3 Maintenance.
5-135
TM 9-6115-668-13
5.16 FILTER BOX FK MAINTENANCE.

Materials/Parts
Cable ties
WARNING
CAUTION

control cabinet connector panel (9).
4. Open control cabinet connector panel (9) and prop with wooden boards.
5. Remove eight screws (10), eight serrated lock washers (11), eight washers (12), and cover (13)
from filter box FK (16).
6. Record labeling and position of cables (17) to output connection strip (14) and disconnect.
7. Record labeling and position of cables (17) to input connection strip (15) and disconnect.
8. Remove four screws (19), four serrated lock washers (20), four washers (21), and remove filter box
FK (16).
5-136
TM 9-6115-668-13
1. Install filter box FK (16) on back panel of power distribution unit (3) and secure using four screws (19) four serrated
lock washers (20) and washers (21).
2. Noting correct labeling and position, install cables (17) to input connection strip (15) of filter box FK (16).
3. Noting correct labeling and position, install cables (18) to output connection strip (14) of filter box FK (16).
4. Install cover (13) on filter box FK (16) and secure with eight screws (10), eight serrated lock washers (11) and eight
washers (12).
5. Close control cabinet connector panel (9) and remove wooden props.
6. Secure with eighteen screws (6), eighteen serrated lock washers (7) and eighteen washers (8).
8. Close flap (2).
5-137
TM 9-6115-668-13
5.17 CURRENT TRANSFORMER MAINTENANCE.


Cable ties
WARNING
or death.
CAUTION
installation.

3. Remove eighteen screws (6), eighteen serrated lock washers (7), and eighteen washers (8).
4. Lower control cabinet connector panel (9) and prop.
5. Remove current transformer T12 (36):
NOTE
Removal procedure for current transformer T5 (52), T6 (54), T7 (55), T8 (61), T9
(62), T10 (63), T11 (47) and T13 (49) Is the same as for current transformer T12
(36), described below.
When removing current transformer T1 (57), T2 (64), T3 (65), T4 (66), also
remove three plastic screws (59) and remove insulator strip (66).
5-138 Change 1
TM 9-6115-668-13
a. Remove screw (42), serrated lock washer (43), washer (44) and cables (45) from bus bar (46).
b. Record labeling and position of cables (29) to current transformer T12 (36) and remove cable ties.
c. Loosen two screws (25), two serrated lock washers (26), two cable clamps (27), and remove cables (29) from
current transformer T12 (36).
d. Remove screw (22), serrated lock washer (23) and washer (24).
e. Remove screw (33), serrated lock washer (34) and washer (35).
f. Pull current transformer T12 (36) with resistor R13 (38) downward from bus bar (46).
6. Remove resistor R13 (38):
NOTE
Removal procedure for resistor R5 (51), R6 (53), R7 (56) and R12 (48), R14 (50),
R15 (56) is the same as for resistor R13 (38), described below.
a. Remove current transformer T12 (36) with resistor R13 (38) as instructed in step 5.
b. Remove two nuts (40), two serrated lock washers (39), and plate with resister R13 (38).
c. Remove two nuts (37), two screws (32), and two serrated lock washers (31) from current transformer T12
(36).
1. Install resistor R13 (38):

a. When replacing current transformer T12 (36), install two screws (32), two serrated lock washers (31) on
current transformer T12 (36) and screw on nut (37).
NOTE
lnstallation procedure for resistor R5 (51), R6 (53), R7 (56) and R12 (46), R14 (50),
R15 (56) is the same as for resistor R13 (38), described below.
b. Install resistor R13 (38) with plate on current transformer T12 (36).
c. Install two serrated lock washers (39) and screw on two nuts (40).
d. Install cables (28, 30) to current transformer T12 (36), using two screws (25), two serrated lock washers (26),
and two cable clamps (27).
2. Install current transformer T12 (36):
5-139
TM 9-6115-668-13
NOTE
Installation procedure for current transformer T5 (52), T6 (54), T7 (55), T8 (61),

T9 (62), T10 (63), T11 (47) and T13 (50) is the same as for current transformer
T12 (36), described below.
When installing current transformer T1 (57), T2 (64), T3 (65), T4 (66), also Install
Insulator strip (60) and secure with three plastic screws (59).
a. Install current transformer T12 (36) with resistor R13 (38) on bus bar (46) from below.
b. Install screw (33), serrated lock washer (34) and washer (35).
c. Install screw (22), serrated lock washer (23) and washer (24).
d. Noting correct labeling and position install cables (29) to current transformer T12 (36), tighten two screws
(25), and secure with cable ties.
e. Install cables (45) on bus bar (46) and secure with screw (42), serrated lock washer (43), and washer (44).
3. Close control cabinet connector panel (9) and remove props.
4. Install eighteen screws (6), eighteen serrated lock washers (7), and eighteen washers (8) securing control cabinet
connector panel (9) on control cabinet assembly (3).
6. Close flap (2).
5-140 Change 1
TM 9-6115-668-13
Figure 5-32 Control Cabinet Assembly, Filter Box FK, Current Transformers, Resistors Maintenance.
5-141
TM 9-6115-668-13
5.18 AUXILIARY CONTACTOR K109 MAINTENANCE.


Materials/Parts
Cable ties
WARNING
tery terminal cables. Failure toobserve this warning could result In se-
CAUTION
REMOVAL

3. Record labeling and position of cables and diodes V101 (9), V102 (10) and V105 (11), V106 (12) to
terminals (13) of auxiliary contactor K109 (14), loosen screws (18), and disconnect cables and diodes.
4. Record labeling and position of cables (16) to lower terminals (15) of auxiliary contactor K109 (14),
loosen screws (17), and disconnect cables (16).
5. Use a screwdriver to push locking element (19) on auxiliary contactor K109 (14) in direction of ar-
row, tilt auxiliary contactor K109 (14) upward, and remove from mounting bar (41).
1. Insert top (8) auxiliary contactor K109 (14) into top of mounting bar (41) and push in at the bottom,
2. Noting correct labeling and position, install cables (16) to lower terminals (15) and tighten screws (17).
3. Noting correct labeling and position, install cables and diodes V101 (9), V102 (10) and V105 (11),
V106 (12) to terminals (13) and tighten screws (18).
5. Close flap (2).
5-142
TM 9-6115-668-13
5.19 DIODE MAINTENANCE.
INITIAL SETUP

Materials/Parts
Cable ties
Solder
Heat-shrink tubing
WARNING
CAUTION

REMOVAL

3. Diode V101 (9), V102 (10), V105 (11), V106 (12):
NOTE
Removal procedure for diode V102, V105, V106 is the same as for
diode V101, described below.
a. Open front of cable conduit (40).

b. Record labeling and position of diode V101 (9) at top terminal (13) of auxiliary contactor K109
(14) loosen screw (18) and disconnect diode V101 (9).
c. Expose cable end terminal of diode V101 (9) and remove insulation at connection point with
cable.
d. Unsolder diode V101 (9) from cable using solder gun.
5-143
TM 9-6115-668-13
4. Diode V103 (38), V104 (39):
NOTE
Removal procedure for diode V104 is the same as for diode V103, de-
scribed below.
a. Open cable conduit (40).

b. Record labeling and position of diode V103 (38) on terminal strip X101 (37) and disconnect
diode V103 (38).
c. Expose cable end terminal of diode V103 (38) and remove insulation at connection point with
cable.
d. Unsolder diode V103 (38) from cable using solder gun.
INSTALLATION
1. Diode V101 (9), V102 (10), V105 (11), V106 (12):
NOTE
Installation procedure for diode V102, V105, V106 is the same as for
diode V101, described below.
a. Slide heat shrink tubing over cable end and solder diode V101 (9) to cable using solder gun.
b. Slide heat shrink tubing over solder joint and shrink on using heating gun.
c. Noting correct labeling and position, install cables and diode V101 (9) to top terminal (13) of aux-
iliary contactors K109 (14),
d. Place cable with diode V101 (9) in correct position and close cable conduit (40).
2. Diodes V103 (38), V104 (39):
NOTE
Installation procedure for diode V104 is the same as for diode V103,
described below.
a. Slide heat shrink tubing over cable end and solder diode V103 (38) to cable using solder gun.
b. Slide heat shrink tubing over solder joint and shrink on using heating gun.
c. Noting correct labeling and position, install cables and diode V103 (38) to terminal of terminal
strip X101 (37).
d. Place cable with diode V103 (38) in correct position and close cable conduit (40).
4. Close flap (2).
5-144
TM 9-6115-668-13
5.20 TIME RELAY MAINTENANCE.
This task covers: a. Removal c. Installation

b. Test d. Adjust
INITIAL SETUP

Watch, stop
Materials/Parts
Cable ties
WARNING
CAUTION
REMOVAL

NOTE
Removal procedure for all time relays is the same as for time relay
K106, described below.
3. Record labeling and position of cables (23, 25) to upper terminals (22, 26) of time relay K106 (27),
loosen screws (21, 24) and remove cables (23, 25).
4. Record labeling and position of cables (31, 34) to lower terminals (32, 35) of time relay K106 (27),
loosen screws (33, 36) and remove cables (31, 34).
5. Use a screwdriver to push locking element (30) on time relay K106 (27) in direction of arrow, tilt
time relay K106 (27) upward, and remove from mounting bar (41).
5-145
TM 9-6115-668-13
TESTING

a. Start up engine preheating assembly as instructed in paragraph 2.5.1.
b. Check that switching cycle proceeds as follows:
Amber PULS LED goes on when supply voltage is applied.
Red PAUSE LED goes on at 60 seconds.
Red PAUSE LED lights up at 150 seconds.
Amber PULS LED lights up at 180 seconds.
Amber PULS LED or red PAUSE LED lights up at 840 seconds.
c. Shut down Generator Set 150 kW, paragraph 2.5.2.

Green LED activates when supply voltage is applied.
Green LED lights up at 60 seconds.

Green LED and amber LED go on at 180 seconds.

Green LED activates when supply voltage is applied.
Green LED lights up after 60 seconds.
Green LED lights up after 150 seconds.
Green LED and amber LED light up at 180 seconds.
Green LED and amber LED light up at 840 seconds.
5-146
TM 9-6115-668-13
ADJUSTMENT
1. Set time relay K106 (27) to switching time time 1 = 108 seconds and time 2 = 60 seconds:
a. Set switching time time1:
On front of time relay K 106 (27), use TIME DIP switches (1) to set a time window of 3 minutes
as shown in figure 5-33.
On front of time relay K 106 (27), use rotary knob (3) to set a multiplication factor of .6.
b. Set switching time time 2:
On front of time relay K 106 (27), use TIME DIP switches (4) to set a time window of 1 minutes
On front of time relay K 106 (27), use rotary knob (6) to set a multiplication factor of 1.
5-147
TM 9-6115-668-13
2. Set time relay K107 (6) to switching time time1 = 108 seconds and time 2 = 60 seconds:
a. Set switching time time1:
On front of time relay K 107 (6), use TIME DIP switches (1) to set a time window of 3 minutes as
shown in figure 5-34.
On front of time relay K 107 (6), use rotary knob (3) to set a multiplication factor of .6.
b. Set switching time time2:
On front of time relay K 107 (6), use TIME DIP switches (1) to set a time window of 1 minutes as
shownin figure 5-34.
On front of time relay K 107 (6), use rotary knob (3) to set a multiplication factor of 1.
3. Set time relay K108 (7) to switching time on 700 seconds:

a. On front of time relay K 108 (7), set FUNCTION DIP switches (1) as shown in figure 5-35.
b. On front of time relay K 108 (7), use TIME DIP switches (3) to set a time window of 30 minutes
as shown in Figure 5-35.
c. On front of time relay K 108 (7), use rotary knob (5) to set a multiplication factor of .4.
5-148
TM 9-6115-668-13

a. On front of time relay K 110 (20), use TIME DIP switches (1) to set a time window of 3 minutes
b. On front of time relay K 110 (20), use rotary knob (3) to set a multiplication factor of 1.
5-149
TM 9-6115-668-13
5.21 POWER SUPPLY NT2 24 V~ MAINTENANCE.
INITIAL SETUP

WARNING
tery terminal cables. Failure to observe this warning could result inse-
CAUTION
REMOVAL
NOTE
Removal procedure for all power supply components NT2 24 V~ is
the same as for time relay K106, described below.
3. Remove time relay K106 (27) as instructed in paragraph 5.20.

4. On power supply component (28), push locking elements toward each other in direction of arrow
and pull power supply component NT2 24 V~ (34) out of time relay K106 (27).
INSTALLATION
NOTE
Installation procedure for all power supply components NT2 24 V~
is the same as for time relay K26, described below.
1. Insert power supply component NT2 24 V~ (12) into time relay K106 (27).
2. Install time relay K106 (27) as instructed in paragraph 5.20.
4. Close flap (2).
5-150
TM 9-6115-668-13
INSTALLATION
NOTE
Installation procedure for all relays is the same as for time relay K106, de-
scribed below.
1. Insert time relay K106 (27) into top of mounting bar (41) and push in at the bottom.
2. Noting correct labeling and position, install cables (31, 34) to lower terminals (32, 35) and
tighten screws (33, 36).
3. Noting correct labeling and position. Install cables (23, 25) to upper terminals (22, 26) and
tighten screws (21, 24).
5. Close flap (2).
5-151
TM 9-6115-668-13
Figure 5-37 Control Cabinet Assembly, Engine Preheating Control Board, Auxiliary Contactor
K109, Diodes, Time Relay Maintenance.
5-152
TM 9-6115-668-13
5.22 MINIATURE RELAY MAINTENANCE.
INITIAL SETUP

Materials/Parts
Cable ties
WARNING
CAUTION
REMOVAL
NOTE
Removal procedure for miniature relay K103 (6), K104 (7), K111 (9) is
the same as for miniature relay K105 (8), described below.
3. Remove miniature relay K105 (8):
a. Pull miniature relay K105 (8) out of relay socket (12).
4. Remove relay socket (12) from miniature relay K105 (8):
a. Remove screws (15), serrated lock washers (14), and washers (13) from clips (10) on mounting
bar (11).
b. Pull the four relay sockets (12) forward.
c. Hold onto the relay sockets and pull each relay socket forward.
5. Note correct labeling and position and remove cables (17) with flat connectors (16) from relay sock-
ets (12).
a. Slide a screwdriver between relay socket (12) and flat connector (16) from above, and push
down snap-in hooks (18).
b. Pull cable (17) with flat connector (16) downward out of relay socket (12).
5-153
TM 9-6115-668-13
INSTALLATION
NOTE
l Installation procedure for miniature relay K103 (6), K104 (7), K111
(9) is the same as for miniature relay K105 (8), described below.
l Before inserting flat connector (16) with cable (17) into relay socket
(12), bend backsnap-in hooks (18).
1. Install cable (17) with flat connector (16) in relay socket (12):
a. Noting correct labeling and position of cables to relay socket (12), insert cables (17) with flat
connectors (16) from below into relay sockets (12) until they stop.
b. Pull on cable (17) to check that snap-in hook (18) has snapped into relay socket (12).
2. Install relay socket (12) of miniature relay K105 (8):
a. Insert relay socket (12) into mounting grooves of adjacent relay sockets and push downward.
b. Push the four relay sockets (12) toward mounting bar (11).
c. Install screws (15), serrated lock washers (14), and washers (13) into clips (10) on mounting bar
(11).
3. Install miniature relay K105 (8):
a. Insert miniature relay K105 (8) into relay sockets (12) and push in all the way.
5. Close flap (2).
5-154
TM 9-6115-668-13
5.23 POWER RELAY K101, K102 MAINTENANCE.XXP
INITIAL SETUP

Materials/Parts
Cable ties
WARNING
CAUTION
REMOVAL

NOTE
Removal procedure for power relay K102 is the same as for power
relay K101, described below.
3. Pull miniature relays K103 (6), K104 (7), K105 (8) and K111 (9) out of the four relay sockets (12).
4. Remove screws (15), serrated lock washers (14), and washers (13) from clip (10).
5. Tilt the four relay sockets (12) forward.
6. Remove nuts (20), serrated lock washers (21), washers (22) and mounting bar (23).
7. Remove washer (24) from spacer (25), remove spacer (25), serrated lock washer (26), and washer
(27).
8. Remove nut (28), serrated lock washer (29), and washer (30).
9. Remove power relay (31) from threaded pin (35) on mounting plate (19).
10. Record labeling and position of cables (34) to terminals (33) of power relay K101 (31) and remove
cables.
5-155
TM 9-6115-668-13
INSTALLATION
NOTE
Installation procedure for power relay K102 is the same as for power
relay K101, described below.
1. Noting correct labeling and position, install cables (34) to terminals (33) on miniature relay K101
(31).
2. Place power relay (31) onto threaded pin (35) on mounting plate (19).
3. Install washer (30), serrated lock washer (29), and nut (28) on threaded pin (35).
4. Install washer (27), serrated lock washer (26) on threaded pin (35) and screw on spacer (25).
5. Install washer (24), mounting bar (23), washer (22), serrated lock washer (21), and nut (20). Tighten
nut 20.
6. Tighten nuts (28) and spacer (25) on threaded pin with torque wrench to the torque value refer-
enced in appendix G.
7. Position the four relay sockets (12) in place.
8. Install screws (15), serrated lock washers (14), and washers (13) into clip (10).
9. Insert miniature relays K103 (6), K104 (7), K105 (8) and K111 (9) into the four relay sockets (12).
11. Close flap (2).
5-156
TM 9-6115-668-13
Figure 5-38 Miniature Relay, Power Relay Maintenance.
5-157
TM 9-6115-668-13
5.24 CONNECTOR RECEPTACLE L1 TO L3 AND N MAINTENANCE.
INITIAL SETUP

Socket wrench, shop manufactured
Materials/Parts
Cable ties
(item 10, appendix F)
Loctite 243
WARNING
tery terminal cables. Failure to observe this warning could result inse-
CAUTION
REMOVAL
4. Lower control cabinet connection panel (9) and prop with wooden boards.
5. Remove connector receptacles L1 (16) and L3 (12):
NOTE
Removal procedure for connector receptacle L3 (12) is the same as for
connector receptacle L1 (16), described below.
a. Remove two nuts (47) from spacer (37) and remove clear plastic cover (46).
b. Remove nut (39) from threaded terminal (38) while holding nut (44 or 45) with a suitable wrench
c. Remove serrated lock washer (40), washer (41), cable (42), and washer (43) from threaded ter-
minal (38).
5-158
TM 9-6115-668-13
d. Remove screw (33), serrated lock washer (36) and spacers (37).
e. Remove two nuts (23), two serrated lock washers (24) and two washers (25).
f. Remove two screws (26), angle piece (32) and interlock switch S12 (17).
g. Use socket wrench (shop manufactured) to remove threaded ring (35) from threaded part on connector
receptacle L1 (16), holding nut (44 or 45) with a suitable wrench.
h. Remove connector receptacle L1 (16).
6. Remove connector receptacles L2 (14) and N (10):
a. Perform steps 5a. through h.
1. Install connector receptacles L1 (16) and L3 (12):
NOTE
Installation procedure for connector receptacle L3 (12) Is the same as for con-
nector L1 (16), described below.
a. Insert connector receptacle L1 (16) into control cabinet connection panel (9) from the front.
NOTE
Apply four drops of Loctite 243 to threaded ring before threading onto the back.
b. Install threaded ring (35) on threaded part (34) of connector receptacle L1 and tighten with socket wrench,
holding nut (44 or 45).
c. Place washer (43), cable (42), washer (41), serrated lock washer (39) on threaded terminal (38).
d. Install nut (39) on threaded terminal (38), holding nut (44 or 45) with a suitable wrench.
e. Install screw (33) on control cabinet connection panel (9) and serrated lock washer (36).
f. Install spacers (37) onto screw (33).
g. Insert two screws (26) on control cabinet connection panel (9) and install angle piece (32) with interlock switch
S12 (17).
h. Install two washers (25), two serrated lock washers (24), and two nuts (23) on two screws (26) and tighten
two nuts (23).
i. Place cover (46) on spacers (37) and screw on two nuts (47).
2. Install connector receptacles l2 (14) and N (10):
a. Perform steps 1 a. through i.
3. Close control cabinet connection panel (9) and remove props.
4. Install eighteen screws (6), eighteen serrated lock washers (7) and eighteen washers 98) on control cabinet
assembly(3).
5-159
TM 9-6115-668-13
5.25 INTERLOCK SWlTCH MAINTENANCE.


Cable ties
nal cables. Failure to observe this warning could result in severe personal Injury
or death.
installation.
1. Remove unit hood assembly (1, figure 5-39) as instructed in paragaph 4.14.
3. Remove eighteen screws (6), eighteen serrated lock washers (7) and eighteen washers (8).
4. Open control cabinet connection panel (9) and prop with wooden boards.
5. Remove two nuts (47) and cover (46).
NOTE
Removal procedure for Interlock switch 513 (15), S14 (13) and S15 (11) Is the
same as for Inter lock switch S12 (17), described below.
6. Remove two screws (18), two washers (19) and cables (20) from interlock switch S12 (17).
7. Remove two screws (21), two serrated lock washers (23) and interlock switch S12 (17 from angle piece (32).
8. To remove angle pieces:
a. Remove two nuts (27), two serrated lock washers (28) and two washers (29) from screws (31).
b. Remove designation plate (30) and two screws (31) from control cabinet connection panel (9).
c. Remove two nuts (23), two serrated lock washers (24), two washers (25), two screws (26) from control cabinet
connection panel (9) and remove angle piece (32).
5-160 Change 1
TM 9-6115-668-13
NOTE
Installation procedure for Interlock switch S13 (15), S14 (13) and S15 (11) Is the
same as for Interlock switch S12 (17), described below.
1. Install angle piece (32) on control cabinet connection panel (9) using screws (26).
2. Install two washers (25), two serrated lock washers (24), and two nuts (23) on two screws (26).
3. Install cable (20), screws (18), and washers (19) on interlock switch S12 (17).
4. Install angle piece:
a. Install angle piece (32) on interlock switch (17).
b. Install two screws (21) and two serrated lock washers (22) on angle piece (32).
c. Insert screws (26) into control cabinet connection panel (9) and install angle piece (32).
d. Install designation plate (30) on outside of control cabinet connection panel (9) using two screws (31).
e. Install two washers (29), two serrated lock washers (28). and two nuts (27) on two screws (31) and tighten
two nuts (27).
5. Install cover (46) on spacers (37) and secure using two nuts (47).
Change 1 5-161
TM 9-6115-668-13
Figure 5-39 Control Cabinet Assembly, Connection Panel, Connector Receptacle L1 to L3 and N, lnterlock
Switch Maintenance.
5-162
TM 9-6115-668-13
5.26 J3 SLAVE RECEPTACLE 24 VOLTS CONNECTOR MAINTENANCE.
INITIAL SETUP

Materials/Parts
Heat shrink tubing

Cable ties
WARNING
CAUTION
REMOVAL

2. Remove heat shrink tubing (20) from J3 slave receptacle 24 V connector (12).
3. Remove screw (17), serrated lock washer (18), washer (19) and negative cable (21) from J3 slave
receptacle 24 V Connector (12).
4. Remove screw (5), serrated lock washer (6), washer (7) and positive cable (8) from J3 slave recep-
tacle 24 V connector (12).
5. Remove four nuts (9), four serrated lock washers (10) and four washers (11) from four screws (14).
6. Remove four screws (14) and four washers (13).
7. Pull J3 slave receptacle 24 V connector (12), with cap (15) and lanyard (16), from the back of base
frame (4).
8. Remove nut (23), serrated lock washer (24), washer (25), negative cable (21) and washer (26) from
threaded pin (22).
9. Remove positive cable (8) from starter (refer to paragraph 4.90).
10. Remove cable ties and pull positive cable (8) out through bottom plate of base frame (4).
5-163
TM 9-6115-668-13
INSTALLATION
CAUTION
After working on J3 slave receptacle 24 V connector, reconnect the

positive terminal first and then the negative terminal of battery set (re-
fer to paragraph 4.90).
1. Install washer (26), negative cable (21), washer (25), serrated lock washer (24), and nut (23), on
threaded pin (22) and tighten nut (23).
2. Pull positive cable (8) through bottom plate of base frame (4) and connect positive cable (8) to
starter (refer to paragraph 4.90).
3. Insert J3 slave receptacle 24 V connector (12), with cap (15) and mount (16), into base frame (4)
from the rear.
4. Insert four screws (14) with four washers (13) in connector (12).
5. Install four washers (11), four serrated lock washers (10), and four nuts (9) on four screws (14).
6. Slide heat-shrink tubing (20) over negative cable (21) and positive cable (8).
7. Install negative cable (21) on J3 slave receptacle 24 V connector (12), with screw (17), serrated
lock washer (18) and washer (19). Tighten screw (17).
8. Install positive cable (8) on J3 slave receptacle 24 V connector (12), with screw (5), serrated lock
washer (6), and washer (7). Tighten screw (5).
9. Slide heat shrink tubing (20) over terminals of positive cable (8) and negative cable (21) and over
J3 slave receptacle 24 V connector (12).
10. Shrink heat shrink tubing (20) using heating gun.
11. Close flap (2).
5-164
TM 9-6115-668-13
5.27 AIR FILTER HOUSING AND PIPING MAINTENANCE.
This task covers: a. Removal b.

Installation
INITIAL SETUP

Materials/Parts
Lubricant
WARNING
CAUTION
REMOVAL
2. Remove plug connector 2J6 with cable (35) from service switch (34).
3. Remove two nuts (27), two serrated lock washers (28), two washers (29), two spacer (30), two
washers (31), and two screws (32).
4. Loosen clamp (37) and remove air filter housing (33) from rubber hose (36).
5. Loosen clamp (38) and remove rubber hose (36) off elbow (39).
6. Loosen clamp (41) and remove elbow (39) out of rubber hose (40).
7. Loosen clamp (42) and remove rubber hose (40) off T-junction (43).
8. Loosen clamp (64) and remove T-junction (43) out of rubber hose (65).
9. Loosen clamp (44) and remove T-junction (43) out of rubber hose (47).
12. Loosen clamp (50) and remove rubber hose (48) off pipe (51).
13. Loosen clamp (53) and remove pipe (51) out of rubber hose (52).
14. Loosen clamp (54) and remove rubber hose (52) off turbocharger inlet.
5-165
TM 9-6115-668-13
17. Loosen clamp (59) and remove rubber hose (61) off pipe (58).
18. Loosen clamp (57) and remove pipe (58) out of rubber hose (56).
19. Loosen clamp (55) and remove rubber hose (56) off turbocharger inlet.
INSTALLATION
NOTE
Before sliding rubber hoses onto pipes, elbows and T-junction, coat
insides with lubricant.
1. Install rubber hose (56) and clamps (55, 57) on turbocharger inlet and tighten clamp (55).
2. Install pipe (58) into rubber hose (56) and tighten clamp (57).
3. Install rubber hose (61) and clamps (59, 61) on pipe (58) and tighten clamp (59).
4. Install elbow (58) into rubber hose (61) and tighten clamp (60).
5. Install rubber hose (65) and clamps (63, 64) on elbow (62) and tighten clamp (63). Do not tighten
clamp (64).
6. Install T-junction (43) into rubber hose (40); do not tighten clamp (41).
7. Install rubber hose (52) and clamps (53, 54) on turbocharger inlet and tighten clamp (54).
8. Install pipe (51) into rubber hose (52) and tighten clamp (53).
9. Install rubber hose (48) on pipe (51) and tighten clamp (50).
11. Install rubber hose (47) on elbow (46) and tighten clamp (45).
12. Install rubber hose (47) and clamps (45, 44) on T-junction (43); do not tighten clamp (44).
13. Install rubber hose (40) and clamps (41, 42) on T-junction (43) and tighten clamp (42).
15. Install rubber hose (36) and clamps (37, 38) on elbow (39) and tighten clamp (38).
16. Install connector piece of air filter housing (33) on rubber hose (36) and place on (33); tighten clamp
(37).
17. Install two screws (32), two washers (31), and two spacers (30), two washers (29), two serrated
lock washers (28) and two nuts (27).
CAUTION
Align air filter housing and piping so that elbow (39) does not contact gen-
erator lifting eye.
18. Tighten clamps (64, 44).

19. Install plug connector 2J6 with cable (35) on service switch (34).
5-166
TM 9-6115-668-13
Figure 5-40 Air filter Assembly, J30 slave receptacle 24 V Connector Maintenance.
Change 1 5-167
TM 9-6115-668-13
5.28 SUBCURRENT FILTER ASSEMBLY MAINTENANCE.

INITIAL SETUP
Materials/Parts
Cable ties
Place a container under sub-fuel filter and collect oil as It emerges.

Completely drain subfuel filter and oil lines.
After removal, plug oil lines and tie up.
2. Remove cables ties (26,29) from oil lines.

3. Remove drain plug (10) and sealing ring (11) from subcurrent filter (5).
NOTE
Use new sealing ring.
4. Allow oil to drain out. and screw in drain plug (10) and sealing ring (11).
5. Remove hollow screw (9),, oil line (7), and sealing rings (6, 6) from s&current filter (5).
6. Remove hollow screw (15), remove oil line (13), and sealing rings (12, 14) from subcurrent filter (5).
7. Remove nuts (19), serrated lock washers (16) and washers (17).
6. Remove screws (3), washers (4), and subcurrent filter (5) from bracket (16).
5-168
TM 9-6115-668-13
INSTALLATION
NOTE
If hollow screws (9,15,23, and 27) and screw (10) were installed to pre-
vent contamination, remove prior to beginning installation proce-
dure. If plastic bags were installed on oil lines, remove prior to begin-
ning installation procedure.
1. Install screw (10) with new seal (11) in subcurrent filter (5).
2. Install hollow screw (9) with new seals (8,6) and oil line (7) on subcurrent filter (5).
3. Install hollow screw (27), new seals (25,26) and oil line (7) in adapter (24)
4. Install hollow screw (15) with new seals (12, 14) and oil line (13) on subcurrent filter (5).
5. Install hollow screw (23) with new seals (22, 21) and oil line (13) in adapter (20).
6. Install screws (3), washers (4), and subcurrent filter (5) on bracket (16).
7. Install nuts (19) serrated lock washers (18), and washers (17) on screws (3) and tighten.
8. Install new cable ties, bundle cable ties (28, 29).
9. Close flap (2).
5-169
TM 9-6115-668-13
5.29 SUBCURRENT FILTER OIL LINES MAINTENANCE.
INITIAL SETUP

Materials/Parts
Sealing rings
Plastic Bags
Rubber Bands
Cable ties
(item 10, Appendix E)
REMOVAL
CAUTION
l Place a container under subcurrent filter and engine block, and col-
lect oil as it emerges.
l Completely drain subcurrent filter and oil lines.
l After disconnecting, plug oil lines and tie up.
2. Remove drain plug (10), and sealing ring (11) from subcurrent filter (5). Discard sealing ring (11).
3. Cut cable ties (28, 29).
NOTE
If oil lines are not to be replaced immediately, bag both ends of oil lines
(7) and (13) with plastic bags and secure with rubber bands to prevent
contamination.
Return hollow screws (9,15,23 and 27) to original position and replace
screw (10) with new sealing ring (11).
4. Remove hollow screw (9) with oil line (7) and sealing rings (6, 8) from subcurrent oil filter (5). Dis-
card sealing rings (6, 8) and bag oil line (7).
5-170
TM 9-6115-668-13
5. Remove hollow screw (15) and remove oil line (13) with sealing rings (12,14). Discard sealing rings (12, 14) and
bag oil line (13).
6. Remove hollow screw (27), sealing rings (26, 25) and oil line (7) from adapter (24) on engine block. Discard sealing
rings (26, 25).
7. Remove hollow screw (23), sealing rings (22, 21) and oil line (13) from adapter (24) on engine block. Discard
sealing rings (22, 21).
NOTE
Use new sealing rings
1. Install hollow screws (23) oil line (13), new sealing rings (21, 22) on adapter (20) on engine block.
2. Install hollow screw (27), oil line (7), new sealing rings (26, 25) on adapter (24) on engine block.
3. Install hollow screw (15) new sealing rings (12, 14) and oil line (13) on subcurrent oil filter (5).
4. Install hollow screw (9) new sealing rings (6, 6) and oil line (7) on subcurrent oil filter (5).
5. Reinstall cable ties, bundle ties.
6. Install screw (10) and new sealing ring (11) on subcurrent oil filter (5) and tighten screw (10).
7. Close flap (2).
5-171
TM 9-6115-668-13
Figure 5-41 Subcurrent Filter Assembly, Oil Lines Maintenance.
5-172 Change 1
TM 9-6115-668-13
5.30 FLAME GLOWPLUG SYSTEM MAINTENANCE.
INITIAL SETUP

Materials/Parts
Plastic bags
Rubber bands
Hylomar
WARNING
Make sure that there are no open flames in the vicinity, and that fuel cannot
splash onto hot components. Failure to observe this warning could result in se-
vere personal injury.
REMOVAL
NOTE
Procedure for flame glowplug on cable 1X6 on opposite side of engine is the
same as this procedure.
2. Remove nut (15) and washer (14) from threaded portion of flame glowplug (11).
3. Remove cable 1X5 (13).
WARNING
l Fire hazard: do not allow fuel to touch hot engine.
l Collect fuel in a container.
4. Remove collar nut (12) from fuel line (6) and bag with plastic bag; secure with rubber band.
5. Loosen locknut (10) and remove flame glowplug (11) from turbocharger air duct (9).
5-173
TM 9-6115-668-13
TEST
1. Check general function:

a. Remove screw (7) and sealing ring (8) from turbocharger air duct (9).
WARNING
Remove plug connector 1J13 (16) from pickup together with cable so that diesel
engine cannot start.
NOTE
GLOWPLUG ON lights up after approximately 90 seconds.
b. On front panel of control cabinet unit, set MASTER SWITCH S1 to ON.
WARNING
Due to explosion hazard, stay at least 80 inches (2 m) away from turbocharger air
duct.
c. On front panel of control cabinet unit, turn GLOWPLUG/START rotary switch to START and hold.
WARNING-
Place suitable container under fuel line (6) to minimize fire hazard.
NOTE
If flame is visible in turbocharger air duct and GLOWPLUG ON indicator does not
light up, perform troubleshooting as indicated in figure 3.3.
d. Check that smoke is emerging from threaded fitting, and flame is visible in turbocharger air duct (9).
2. Check fuel delivery:
a. Remove collar nut (12) on fuel line (6) from flame glowplug (11) and pull fuel line (6) off.
NOTE
l Fuel must emerge from the fuel line while the engine turns over.
l If no fuel emerges, check fuel line (6) and operation of solenoid valve (5) and
repair if necessary. Remove panels (17) to check solenoid valve (5).
5-174
TM 9-6115-668-13
3. Check electrical function:

a. Remove collar nut (12) on fuel line (6) from flame glowplug (11) pull fuel line (6) off flame glowplug (11 ), and
Plug-
NOTE
If voltage is <17 VDC or >22 VDC, perform troubleshooting as indicated in figure
3-3.
d. Use multimeter to measure DC voltage at cable 1X5 (13): should be approximately 1 SVDC.
4. Check flame glowplug:

a. Remove flame glowplug as instructed in steps 2. through 5.
d. Install fuel line (6) and cable 1X5 (13) on flame glowplug (11).
NOTE
Fuel must emerge from flame glowplug as engine turns over.
lf no fuel emerges, replace flame glowplug (11).
e. On front panel of control cabinet unit, set MASTER SWITCH S1 to ON.

f. Turn GLOWPLUG/START rotary switch to START and hold.
NOTE
Use Hylomar when Inserting flame glowplug.
1. Install flame glowplug (11) on turbocharger air duct (9) and tighten locknut (10).
2. Install cable 1X5 (13) on threaded portion of flame glowplug (11) with washer (14) and nut (5).
3. Install collar nut (12) on fuel line (6) to flame glowplug (11).
4. Screw plug connector 1J13 (16) with cable onto pickup.
5. Close flap (2).
5-175
TM 9-6115-668-13
Figure 5-42 Flame Glowplug System Maintenance.
5-176 Change 1
TM 9-6115-668-13
5.31 ENGINE PREHEATING ASSEMBLY MAINTENANCE.
INITIAL SETUP

Materials/Parts
Cable ties
WARNING
Make sure that there are no open flames in the vicinity, and that fuel cannot
splash onto hot components. Failure to observe this warning could result in se-
vere personal injury.
REMOVAL
2. Remove cable J102 (23) from plug connector X102 on connector box (24) of heating unit (12).
3. Remove nut (22), washers (21, 19), serrated lock washer (20), and grounding cable (18) from threaded pin (17)
on heating unit (12).
4. Pull plug connector X103 (27) out of rear of heat exchanger box (3).
5. Loosen clamp (28) and pull air hose (29) off fitting of heat exchanger box (3).
6. Loosen screw on clamp (31) and remove clamp (31) with seal (30).
7. Loosen locknut (24) and unscrew screw (35) five turns out of nut (33) on exhaust manifold (32).
8. Remove exhaust manifold (32) from heating unit (12).
9. Loosen screw on clamp (25) and remove air inlet pipe (26) from heating unit (12).
10. Remove screws (6) of clamp strap closures (7) and unhook clamp strap closures (7).
11. Remove screws (8), serrated lock washers (9), and washers (10).
CAUTION
Place a container under fuel line connectors and collect any fuel that emerges.
NOTE
For better access to clamps on fuel lines, rotate heating unit to the left. If fuel lines
are not to be reinstalled immediately, bag with plastic bag and secure with rubber
band.
5-177
TM 9-6115-668-13
12. Loosen clamp (16), pull fuel supply line (15) off fitting on heating unit (12) and tie up.
13. Loosen clamp (13), pull fuel return line (14) off fitting on heating unit (12) and tie up.
14. Lift heating unit (12) out of brackets (11) and remove clamp straps (7).
TEST
1. Start up engine preheating assembly as instructed in paragraph 2.5.1.

2. Open flap (2, figure 5-43) and check that hot air is being blown onto V belts.
3. Open flap (2, figure 5-27) and front panel (4) of control cabinet assembly (3) and check that mounting
plate (36) behind speed governor assembly N1 (31) is being heated.
INSTALLATION
1. Insert clamp straps (7, figure 5-43) into brackets (11).

2. Place heating unit (12) in clamp straps (7) and turn onto left side.
3. Slide fuel return line (14) on fitting of heating unit (12) and tighten clamp (13).
4. Slide fuel supply line (15) on fitting of heating unit (12) and tighten clamp (16).
5. Install screws (8), serrated lock washers (9), and washers (10).
6. Hook in clamp strap closures (7) and tighten screws (6) of clamp strap closures (7).
7. Place air inlet pipe (26) with clamp (25) on heating unit (12) and tighten screw on clamp (25).
8. Insert exhaust manifold (32) into exhaust intermediate pipe (36) and place on heating unit (12) with clamp (31)
and seal (30).
9. Tighten screw on clamp (31).
10. Tighten screws (35) onto exhaust intermediate pipe (36).
11. Slide air hose (29) onto fitting of heat exchanger box (3) and tighten clamp (28).
NOTE
Do not run cable under clamp straps.
12. Insert plug connector X103 (27) into rear of heat exchanger box (3).
13. Place grounding strap (18), washer (19), serrated lock washer (20), and washer (21) on threaded pin (17) and
screw on nut (22).
14. Place cable J102 (23) on plug connector X102 on connector box (24) of heating unit (12).
NOTE
Exhaust manifold and exhaust intermediate pipe must be aligned.
15. Align heating unit (12) and tighten locknuts (34) on exhaust intermediate pipe (36).
5-178
TM 9-6115-668-13
Figure 5-43 Preheating Assembly Maintenance.
Change 1 5-179
TM 9-6115-668-13
5.32 BURNER MONITORING TEMPERATURE SWlTCH MAINTENANCE.

INITIAL SETUP
nal cables. Failure to observe this warning could result In severe personal injury
or death.
installation.
Do not pull round plugs off cables.

2. Unplug both round plug parts (3, 4) of X109 on burner monitoring temperature switch S109 (5).
3. Remove probe with microswitch (5, 6) from heating unit (10).
4. Hold probe with microswitch (56) at unthreaded portion (8) and screw in threaded hex portion (7).
5. Disassemble probe with microswitch (5, 6) from fasteners (7, 8, 9).
1. Reassemble probe with microswitch (5, 6) and fasteners (7, 8, 9).

2. Hold probe with microswitch (5, 6) at unthreaded portion (8) and screw in threaded hex portion (7).
3. Install probe with microswitch (5, 6) into heating unit (10).
4. Plug parts (3, 4) together.
5. Close nap (2).
5-180
TM 9-6115-668-13
5.33 GLOWPLUG MAINTENANCE.
INITIAL SETUP

WARNING
CAUTION
REMOVAL
NOTE
Retain insulator for re-use.
2. Remove knurled nut (16), washer (15), and cable X108 (14), insulator (13), and cable X108 (12)
from threaded portion of flame glowplug (11).
3. Remove flame glowplug (11) from heating unit (10).
INSTALLATION
1. Install flame glowplug (11) on heating unit (10).

2. Install cable X108 (12), insulator (13), cable X108 (14), washer (15), and nut on threaded portion of
flame glowplug (11). Tighten nut (16).
3. Close flap (2).
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5.34 OVERTEMPERATURE SWITCH MAINTENANCE.
INITIAL SETUP

WARNING
CAUTION

REMOVAL
CAUTION
Do not pull flat connectors off cables.
2. Remove both flat connectors X110 (18) on overtemperature switch S110 (17).
3. Remove overtemperature switch S110 (17) from heating unit (10).
INSTALLATION
1. Screw overtemperature switch S110 (17) into heating unit (10).
NOTE
Pass cables under cable bridges.
2. Connect both flat connectors X110 (18) on overtemperature switch S110 (17).
3. Close flap (2).
5-182
TM 9-6115-668-13
Figure 5-44 Temperature Switch, Glowplug Maintenance.
Change 1 5-183
TM 9-6115-668-13
5.35 PREHEATlNG ASSEMBLY CABLE.

INITIAL SETUP
Material/Parts
Cable ties
nal cables. Failure to observe this warning could result In severe personal Injury
or death.
installation.
5. Remove two nuts (26). serrated lock washers (25), washers (24), screws (22), wahers (23) and cover (27) from
control cabinet assembly (2).
6. Remove upper covers from bus bars and open cable conduit above load contactor K1 (16) and the one to the right
of it.
7. Record labeling and position of cables (20) to load contactor K1 (16).
8. Remove three nuts (17). three serrated lock washers (18), three washers (19), cables (20) and heat sinks (21)
from load contactor K1 (16).
9. Record labeling and position of cables to terminal strip X101 (14) on preheating control board (15).
10. Disconnect cables from terminal strip X101 (14).
11. Remove locknut (9) of PG union on back of control cabinet assembly (2) and pull preheating assembly cable (10)
with PG union out of back of control cabinet assembly (2).
5-184
TM 9-6115-668-13
12. Loosen PG union and remove from preheating assembly cable (10).
13. Remove plug connector (13) of preheating assembly cable (10) from connector receptacle X103 (12) on heating
unit (11).
14. Remove cable (10).
1. Install plug connector (13) of preheating assembly cable (10) onto connector receptacle X103 (12) on heating unit
(11).
2. Slide PG union onto preheating assembly cable (10) and tighten.
3. Install preheating assembly cable (10) with PG union through back panel of control cabinet and screw on locknut
(9).
4. Noting correct labeling and position, connect cables (10) to terminal strip X101 (14) of preheating control board
(15).
5. Close cable conduits and place covers on busbars.
Tighten nuts on threaded pin with torque wrench to torque values In table (item
G.2, appendix C), while holding screws.
6. Noting correct labeling and position, install heat sinks (21), cables (20), three washers (19), three lock serrated
washers (18) and three nuts (17). lighten nuts (17).
Fasten left side of cover first.
7. Install two screws (22), two washers (23), cover (27), two washers (24), two serrated lock washers (29, and two
nuts (26). Tighten nuts (26).
8. Close control cabinet connection panel (5) and remove props.
9. Install eighteen screws (8), eighteen serrated lock washers (7), and eighteen washers (6).
5-185
TM 9-6115-668-13
Figure 5-45 Preheating Cable Assembly Maintenance.
5-186 Change 1
TM 9-6115-668-13
5.36 AIR FLAP PULLER MAGNET MAINTENANCE.
INITIAL SETUP

WARNING
CAUTION
REMOVAL
1. Open flap on unit hood assembly (1, figure 5-46).

2. Remove screw (24) from plug connector X104 (25); remove plug connector (25).
3. Loosen locknut (30) and unscrew tie rod (27) from fork member (31).
4. Remove locknut (30) from tie rod (27) and remove helical spring (29).
5. Remove four screws (40), four serrated lock washers (39), and four washers (38) from bracket (28).
6. Remove air flap puller magnet (26) from bracket (28).
INSTALLATION
1. Place air flap puller magnet (26) on bracket (28).

2. Install four screws (40), four serrated lock washers (39), and four washers (38) on bracket (28).
Tighten screws (40).
3. Slide helical spring (29) an locknut (30) on tie rod (27).
4. Screw tie rod (27) into fork member (31) and tighten locknut (30).
5. Install plug connector X104 (25) using screw (24). Tighten screw (24).
CAUTION
Check that air flap closes and linkage moves freely.
6. Close flap (2).
5-187
TM 9-6115-668-13
5.37 ELECTRIC OIL PUMP MAINTENANCE.
INITIAL SETUP

WARNING
CAUTION

REMOVAL
1. Loosen clamp (36) on air hose (37) and remove air hose (37) from cover (35).
2. Remove six screws (32), six serrated lock washers (33), and six washers (34).
3. Remove cover (35) from heat exchanger box (23).
4. Remove plug connector J103 (10) with cable from electric oil pump (15).
5. Pump out oil with scavenge pump as instructed in paragraph 2.3.2.3.
CAUTION
l Use a container and/or rags to collect oil that emerges when oil
hoses are pulled off.
l Plug oil hoses with stoppers or rags
6. Loosen clamp (22) and remove air hose (21) from heat exchanger box (23).
7. Loosen clamps (6) and remove oil hose (5) from electrical oil pump (15).
8. Loosen clamps (17, 18) and remove oil hose (16) from air-oil heat exchanger fitting (19).
9. Remove three nuts (9), three serrated lock washers (8) and three washers (7), three screws (2) and
three washers (3) from bracket (4).
10. Lift electrical oil pump (15) and air-oil heat exchanger (20) together out of heat exchanger box (23).
11. Loosen clamps (12) and pull oil hose (14) off fitting (13) on air-oil-heat exchanger (20).
5-188
TM 9-6115-668-13
INSTALLATION
1. Install oil hose (14) on fitting (13) with clamps (12) and tighten clamps (12).
2. Insert oil pump (15) and air-oil-heat exchanger (20) together into heat exchanger box (23).
3. Install three screws (2), three washers (3), three washers (7), three serrated lock washers (8), and
three nuts (9) on brackets (4). Tighten nuts (9).
4. Install oil hose (16) on fitting (19) with clamps (17, 18) and tighten clamps.
5. Install oil hose (5) with clamps (6) on oil pump (15) and tighten clamps.
6. Install air hose (21) with clamp (22) on heat exchanger box (23) and tighten clamp.
7. Refill oil as instructed in paragraph 2.3.2.3.
8. Insert plug connector J103 (10) with cable on electric oil pump (15).
9. Place cover (35) on heat exchanger box (23).
10. Install six screws (32), six serrated lock washers (33) and six washers (34).
11. Install air hose (37) with clamp (36) on cover (35) and tighten clamp.
5-189
TM 9-6115-668-13
5.38 AIR-OIL HEAT EXCHANGER MAINTENANCE.
INITIAL SETUP

Materials/Parts
Sealing tape
WARNING
CAUTION
REMOVAL
1. Remove unit hood assembly (1, figure 5-46) as instructed in paragraph 4.14
2. Loosen clamp (36) on air hose (37) and remove air hose (37) from cover (35).
4. Remove cover (35) from heat exchanger box (23).
5. Remove plug connector J103 (10) and remove together with cable from electric oil pump (15).
CAUTION
l Use a container and/or rags to collect oil that emerges when hoses
are pulled off.
l Plug oil hoses with stoppers or rags.
7. Loosen clamp (22) and remove air hose (21) from fitting on heat exchanger box (23).
8. Loosen clamps (6) and remove oil hose (5) from electric oil pump (15).
9. Loosen clamp (17, 18) and remove oil hose (16) from fitting (19).
5-190
TM 9-6115-668-13
10. Remove three nuts (9), three serrated lock washers (8), three washers (7, 3) and three screws (2) from bracket
(4).
11. Lift electrical oil pump (15) and air-oil heat exchanger (20) together, out of heat exchanger box (23).
12. Loosen clamps (11) and remove oil hose (14) from oil pump (15).
NOTE
Retain threaded fitting for reuse.
13. Remove fittings (13, 19) from air-oil heat exchanger (20).
1. Install fittings (13, 19) by using sealing tape on air-oil heat exchanger (20).
2. Install air hose (14) and clamps (11) on electrical oil pump (15), tighten clamps (11).
3. Install electrical oil pump (15) and air-oil heat exchanger (20), into heat exchanger box (23).
4. Install three screws (2), three washers (7, 3), three serrated lock washers (18), and three nuts (9) on brackets (4).
5. Install oil hose (16) and damps (17, 18) on fitting (19), tighten clamps (17, 18).
6. Install oil hose (5) with clamps (6) on electrical oil pump (15), tighten clamps (6).
7. Install air hose (21) with clamp (22) on fitting on heat exchanger box (23), tighten clamp (22).
9. Install plug connector J 103 (10) on electrical oil pump (15).
10. Install cover (35) on heat exchanger box (23).
11. Install six screws (32), six serrated lock washers (33), and six washers (34).
12. Install air hose (37) with clamp (36).
13. Install unit hood assembly as instructed in paragraph 4.14.
5-191
TM 9-6115-668-13
Figure 5-46 Air Flap Puller magnet, Electric Oil Pump, Air- Oil heat Exchanger Maintenance.
5-192 Change 1
TM 9-6115-668-13
5.39 OIL HOSE MAINTENANCE.

4. Remove cover (32) with air hose (33) from heat exchanger box (25) and set to one side.
5. Remove nut (22), serrated lock washer (21), washer (20), washer (18), screw (17) from clamp (19).
6. Loosen clamp (24) and pull air hose (23) off fitting of heat exchanger box (25) and pull air hose (23)
back and secure.
CAUTION
Use a container and/or rags to collect oil that emerges when hose
is pulled off.
Plug oil hose with stoppers or rags.
7. Loosen clamp (7) and remove oil hose (8), off nipple (6) on oil pan.
8. Loosen clamps (16) and remove oil hose (8) from fitting on oil pump (15).
9. Pull oil hose (8) out of air hose (23).
CAUTION
Use a container and/or rags to collect oil that emerges when hose
is pulled off.
Plug oil hose with stoppers or rags.
10. Loosen clamps (27) and pull oil hose (4) off fitting (28).
11. Loosen clamp (3) and pull oil hose (4) off T-junction on oil filler neck (2).
12. Pull other end of oil hose (4) from heat exchanger box (25).
5-193
TM 9-6115-668-13
1. Slide oil hose (8) into air hose (23).

2. Install oil hose (8) with clamps (16) on fitting on oil pump (15) and tighten clamps (16).
3. Install oil hose (8) with clamps (7) on nipple (6) on oil pan and tighten clamps (7).
4. Install screw (17), washer (18) through clamp (19) and bottom plate of base frame, washer (20),
serrated lock washer (21), and nut (22). Tighten nut (22).
5. Install air hose (21) with clamp (24) on fitting of heat exchanger box (25) and tighten clamp (24).
6. Install cover (32) with six screws (31) six serrated lock washers (30) and six washers (29). Tighten
screws (31).
7. Slide oil hose (4) into heat exchanger box (20).
8. Install oil hose (4) with clamps (3) on T-junction on oil filler neck (2) and tighten clamps (3).
9. Install oil hose (4) with clamps (27) on fitting (28) of air-oil heat exchanger (26) and tighten clamps
(27).
5-194
TM 9-6115-668-13
5.40 OIL TEMPERATURE SWITCH MAINTENANCE.

Materials/Parts
Cable ties
Thermoconductive paste
WARNING
CAUTION
1. Remove unit hood assembly (1, figure 5-47).

2. Unplug cable X 104 at receptacle (13).
3. Remove flat terminal (14) from receptacle (13) of the switch to be changed, (10) for S 103 and (9)
for S 104.
NOTE
Care must be exercised to Insure the proper wire is selected.
4. Cut cable tie (11) and remove.

5. Cut the flat terminal (14) from the cable removed from plug (13) and remove from insulation (12).
6. Remove temperature switch S 103 (10) or S 104(9) from hose connector fitting (5).
5-195
TM 9-6115-668-13
NOTE
Coat mating surface of temperature switch with thermoconductive

paste before installing.
1. Install temperature switch S 103 (10) or S 104 (9), in hose connector fitting (5).
2. Install cable through insulation (12).
3. Install new cable tie (11).
4. Install new wire flat terminal (14).
5. Install flat terminal (14) in plug (13)
6. Reconnect both halves of receptacle (13).
5-196
TM 9-6115-668-13
Figure 5-47 Oil Hose, Oil Temperature Switch Maintenance.
Change 1 5-197
TM 9-6115-668-13
5.41 ACTUATOR ASSEMBLY MAINTENANCE.

INITIAL SETUP
or death.
2. Remove retaining clip (6) from ball socket (7).
3. Remove ball socket (7) from ball head (10).
4. Loosen locking screw (9) and remove lever 96).
5. Remove two screws (17), and two serrated lock washers (18) and two washers (19) from plug connector 1J12
(20).
6. Remove plug connector 1J12 (20) off actuator assembly (4).
7. Remove four screws (21). and four serrated lock washers (22). and four washers (23) from actuator assembly
(4).
8. Remove actuator assembly (4) from diesel engine (3).
Adjust regulator linkage only for the following reasons:

Engine or regulator replacement or overload setting is incorrect.
The regulator linkage between the injection pump and actuator assembly is
preset at the factory. It should not be readjusted unless absolutely necessary.
1. Start up diesel engine as instructed in paragraph 2.5.1.

2. Pull link rod (12) toward actuator assembly (4) to overload position (II) until it stops, and measure spacing (g1)
between ball socket (7) and engine cover panel (13).
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TM 9-6115-668-13
3. Restart engine.
4. Push link rod (12) toward engine cover panel (13) into stop position (I), when diesel engine (3) shuts down, and
hold in that position.
5. Measure spacing (g2) between center of ball socket (7) and engine cover panel (13).
6. Calculate travel (G) between overload position (II) and stop position (I) (G=g1 - g2) and record.
7. Push ball socket (7) onto ball head (10) and hold lever (6) in front of actuator assembly shaft (5).
8. Move lever (6) to stop position (I) (45° angle/spacing g2), slide onto actuator shaft (5), and tighten locking screw
(9).
9. Move lever (6) from stop position (I) to overload position (II), checking that control occurs over the calculated travel
(G) and that the stop in stop position (I) corresponds to the end position of lever (6).
10. Check that link rod (12) moves freely between stop position (I) and overload position (II) on passthrough (11) in
engine cover panel (13).
11. If control is not possible over the entire travel (G), remove engine cover panels (2), loosen nut (16) on ball head,
and shift ball head linkage in oblong hole (15) of lever (14).
12. Check speed governor system:
a. Pull regulator linkage approximately 0.2 inches (5 mm) toward actuator (4):
Diesel engine must shut down properly.
b. Connect load bank.
c. Start diesel engine as instructed in paragraph 2.51:
Speed must stabilize immediately after load is applied (150 kVV).
13. Repeat adjustment if necessary until speed stabilizes in the correct range.
14. Insert retaining clip (8).
15. If engine cover panels (2) were removed, attach engine cover panels (2).
NOTE
Perform the ADJUSTMENT procedure when installing a different actuator.
1. Install actuator assembly (4) on diesel engine (3) and secure with four screws (21), four washers (22). and four
serrated lock washers (23).
2. Install plug connector 1J12 (20) into actuator (4).
3. Install two washers (19), two serrated lock washers (18) and two screws (17). Tighten screws (17).
4. Install lever (6) on actuator assembly shaft (5).
5. Tighten locking screw (9) on lever (6).
Change 1 5-199
TM 9-6115-668-13
Figure 5-48 Actuator Maintenance.
5-200 Change 1
TM 9-6115-668-13
5.42 ACTUATOR CABLE MAINTENANCE.

INITIAL SETUP
Materials/Parts
Cable ties
or death.
Tag all cables prior to removal to ensure correct connection of the Cables during
installation.
2. Open front panel (4) of control unit assembly (3) and secure with prop (5).
NOTE
Hold standoffs (19) while removing nuts (18).
3. Remove two nuts (16), two serrated lock washers (17) and two washers (18).
4. Swing digital isochronous load sharing module N4 (15) aside and open cable conduits (12 to 14).
5. Record labeling and position of cables to terminal strip (11).
6. Disconnect cables (9) from terminals 1 to 5 of terminal strip (11).
7. Remove locknut (8) of PG union on back panel of control cabinet (3) and pull actuator cable (9) with PG union
out of control cabinet (3).
8. Loosen PG union and remove from actuator cable (9).
9. Remove five nuts (23), five serrated lock washers (24), five washers (25), five screws (27), and five washers (26)
from partition (20) and remove plate (21).
10. Remove two screws (34). two serrated lock washers (35), and two washers (36) from plug connector (37) and
pull actuator cable (9) through opening in partition (20).
Change 1 5-201
TM 9-6115-668-13
1. Install actuator cable (9) through opening in partition (20) of base frame (22) and place plug connector (37) on
actuator assembly (38).
2. Install two screws (34) two serrated lock washers (35) and two washers (36) on plug connector (37).
3. Install five screws (27), five washers (26) on partition (20) and install plate (21) using five serrated lock washers
(24), five washers (25), five screws (27) and five nuts (23). Tighten nuts (23).
4. Slide PG union onto actuator cable (9) and tighten.
5. Slide actuator cables (9) with PG union through back panel of control cabinet (3) and install locknut (8).
6. Noting correct labeling and position, lay actuator cable (9) in cable conduits (12 to 14) and connect to terminal
strip (11).
7. Close cable conduits (12 to 14) and swing digital isochronous load sharing module N4 (15) back into place.
NOTE
Hold standoffs (19) while Installing nuts (16).
8. Install two washers (18) and two serrated lock washers (17) and two nuts (16).
5-202 Change 1
TM 9-6115-668-13
5.43 ACTUATOR CABLE MAINTENANCE.

This task covers: a. Removal c. Installation
b. Adjustment
INITAIL SETUP
nal cables. Failure to observe this warning could result in severe personal Injury
or death.
installation.
2. Remove knurled nut (32) from pick-up (31) and remove plug connector 1J13 (33) with pick-up cable (7).
3. Loosen locknut (30) and unscrew pick-up (31) from flywheel housing (29) of diesel engine (2).
When installing pick-up (31) care must be exercised to align a tooth of flywheel
gear (28) in the center of hole that houses the pick-up.
1. Gently thread pick-up (31) into flywheel housing (29). until it rests on top of tooth (28) of flywheel.
2. Rotate pick-up (31) back off top of tooth (28) one half turn.
Change 1 5-203
TM 9-6115-668-13
Pick-up position must not change.
3. Hold pick-up (31) and tighten locknut (30).

4. Connect multimeter to speed governor assembly N1 (10) between terminals 10 and 11.
5. Measure pick-up voltages:
Counterclockwise will decrease voltage - clockwise will Increase voltage.
Extreme caution should be exercised during this procedure to avoid touching

other areas due to risk of electrical shock.
a. Start diesel engine as instructed in paragraph 2.5.1 and measure voltage during starting procedure:
Should be: 21.5 VAC.
b. Allow diesel engine to run at rated speed and measure voltage:
Should be: 20 to 30 VAC.
c. If either reading is incorrect, loosen locknut (30) and change pick-up position until readings are correct, and
retighten locknut (30).
1. Install pick-up (31) following the adjustment procedures steps 1. through 3.

2. Connect plug connector 1J13 (33) of pick-up cable (7) to pick-up (31).
5-204 Change 1
TM 9-6115-668-13
5.44 PICK-UP CABLE MAINTENANCE.

INITIAL SETUP
Materials/Parts
Cable ties
or death.
installation.
Hold standoffs (19) while removing nuts (16).
3. Remove two nuts (16), two serrated lock washers (17) and two washers (18).
4. Swing digital isochronous load sharing module N4 (15) aside and open cable conduits (12 to 14).
5. Record labeling and position of cables to terminal strip (11) of speed governor assembly N1 (10).
6. Disconnect cables (7) from terminals 10 and 11 of speed governor assembly N1 (10).
7. Remove locknut (6) of PG union on back panel of control cabinet (3) and pull actuator cable (7) with PG union
out of control cabinet (3).
8. Loosen PG union and remove from actuator cable (7).
Change 1 5-205
TM 9-6115-668-13
9. Remove five nuts (23), five screws (27), five serrated lock washers (24), five washers (25), five screws (27), and
five washers (26) from partition (20) and remove plate (21).
10. Remove knurled nut (32) and remove plug connector (33) of pick-up cable (7).
11. Pull pick-up cable (7) through opening in partition (20).
1. Install pick-up (7) through opening in partition (20) and place plug connector (33) on pick-up (31).
2. Install five screws (27). five washers (28) into partition (20) and set plate (21) on screws (27).
3. Install five serrated lock washers (24), five washers (25), five screws (27) and five nuts (23). Tighten nuts (23).
4. Slide PG union onto pick-up cable (7) and tighten.
5. Slide pick-up cable (7) with PG union through back panel 01 control cabinet (3) and install locknut (6).
6. Noting correct labeling and position, lay pick-up cable (7) in cable conduits (12 to 14) and connect to terminal strip
(11).
7. Install cables (7) on terminal strip (11).
8. Close cable conduits (12 to 14) and swing digital isochronous load sharing module N4 (15) back into place.
NOTE
Hold standoffs (19) while installing nuts (16).
9. Install two washers (18), two serrated lock washers (17), and two nuts (16). lighten nuts (16).
5-206 Change 1
TM 9-6115-668-13
Figure 5-49 Actuator Cable, Pick-up Cable Maintenance.
Change 1 5-207
TM 9-6115-668-13
5.45 EHG TEMPERATURE SENSOR MAINTENANCE.

INITIAL SETUP
or death.
Installation.
Remove first two cover panels (6) only, located next to partition (6).
2. Remove eight screws (2), eight washers (4), and eight serrated lo&washers (3) from two cover panels (5) and
set panels (5) with air hose (7) aside.
Air hose doss not have to be removed.
3. Remove flat connector 1J5 (8) and temperature sensor (9) from cylinder head.
4. Remove round plug connector 1J30 (11) and temperature sensor (10) from cylinder head.
5. Remove round plug connector 1J31 (13) and temperature sensor (12) from cylinder head.
5-208
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1. Install temperature sensor (12) and round plug connector 1J31 (13) or cylinder head.
2. Install temperature sensor (10) and round plug connector 1J30 (11) on cylinder head.
3. Install temperature sensor (9) and flat connector 1J5 (8) on cylinder head.
4. Install cover panel (5) next to partition (6) and cover panel with air hose (7) using eight screws (2), eight washers
(4). and eight serrated lock washers (3).
5. Install unit hood assembly (1) as instructed in paragraphs 4.14.
5-209
TM 9-6115-668-13
Figure 5-50 EHG and Cylinder Head Temperature Sensor Maintenance.
5-210 Change 1
TM 9-6115-668-13
5.46 GENERATOR WIRING HARNESS MAINTENANCE.

INITIAL SETUP
Materials/Parts
Cable ties
or death.
Tag ail cables prior to removal to ensure correct connection of the cables during
installation.
Any cable indicated with a “0” is a ground cable. Disconnecting any cable
indicated with a “0” will lose ground to the rest of the circuit.
5. Remove eight screws (26) eight serrated lock washers (25), and eight washers (24) and remove cover (23) from
filter box FK (20).
6. Tag all wires and disconnect generator wiring harness (22) from input terminal strip (19).
7. Remove locknut (21) from cable union and pull generator wiring harness (22) out of back panel of control cabinet
assembly (33).
8. Remove all cable ties from generator wiring harness.
Change 1 5-211
TM 9-6115-668-13
9. Pull plug connector 2J5 (9) off battery charging alternator regulator N6 (8).
10. Tag cables to terminal strip 2X50 (10) and disconnect.
11. Disconnect plug connector, X2 to X4 (7) above grounding stud (6).
12. Remove cable from grounding stud (6).
13. Remove cables from starter (5) as instructed in paragraph NO TAG.
14. Remove cables from resistor (Shunt) R11 (4) as instructed in paragraph NO TAG.
15. Disconnect cables from battery ‘charging alternator (3) as instructed in paragraph NO TAG and remove plug
connector 2J3.
16. Remove five nuts (11). five serrated lock washers (12) and five washers (13) and plate (17) and five washers (14)
and five screws (15) from partition (16).
17. Remove generator wiring harness (22) through partition (16) on base frame (16).
1. Install generator wiring harness (22) through partition (16), on base frame (18), and secure with cable ties.
2. Install five screws (15), five washers (14) into partition (16) and install plate (17), five washers (13), five serrated
lock washers (12) and five nuts (11). Tighten nuts (11).
3. Connect cables to battery charging alternator (3) as instructed in paragraph NO TAG.
4. Install cables on resistor (Shunt) R11 (4) as instructed in paragraph NO TAG.
5. Install cables onto starter (5) as instructed in paragraph NO TAG.
6. Install cables onto grounding stud (6).
7. Install plug connectors X2 to X4 (7).
8. Noting correct labeling and position, connect cables to terminal strip 2X50 (10).
9. Install plug connector 2J5 (9) in battery charging alternator regulator N6 (8).
10. Insert generator wiring harness (21) through back panel 01 control cabinet assembly (33) and secure with locknut
(21).
11. Connect generator wiring harness (22) to input terminal strip (19) of filter box FK (20).
12. Install cover (23) on filter box FK (20) and secure with eight screws (26), eight serrated lock washers (25), and
eight washers (24).
13. Close control cabinet connection panel (27).
14. Install eighteen screws (30), eighteen serrated lock washers (29), and eighteen washers (28) on control unit
assembly (33).
5-212 Change 1
TM 9-6115-668-13
Figure 5-51 Generator Wiring Harness Maintenance.
Change 1 5-213
TM 9-6115-668-13
5.47 DIESEL ENGINE AND SYNCHRONOUS GENERATOR MAINTENANCE.

INITIAL SETUP
Eyebolts
(item 17, 18, appendix B)
Load bank (item 19, appendix B) Personnel required
Material/Parts
Lubricant Two
Cable ties
Loctite 243
Plastic bags
Rubber bands
or death.
Do not stand in the operating area of the crane or forklift.

Do not walk under the suspended load.
nal cable.
Fire hazard: clean up all fuel leaks.
Failure to observe these warnings could result in severe personal injury or
death.
5-214 Change 1
TM 9-6115-668-13
CAUTION
Clean up ail oil leaks.

Do not damage fuel lines, oil lines, or cables.
Bag ail fuel and oil lines with plastic bags and secure with rubber
bands to prevent contamination.
Do not sit engine on oil pan. Blocking must be used to support the
engine and generator on mounts.
1. Remove unit hood assembly (1, figure 5-52, sheet 1 of 2) as instructed in paragraph 4.14.
2. Remove battery set (2) as instructed in paragraph 4.74.
3. Remove air filter housing and piping (3) as instructed in paragraph 5.27.
4. Remove rubber seal (5) from lower part (6) of partition.
5. Remove four nuts (7), four serrated lock washers (8), and four washers (9) from threaded pins (10).
6. Remove upper part (4) of partition.
7. Remove control cabinet unit (11) as instructed in paragraph 4.43.
8. Remove generator wiring harness (12) as instructed in paragraph 5.46.
NOTE
Leave EHG regulator N7 on diesel engine.
9. Remove EHG regulator N7 (13) as instructed in paragraph 4.76. Coil up cable and secure to diesel
engine (28) together with EHG controller N7 (13).
10. Remove fuel lines (14) as instructed in paragraph 4.42 and tie up to fuel tank (31).
11. Loosen clamp (16) and remove air hose (15).
12. Loosen clamps (19, 21) and remove air hose (18). Retain clamps (19, 21).
13. Remove exhaust manifold (23) from heating unit (24) as instructed in paragraph 5.31.
14. Remove filter cup (25, 26) as instructed in paragraph 4.33.
15. Remove oil hoses (27) from heat exchanger box (22) and diesel engine (28) as instructed in para-
graph 5.38.
16. Remove subcurrent filter oil lines (29) from diesel engine (28) as instructed in paragraph 5.29.
17. Remove exhaust pipes with header (30) from diesel engine (28) as instructed in paragraphs 4.82
and 4.83.
18. Remove pickup cable (32) as instructed in paragraph 5.44.
19. Remove actuator cable (33) as instructed in paragraph 5.42.
20. Screw long eyebolt (65) into engine block of diesel engine (64).
21. Remove bolt (69), washer (67), serrated lock washer (68) and closure plate (66).
5-215
TM 9-6115-668-13
22. Insert short eyebolt (63) into engine block of diesel engine (64).
23. Hook lifting device into eyebolts (63, 65) on diesel engine (64) and into lifting lug (62) on synchro-
nous generator (61).
24. Remove two bolts (34) and two serrated lock washers (35) from shock absorbers (41) and engine
mount (36).
25. Remove two bolts (60), two serrated lock washers (59) and two washers (58) from shock absorbers
(50).
CAUTION
Secure diesel engine and synchronous generator to prevent tilting or
slippage.
26. Lift diesel engine (64) and synchronous generator (61) off shock absorbers (41, 50) on base frame
(45) and set down on suitable mounting blocks.
NOTE
For easier positioning of diesel engine and synchronous generator,
apply assembly lubricant to rubberseal on synchronous generator air
guide box and to diesel engine and synchronous generator shock ab-
sorbers.
1. Place diesel engine (64) and synchronous generator (61) on shock absorbers (41, 50) on base
frame (45).
CAUTION
Use Loctite 243 when inserting bolts.

Tighten bolts to torque values in table (item G.1, appendix G).
NOTE
Thread in bolts (34, 60) only three turns when first installing.
2. Install two bolts (60), two washers (58), two serrated lock washers (59) in generator mount (57) and
thread in three turns.
3. Install two bolts (34), two serrated lock washers (35) in engine mount (36) and shock absorbers
(41), and thread in three turns,
4. Torque bolts (34, 60) with torque wrench.
5. Detach lifting device from eyebolts at positions (63, 65) on diesel engine (28) and from lifting lug
(62) on synchronous generator (61).
6. Remove short eyebolt (63).
7. Install bolt (69) with washer (68), serrated lock washer (67) and closure plate (66).
5-216
TM 9-6115-668-13
8. Remove long eyebolt (65) from engine block of diesel engine (64).
9. Install actuator cable (33) as instructed in paragraph 5.42.
10. Install pickup cable (32) as instructed in paragraph 5.44.
11. Align exhaust pipes with header (30) and install on diesel engine (28) as instructed in paragraphs 4.82 and 4.83.
12. Install subcurrent filter oil fines (29) on diesel engine (28) as instructed in paragraph 5.29.
13. Install oil hoses (27) on heat exchanger box (22) and diesel engine (28) as instructed in paragraph 5.38.
14.. Install filter cup (25, 26) as instructed in paragraph 4.33.
15. Install exhaust manifold (23) on heating unit (24) as instructed in paragraph 5.31.
16. Install air hose (18) on header (20) and heat exchanger box (22) and tighten clamps (19,21).
17. Install air hose (15) on generator (17) and tighten clamp (16).
18. Install fuel lines (14) as instructed in paragraph 4.42.
19. Install EHG controller N7 (13) as instructed in paragraph 4.76.
20. Install control cabinet unit (11) as instructed in paragraph 4.43.
21. Install generator wiring harness (12) as instructed in paragraph 5.46.
22. Install upper part (4) of partition on lower part (6) of partition and push rubber seal (5) into place.
23. Install four washers (9) four serrated lock washers (8). and four nuts (7) on threaded pins (10).
24. Install air fitter housing and piping (3) as instructed in paragraph 5.27.
25. Install battery set (2) as instructed in paragraph 4.74.
Change 1 5-217
TM 9-6115-668-13
5.48 DIESEL ENGINE SHOCK ABSORBERS MAINTENANCE.

INITIAL SETUP
Eyebolts
(item 17, 18 appendix B)
Materials/Parts Personal required
Loctite 243 Two - Three
Lubricant
or death.
Engine and generator shock mounts are not repairable. Do not attempt to
disassemble. Failure to comply may cause injury or death.
Do not stand in the operating area of the crane or forklift. Failure to observe
these warnings could result in severe personal injury or death.
Engine should be lifted only far enough so that the engine mount can be
removed. Equipment will be damaged if the engine is lifted too high.
Suitable spacing must be provided when engine shock absorbers are re-
moved. Failure to provide proper support to the engine will cause damage to
the equipment. The engine must be supported on the engine mounts.
2. Remove upper part of partition (4) as instructed in paragraph 5.47, steps 3 through 6.
5-218
TM 9-6115-668-13
3. Remove bolt (69), with serrated lock washer (68), washer (67), and closure plate (66).
4. Install long eyebolt (65) in diesel engine block (64).
5. Install short eyebolt (63) in diesel engine block (64).
6. Install lifting device in eyebolts (63, 65).
7. Remove two bolts (34) and two serrated lock washers (35).
8. Lift diesel engine (64) enough to take the weight off shock absorbers (41).
9. Remove four bolts (37), four serrated lock washers (38), and four washers (39).
10. Remove two shock absorber plates (40).
11. Remove two bolts (44), two serrated lock washers (43), and two washers (42) from two shock ab-
sorbers (41).
12. Remove two shock absorbers (41).
NOTE
It Is not necessary to install suitablespacing material or remove lifting
device if shock absorber is to be replaced immediately.
13. Install suitable spacing material between bracket (72) and engine mount (36).
CAUTION
Use Loctite 243 on bolts.
Tighten bolts to torque values in table (item G.1, appendix G)
NOTE
For easier positioning of components coat mating surfaces with lubri-
cant.
1. If necessary install lifting device in eyebolts (63, 65).

2. Lift diesel engine (64) enough to allow spacing material to be removed if installed.
3. Install two shock absorbers (41) on two brackets (72) and secure with two bolts (44), two serrated
lock washers (43), and two washers (42).
4. Install two shock absorber plates (40) on shock absorbers (41) and secure with four bolts (37), four
serrated lock washers (38), and four washers (39).
5. Lower engine until weight has been transfered to shock absorbers (41).
6. Install two bolts (34) and two serrated lock washers (35) on mounts (36) and shock absorbers (41).
7. Remove lifting device (73) and eyebolts (63, 65).
8. Install ciosure plate (66) and secure with bolt (69), serrated lock washer (68), and washer (67).
9. Install upper part of partition (4) as instructed in paragraph 5.47, steps 22 through 24.
5-219
TM 9-6115-668-13
5.49 SYNCHRONOUS GENERATOR SHOCK ABSORBERS MAINTENANCE.

Materials/Parts Personnel Required
Loctite 243 Two

item 16, appendix E)
Lubricant
WARNING
Disconnect the negative battery cable first and then the positive
battery terminal cables. Failure to observe this warning could re-
suit in severe personal injury or death.
WARNING
Engine and generator shock mounts are not repairable. Do not

attempt to disassemble. Failure to comply may cause injury or
death.
Do not stand in the operating area of the crane or forklift. Failure
to observe these warnings could result in severe personal injury
or death.
CAUTION
Engine should be lifted only far enough so that the engine mount
can be removed. Equipment will be damaged if the engine is lifted
too high.
Suitable spacing must be provided when engine shock absorbers
are removed. Failure to provide proper support to the engine will
cause damage to the equipment. The engine must be supported on
the engine mounts.
5-220
TM 9-6115-668-13
NOTE
To remove right hand shock absorber, control cabinet must be re-

moved.
To remove left hand shock absorber, battery set must be removed.
2. Remove upper part of partition (4) as instructed in paragraph 5.47, steps 3 through 6.
3. Remove air filter and piping (3) as instructed in paragraph 5.27.
4. Remove control cabinet (11) as instructed in paragraph 4.43 and battery set (2) as instructed in
paragraph 4.74.
5: Install lifting device to lifting lugs (62) and (70).
6. Remove two bolts (60), two serrated lock washers (59), and two washers (58).
7. Lift synchronous generator (61).
8. Remove two bolts (56) and two serrated washers (55).
9. Remove shock absorber plate (54)
10. Remove two bolts (53), two serrated lock washers (52), and two washers (51).
11. Remove shock absorber (50).
12. Remove two bolts (46), two serrated lock washers (47), two washers (48), and mounting plate (49)
from shock absorber (50).
NOTE
It is not necessary to install suitablespacing material or remove lifting
device if shock absorber is to be replaced immediately.
13. Install suitable spacing material.
CAUTION
Use Loctite 243 on bolts.

Tighten wrench to torque values in table (item G.1, appendix G)
5-221
TM 9-6115-668-13
NOTE
For easier positioning of components coat mating surfaces with lubricant.
1. If necessary, install lifting device on lifting lugs (62) and (70).

2. Lift synchronous generator (61) enough to allow spacing material to be removed if installed.
3. Install mounting plate (49) on shock absorber (50) and secure with two bolts (46), two serrated lock
washers (47), and two washers (51) on shock absorber (50).
4. Install shock absorber plate (54) on shock absorber (50) and secure with bolts (56) and serrated
lock washers (55).
5. Insert shock absorber (50) and secure to base (45) with two bolts (53), two serrated lock washers
(52), and two washers (51).
6. Lower synchronous generator (61) until weight has been transferred to shock absorbers (50).
7. Install two bolts (60) and two serrated lock washers (59) and two washers (58).
8. Remove lifting device from lifting lugs (62) and (70).
9. Install upper part of partition (4) as instructed in paragraph 5.47, steps 22 through 24.
10 Install air filter and piping (3) as instructed in paragraph 5.27.
11. Install control cabinet (11) as instructed in paragraph 4.43 and install battery set (2) as instructed in
paragraph 4.74.
5-222
TM 9-6115-338-13
Figure 5-52 Diesel Engine and Synchronous Generator Maintenance (Sheet 1 of 2).
Change 1 5-223
TM 9-6115-668-13
Figure 5-52 Diesel Engine and Synchronous Generator Maintenance (Sheet 2 of 2).
5-224
TM 9-6115-338-13
5.50 DIESEL ENGINE MAINTENANCE.

INITIAL SETUP
Eyebolts
(item 17,18 appendix B)
Materials/Parts Personnel required
Loctite 243 Two
Cable ties
Lubricant
Plastic bags
Rubber bands
or death.
Engine and generator shock mounts are not repairable. Do not attempt to
disassemble. Failure to comply may cause injury or death.
Do not stand in the operating area of the crane or forklift. Failure to observe
these warnings could result in severe personal injury or death.
NOTE
To prevent contamination, bag the ends of ail fuel and oil lines when removed
with plastic bags and rubber bands.
2. Disconnect batteries as instructed on paragraph 4.74.
Change 1 5-225
TM 9-6115-668-13
3. Remove generator wiring harness (24) of diesel engine as instructed in paragraph 5.46.
4. Remove EHG controller N7 (35) as instructed in paragraph 4.76 and secure to engine (3).
5. Loosen clamps (4) and (5) and remove air pipes (2) on engine side of partition.
6. Tag fuel lines (37, 38) and remove from engine block.
7. Tag fuel line (29) and remove from priming pump as instructed in paragraph 4.42.
8. Cut cable ties holding fuel lines to engine (3) or other objects.
9. Remove filter cups (30, 31) as instructed in paragraph 4.33.
10. Loosen clamp (11) and remove air hose (10) from battery charging generator (9).
11. Remove screw (15), serrated lock washer (16), and washer (17).
12. Remove spacer (20) and washer (21).
NOTE
Clamp (N) is retained on hose (8)
13. Loosen clamp (14) and remove air hose (19) and clamp (18) from elbow (13) on panel (12).
14. Remove oil hose (25) from heat exchange box (23) as indicated in paragraph 5.39.
15. Remove oil hoses (8) from engine (3) as instructed in paragraph 5.29.
16. Remove exhaust pipes with header (28) as instructed in paragraph 4.82 and 4.83.
17. Remove actuator cable (6) as instructed in paragraph 5.42.
18. Remove pick-up cable (7) as instructed in paragraph 5.44.
19. Remove bolt (43), serrated lock washer (44), washer (45) and closure plate (46).
20. Install long eyebolt (41) on diesel engine block (42).
21. Install short eyebolt (40) on diesel engine block (42).
22. Install lifting device on eyebolts (40.41) and lift until there is no slack in the cables.
23. Remove two bolts (47) two serrated lock washers (48) from engine mounts (49).
24. Support synchronous generator (60) at intemediate flange (54) with suitable support (56 to 58).
25. Remove eight bolts (51), eight serrated lock washers (52) and eight washers (53) from the diesel engine side of
intermediate flange (54).
26. Separate the diesel engine (42) from the intermediate flange (54) by installing two bolts (59) in threaded hole
(found above the mounting holes on the intermediate flange (54) on each side of engine).
27. Tighten bolts (59) evenly (on both sides of engine) until diesel engine (42) is disengaged from intermediate flange
(54).
28. Remove two bolts (59).
29. Lift diesel engine (42) off base (34).
30. Support engine by placing suitable support under engine mounts and the clutch housing (55).
5-226
TM 9-6115-668-13
Use Loctitie 243 on bolts.

Tighten bolts to torque values in table (item G.1, appendix G).
1. Lift diesel engine (42) off mounting blocks and place on shock absorbers (50).
Make sure that coupling elements do not jam when pushed together.
2. Push diesel engine (42) onto synchronous generator (60).

3. Install eight bolts (51), eight serrated lock washers (52), and eight washers (53) on intermediate flange (54) on
diesel engine (42). lighten bolts (51).
4. Install two bolts (47) and two serrated lock washers (48) into mounts (49) of diesel engine (42) and shock
absorbers (50). Iighten bolts (47).
5. Remove support (56 to 53) from beneath intermediate flange (54).
6. Detach lifting device from eyebolts (40, 41) on diesel engine (42).
7. Remove short eyebolt (40) out of diesel engine block.
8. Remove long eyebolt (41) out of diesel engine block (42).
9. Install bolt (43), washer (44), serrated lockwasher (45), and closure plate (46) on diesel engine block (42). Tighten
bolt (43).
10. Install pickup cable (7) as instructed in paragraph 5.44.
11. install actuator cable (6) as instructed in paragraph 5.42.
12. Align exhaust pipes with header (28) and install on diesel engine (42) as instructed in paragraph 4.82 and 4.83.
13. install oil hoses (8) on diesel engine (42) as instructed in paragraph 5.29.
14. Install oil hoses (25) on heat exchanger box (23) and diesel engine (42) as instructed in paragraph 5.39.
15. Install air hose (19) with clamps (14, 18) on elbow (13) of panel (12) and tighten clamp (14).
16. Install spacer (20) on diesel engine block (42).
17. Install screw (15) serrated lock washer (16), washer (17) and air hose (19) with damps (18) on spacer (20).
18. Install air hose (10) with clamp (11) on battery charging generator (9) and tighten clamp (11).
19. Install filter cup (31, 32) as instructed in paragraph 4.33.
20. Install fuel line (29) on priming pump as instructed in paragraph 4.42.
21. Install fuel lines (37, 38) on diesel engine (3) as instructed in paragraph 4.42.
22. Bundle fuel lines using cable ties.
23. Install air pipes (2) on engine side of partition and tighten clamps (4) and (5).
24. Install EHG regulator N7 (35) as instructed in paragraph 4.76.
25. Install generator wiring harness (24) on diesel engine (3) as instructed in paragraph 5.46.
26. Connect battery set as instructed in paragraph 4.74.
Change 1 5-227
TM9-6115-668-13
Figure 5-53 Diesel Engine Maintenance (Sheet 1 of 2).
5-228 Change 1
TM 9-6115-668-13
Figure 5-53 Diesel Engine Maintenance (Shett 2 of 2).
5-229
TM 9-6115-668-13
5.51 SYNCHRONOUS GENERATOR MAINTENANCE.

INITIAL SETUP
Loctite 243 Two
Cable ties
Lubricant
nal cables. Failure to observe this warning could result In severe personal injury
or death.
2. Remove battery set (12) as instructed in paragraph 4.74.
3. Remove air filter housing and piping (11) as instructed in paragraph 5.27.
4. Remove rubber seal (5), four nuts (10), four serrated lock washers (9). four washers (8) from lower part (7) of
partition (4).
5. Remove upper part of partition (4).
6. Remove control cabinet unit (2) as instructed in paragraph 4.43.
7. Hook lifting device into lifting lug (16) on synchronous generator (14) and into lifting lug (15) on intermediate flange
(13) and lift until there is no slack in cables.
8. Support diesel engine (3) at flywheel housing (28) with suitable support (22 to 24).
9. Remove two bolts (17). two serrated lock washers (18) and two washers (19) from synchronous generator
mounting (21).
10. Remove eight bolts (27), serrated lock washers (26) and washers (25) from intermediate flange (13) and flywheel
housing (28).
11. Remove synchronous generator (14) from diesel engine (3) by installing bolts (29) in housing of intermediate
flange (13) and tightening both sides gently.
12. Remove bolts (29) and lift synchronous generator (14) off shock absorbers (20) and place on mounting blocks.
5-230 Change 1
TM 9-6115-668-13
Use Loctitie 243 on bolts.

Tighten bolts to torque values In table (Item G.1, appendix G).
NOTE
For easier positioning of synchronous generator, apply assembly lubricant to
rubber seal on air guide box of synchronous generator, synchronous generator
shock absorbers, and rubber coupling element.
1. Lift synchronous generator (14) off mounting blocks and place on shock absorbers (20).
Make sure that coupling elements do not jam when pushed together.
2. Install synchronous generator (14) on diesel engine (3).

3. Install eight bolts (27), eight serrated lock washers (26), and eight washers (25) into intermediate flange (13) and
screw into flywheel housing (28).
4. Install two bolts (17), two serrated lock washers (18) and two washers (19) through synchronous generator mount
(21) and on shock absorbers (20). lighten bolts (17).
5. Remove suport (22 to 24) from beneath flywheel housing (28) of diesel engine (3).
6. Remove lifting device from lifting lug (16) on synchronous generator (14) and lifting lug (15) on intermediate flange
(13).
7. Install control cabinet unit (2) as instructed in paragraph 4.43.
8. Install upper part of partition (4) and secure with four washers (8) and four serrated lock washers (9) on studs (6).
9. Install rubber seal (5).
10. Install air filter housing and piping (11) as instructed in paragraph 5.27.
11. Install battery set (12) as instructed in paragraph 4.74.
Change 1 5-231
TM 9-6115-668-13
Figure 5-54 Synchronous Generator Maintenance.
5-232 Change 1
TM 9-6115-668-13
5.52 CLUTCH ASSEMBLY MAINTENANCE.

INITIAL SETUP
Puller
Loctite 243 Two
Lubricant
or death.
2. Remove synchronous generator (2) as instructed in paragraph 5.51.
3. Remove bolts (6), and serrated lock washers (5) from flywheel (4).
4. Remove driver ring (7) from flywheel (4).
5. Remove tubber element (10) from clutch hub (16).
6. Remove bolt (11). serrated lock washer (12) and thrust washer (13) from shaft (14) of synchronous generator (2).
7. Remove eight bolts (8) and eight serrated lock washers (9).
Wear gloves and eye protection. Failure to observe this warning could result In
NOTE
For easier removal of clutch hub, heat to approximately 212 °F (100 °C).
8. Remove dutch hub (16) with puller.
Change 1 5-233
TM 9-6115-668-13
NOTE
Leave woodruff key on clutch hub. --
1. Place clutch hub (16 on shaft (14).
CAUTION
Tighten bolts with torque wrench to torque values In table (item G.1, appendix G).
2. Install thrust washer (13) and serrated lock washer (12) and install bolt (11) in shaft (14).
3. Install rubber element (10) into clutch hub (16).
4. Install eight bolts (8) and eight serrated lock washers (9) into rubber element (10) on clutch hub (16).
5. Place driver ring (7) on flywheel (4) and secure with eight serrated lock washers (5) and eight bolts (6). lighten
bolts (6).
6. Install synchronous generator (2) as instructed in paragraph 5.51.
5-234 Change 1
TM 9-6115-668-13
Figure 5-55 Clutch Assembly Maintenance.
Change 1 5-235
TM 9-6115-668-13
5.53 LOAD BANK PROCEDURES (AVTRON 150 kW RESISTIVE).

This task covers: a. Operating b. Shutdown
INITIAL SETUP
Load bank Reference
down
paragraph 2.5.2
None Two
Potential 203 VAC shock hazard. Do not disconnect or connect control or

power cables while Generator Set 1 or 2 is running.
Always Install protective covers on control and power cables when cables are
disconnected.
Load bank Is configured for 120/203 volt, 3-phase, 400 Hz condition, make sure
generator set matches this configuration.
Never exceed the rated voltage, as this will cause the load bank to overheat.
Do not apply DC voltages, as the contractors do not have arc blowout mag-
nets.
Do not exceed the 30 kW rating on the PU-739 or PU-304 30 kW generator set.
1. Set-up load bank.

a. Set all switches on the EPP III/EPU junction box to OFF.
b. Set all switches on the load bank to OFF.
c. Connect load bank cables L1, L2, L3, and LO to EPP III/EPU junction box. Connect power and control cables
of generator set to junction box. Connect all ground cables to earth ground.
5-236 Change 1
TM 9-6115-668-13
2. Start generator set.

a. Adjust voltage and frequency to rated values.
b. Close the “AC circuit interrupter” on the generator set.
3. At EPP-III-EPU junction box, set ICC, CRG or ECS ON/OFF switch to ON.
a. Observe that the INPUT POWER indicator on the side of junction box Is illuminated.
b. Observe that the appropriate shelter indicator is illuminated.
c. Observe that the appropriate GENERATOR ONLINE indicator is illuminated.
d. If indicators in a. through c. above do not illuminate, check to insure all switches are in the on position, all
cables are tight, and no lamps are burned out.
4. At load bank:
a. Set BLOWER/CONTROL POWER switch on the load bank to ON.
b. Set POWER switch on digital display panel at the load bank to ON.
c. Select desired load using KW LOAD STEP switches.
Do not apply Instantaneous (one step) loads greater than 50 kW on the EPP
Ill 150 kW generator set.
Do not exceed the 30 kW rating on the PU-789/PU-804 30 kW generator set.
d. Apply load by turning MASTER LOAD to ON.

e. Observe function display for appropriate indication.
f.Operate each of the 150 kW generator sets for approximately 30 minutes after reaching 100 percent load.
g. If the appropriate indications are not displayed, check to insure that all switches are in the correct position
and all cables are tight. Refer to the appropriate maintenance procedures.
5. At generator set:
a. Observe voltage, frequency, and load meters for proper indications.
b. If proper indications are not present on any meter, refer to the appropriate maintenance procedures.
Change 1 5-237
TM 9-6115-668-13
1. Set MASTER LOAD switch on load bank to OFF.

2. Open “AC Circuit Interrupter” on generator set.
3. After a 36-second cool down, turn BLOWER/CONTROL POWER switch on load bank to OFF.
4. Set all remaining switches on the load bank to OFF.
5. Set all switches on the EPP-III/EPU junction box to OFF.
6. Shut down generator set.
7. Disconnect load bank cables L1, L2, L3, L0 and generator power and control cables from EPP III/EPU junction
box. Disconnect all ground cables.
5-238 Change 1
TM 9-6115-668-13
5.54 CHECKING AND ADJUSTING VALVES.
INITIAL SETUP
General Mechanic's Tool Kit Reference

(item 2, appendix B) Generator Set 150kw shut
Engine Cranking Gear (PN 100300) down.
Mandrel (PN 190200) paragraph 2.5.2
WARNING
Disconnect the negative battery cable first and then the positive battery terminal
cables. Failure to observe this warning could result in severe personal injury or
death.
REMOVAL
1. Remove eight screw caps (1. figure 5-56), eight packing preform (2), eight 0-ring t3), eight valve cover (4), and
eight gaskets (5).
NOTE
Engine must be cooled at least 3 hours.
ADJUSTMENT
1. Turn engine using Engine Cranking Gear (PN 100300) or Mandrel (PN 190200) until valves of number one
cylinder overlap.
NOTE
Valve overlapping means Exhaust valve is about to close and the Intake valve is
about to open. Both pushrods are now non-rotatable.
2. Check valve clearance for valves marked in black (fig 5-57), using a feeler gauge (2, fig 5-59). Gauge should just
slide into gap (3, fig 5-60) between rocker arm lug (4) and valve (5):
• Intake valve (I) 0.2 mm

• Exhaust valve (E) 0.3mm
3. If gap is too small or too large. loosen locknut (1, fig 5-60) one or two turns and turn adjusting screw and turn
adjusting screw (2) with a screwdriver (1, fig 5-59); once locknut is tightened gauge should slip out with little
resistance.
4. Turn crankshaft 360 degrees so that number seven cylinder is overlapped.
Change 2 5-239
TM 9-6115-668-13
NOTE
Valve overlapping means Exhaust valve is about to close and the Intake valve is
about to open. Both pushrods are now non-rotatable.
5. Check valve clearance for valves marked in black (fig 5-58), using a feeler gauge (2, fig 5-59). Gauge should just
slide into gap (3. fig 5-60) between rocker arm lug (4) and valve (5):
• Intake valve (I) 0.2 mm

• Exhaust valve (E) 0.3mm
6. If gap is too small or too large, loosen locknut (1, fig 5-60) one or two turns and turn adjusting screw and turn
adjusting screw (2) with a screwdriver (1, fig 5-59); once locknut is tightened gauge should slip out with little
resistance.
INSTALLATION
1. Replace O-ring (3, fig 5-56) and gasket (S5) with new ones.
2. Install valve cover (4), packing perform (2), and screw cap (1).
3. Tighten to 12 Nm.
Figure 5-56
5-240 Change 2
TM 9-6115-668-13
I= Intake
E = Exhaust
Change 2 5-241
TM 9-6115-668-13
5.55 Cooling Blower Assembly Maintenance.
INITIAL SETUP
General Mechanic's Tool Kit Reference

(item 2, appendix B) Generator Set, 150kw, shut down,
Puller for Centrifugal Oil paragraph 2.5.2
Filter (PN 160010)
Sling/hoisting device, Universal
(item 7 appendix B)
WARNING
Disconnect the negative battery cable first and then the positive battery terminal
cable. Failure to observe this warning could result in severe personal injury or
death.
REMOVAL
1. Remove unit hood assembly IAW Paragraph 4.14.
2. Remove oil line (27) from cover (7).
3. Remove screw cap hexagon (4), washer spring tension (5), washer flat (6), and remove cover (7).
4. Remove screw cap hexagon (4), washer spring tension (5) and ring (9).
5. Remove cover filter ( I 0) with puller (PN 160010).
SERVICE
1. Clean cover filter (10) and coupling clutch (15) with solvent and cloth to remove old oil and build up.
2. Replace O-ring (8) and O-ring (I 1).
INSTALLATION
1. Install cover filter (10), ring (9), washer spring tension (5). and screw cap hexagon (4) and tighten.
2. Install cover (7), washer flat (6), washer spring tension (5) and screw cap hexagon (4) and tighten.
Change 2 5-242
TM 9-6115-668-13
3. Install oil line (27) and tighten.
4. Install unit hood assembly IAW paragraph 4.14
Figure 5-61. Cooling Blower Assembly
5-243/5-244 blank Change 2

TM 9-6115-668-13
APPENDIX A
REFERENCES
A.1 SCOPE.
This appendix lists all forms, regulations, pamphlets, specifications, standards, technical manuals, and
field manuals referenced in this manual.
A.2 FORMS.
Recommended Changes to Publications and Blank Forms. . . . . . . . . . . . DA Form 2028

Recommended Changes to DA Publications . . . . . . . . . . . . . . . . . . . . . . . DA Form 2028-2
Depreservation Guide for Vehicles and Equipment . . . . . . . . . . . . . . . . . . . DA Form 2258
Equipment Inspection and Maintenance Worksheet . . . . . . . . . . . . . . . . . . DA Form 2404
Report of Discrepancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF 364
Product Quality Deficiency Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF 368
A.3 ARMY REGULATIONS.
Dictionary of United States Army Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 310-25
A.4 DEPARTMENT OF THE ARMY PAMPHLETS.
The Army Maintenance Management System (TAMMS) . . . . . . . . . . . . . . DA PAM 738-750
A.5 MILITARY SPECIFICATIONS.
Preservation, Methods of. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-P-116

Barrier Materials, Transparent, Flexible, Heat Sealable . . . . . . . . . . . . . . . MIL-B-22191
Generator Sets, Mobile Electric Power; Packaging of . . . . . . . . . . . . . . . . . MIL-G-28554
A.6 MILITARY STANDARDS.
Abbreviations for Use on Drawings, and in Specifications, Standards and

Technical Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-STD-12
Marking for Shipment and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-STD-129
Standard Requirements for Soldered Electrical and Electronic Assemblies MIL-STD-2000
A-l
TM 9-6115-668-13
A.7 TECHNICAL MANUALS.
Procedures of Destruction of Equipment to Prevent Enemy Use . . . . . . . . TM 750-244-3

Repair Parts and Special Tools List (Including Depot Maintenance Repair
Parts and Special Tools), Electrical Generator Assembly, 150 kW 400 Hz . TM 9-6115-668-23P
Operator, Unit, and Direct Support Maintenance Manual (Including Repair
Parts and Special Tools List) Electrical Power Plant Ill (EPP Ill) 150 kW TM 9-6115-669-13&P
400 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.8 FIELD MANUALS.
Electrical Power Generation in the Field . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 20-31

First Aid for Soldiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 21-11
A-2
TM 9-6115-668-13
APPENDIX B
MAINTENANCE ALLOCATION CHART
Section I. INTRODUCTION
B.1 THE ARMY MAINTENANCE SYSTEM MAC.
a. This introduction (section I) provides a general explanation of all maintenance and repair func-
tions authorized at various maintenance levels under the standard Army Maintenance System concept.
b. The Maintenance Allocation Chart (MAC) in section II designates overall authority and re-
sponsibility for the performance of maintenance functions on the identified end item or component. The
application of the maintenance functions to the end item or component will be consistent with the capaci-
ties and capabilities of the designated maintenance levels, which are shown in the MAC in column (4) as:
Unit - includes two sub columns, C (operator/crew) and O (unit) maintenance.

Direct Support - includes an F sub column.
General Support - includes an H sub column.
Depot - includes an D sub column.
c. Section III lists the tools and test equipment (both special tools and common tools sets) re-
quired for each maintenance function as referenced from section II.
d. Section IV contains supplemental instructions and explanatory notes for a particular mainte-
nance function.
B.2 MAINTENANCE FUNCTIONS. Maintenance functions will be limited to and defined as

follows:
a. Inspect. To determine the serviceability of an item by comparing its physical, mechani-
cal, and/or electrical characteristics with established standards through examination,
b. Test. To verify serviceability and detect early minor, or intermittent faults by measur-
ing the mechanical or electrical characteristics of an item and comparing those characteristics with pre-
scribed standards.
c. Service. Operations required periodically to keep an item in proper operating condition,

i.e., to clean ( decontaminate), to preserve, to drain, to paint, or to replenish fuel, lubricants, chemical
fluids, or compressed air supplies,
d. Adjust. To maintain, within prescribed limits, by bringing into proper or exact position, or
by setting the operating characteristics to specified parameters.
e. Aline. To adjust specified variable elements of an item to bring about optimum or de-
sired performance.
f. Calibrate. To determine and cause corrections to be made or to be adjusted on instru-

ments or test, measuring, and diagnostic equipment used in precision measurement. Consists of compar-
isons of two instruments, one of which is a certified standard of known accuracy, to detect and adjust any
discrepancy in the accuracy of the instrument being compared.
B-l
TM 9-6115-668-13
g. Remove/Install. To remove and install the same item when required to perform service or
other maintenance functions. Install may be the act of emplacing, sealing, or fixing into position a spare,
repair part, or module (component or assembly) in a manner to allow the proper functioning of an equip-
ment or system.
h. Replace. The act of substituting a serviceable like - type part, subassembly, or module
(component or assembly) for an unserviceable counterpart.
i. Repair. The application of maintenance services (inspect, test, service, adjust, align,
calibrate or replace) or other maintenance actions (welding, grinding, riveting, straightening, facing, rema-
chining, or resurfacing) to restore serviceability to an item by correcting specific damage, fault, malfunc-
tion, or failure in a part, subassembly, module (component or assembly), end item or system.
j. Overhaul. That maintenance effort (service/action) necessary to restore an item to a com-

pletely serviceable/operational condition as required by maintenance standards in appropriate technical
publications (i.e.T.M, DMWR). Overhaul in normally the highest degree of maintenance performed by the
Army. Overhaul does not normally return an item to like new condition.
k. Rebuild. Consists of those services/actions necessary for the restoration of unservice-

able equipment to a like new condition in accordance with original manufacturing standards. Rebuild is
the highest degree of material maintenance applied to Army equipment. The rebuild operation includes
the act of returning to zero those age measurements (hours, miles, etc.) considered in classifying Army
equipment and components.
B.3 EXPLANATION OF COLUMNS IN THE MAC, SECTION II. Below are listed and defined
column entries for Section II, Maintenance Allocation Chart.
a. Column 1 - Group Number. Column 1 lists group numbers, the purpose of which is to
identify components, assemblies, subassemblies, and modules with the next higher assembly.
b. Column 2 - Component/Assembly. Column 2 contains the noun names of components,

assemblies, subassemblies, and modules for which maintenance is authorized.
c. Column 3 - Maintenance Function. Column 3 lists the functions to be performed on the

items listed in column 2. These functions, are defined in paragraph B.2 above.
d. Column 4 - Maintenance Level. Column 4 specifies, by the listing of a “work time” figure
in the appropriate sub column(s), the lowest level of maintenance authorized to perform the function listed
in Column 3. The figure represents the active time required to perform that maintenance function at the
indicated level of maintenance. If the number or complexity of the tasks within the listed maintenance
function varies at different maintenance levels, appropriate “work time” figure represents the average time
required to restore an item (assembly, subassembly, component, module, end item, or system) to a ser-
viceable condition under typical field operating conditions. This time includes preparation time, trouble-
shooting time, and quality assurance/quality control time in addition to the time required to perform the
specific tasks identified for the maintenance functions authorized in the MAC. The sub columns of Col-
umn 4 are as follows:
C. . . Operator or Crew
O . . . Unit Maintenance
F . . . Direct Support Maintenance
H . . General Support Maintenance
D . . . Depot Maintenance
e. Column 5 - Tools and Equipment. Column 5 specifies, by code, those common tool
sets (not individual tools) and special tools, TMDE, and support equipment required to perform the desig-
nated function.
B-2
TM 9-6115-668-13
f. Column 6 - Remarks. This column shall, when applicable, contain a letter code, in
alphabetic order, which shall be keyed to the remarks contained in section IV.
B.4 EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENT,

SECTION Ill. Below are listed the column entries for this chart.
a. Column 1 - Reference: Code. The numbers in this column coincide with the numbers
used in Column 5 of the MAC. The numbers indicated the applicable tool or test equipment for the
maintenance function(s).
b. Column 2 - Maintenance Level. The codes in this column indicate the maintenance
level(s) allocated for the tool or the test equipment.
c. Column 3 - Nomenclature. This column lists the noun name and nomenclature of
the test equipment or tool required to perform the maintenance function.
d. Column 4 - National Stock Number. This column lists the National/NATO Stock
Number (NSN) of a specific tool or test equipment.
e. Column 5 - Tool Number. This column lists the manufacturer’s part number or tool fol-
lowed by the Contractor and Government Entity (CAGE) Code (5 digit) in parentheses,
B.5 EXPLANATION OF COLUMNS IN REMARKS. SECTION IV. This two column chart
provides definition and information of the reference codes in the MAC.
a. Column 1 - Reference Code. This code refers to the appropriate letter code in Section
II, Column 5.
b. Column 2 - Remarks. This column provides the required explanatory information

necessary to clarify items appearing in Section II, Column 5.
B-3
TM 9-6115-668-13
Section II, MAINTENANCE ALLOCATION CHART (MAC)

FOR
GEN SET 150 KW
(1) (2) (3) (4) (5) (6)
MAINTENANCE TOOLS
GROUP MAINTENANCE AND
NUMBER COMPONENT/ASSEMBLY FUNCTION C O F H D EQUIPMENT REMARKS
00 Generator Set, 150KW Inspect .3 I
Service .5 .5 2,3 A,B
Test .5 .5 2,3 K
Replace 15 2,3,7,17,18,20
Repair 1.5 3.0 2,3,7,17,18,20 B,C,L
Overhaul 300 1 Thru 20 D
01 Unit Hood Assembly Inspect .2 I

Rem/lnst 1.5 2.5 2,3 B,C
Repair 1.5 2.5 2,3 B,C,L
0101 Hood Assembly Inspect .2 I
Rem/lnst 1.5 2.5 2,3 B,C
Repair 1.5 2.5 2,3 B,C
02 Control Cabinet Assembly Inspect .2 I
Service .5 2,3 A,B
Test .5 .5 2,3,7,8 B,C,G
Adjust .5 2,3 C,E
Rem/lnst 2.0 2.0 2,3,7,8 B,C
Replace 2.0 2,3,7,8
Repair 3.0 3.5 2,3,7,8 B,C,L
0201 Control Cabinet, Inspect .1 I
Control Panel Test .5 .8 3 G
Rem/lnst 1.5 2,3 C
Repair 1.5 2.0 2,3,9 B,C,L
020101 Wiring, Control Cabinet Inspect .1 I
Test 1.0 3 G,J
Rem/lnst 3.0 2,3 C
Repair 3.5 2,3,6 C
020102 Light Assembly, Test .5 1,2,3 B,G
Panel lllumination Rem/lnst 1.0 1,2,3 B
Repair 1.0 2,3,6 B
020103 Push Button Switch and Test 5 2.3 B,G
B
Indicator Assembly Rem/lnst 1.0 1,2,3,4 B
020104 Push Button Switch Test .5 2,3 B,G
Rem/lnst 1.0 2,3 B
Repair 1.0 2,3 B
020105 Light Indicator Assembly Test .5 1,2,3 B,G
Replace 1.0 2,3 B
Repair 1.0 2,3 B
B-4
TM 9-6115-668-13
(1) (2) (3) (4) (5) (6)
MAINTENANCE TOOLS
020106 Voltage Adjust Assembly Test .3 2, 3 a

Rem/lnst .5 2, 3 B
Repair .5 2, 3 B
020107 Frequency Adjust Test .5 2, 3 C

Assembly Rem/lnst .5 2, 3 C
Repair .5 2, 3 C
020108 Battle Short Switch Test .3 2, 3 B

Rem/lnst .5 2, 3 B
Repair .5 2, 3 B
020109 Panel Dimmer Test .3 2, 3 B

Rem/lnst .3 2, 3 B
Repair 5 2, 3 B
0202 Control Cabinet, Inspect .2 I

Connecting Panel Test .5 .8 2, 3 B, C
Rem/lnst 1.5 2, 0 2, 3 B, C
Repair 1.5 1, 5 2, 3 B, C, L
020201 Connector Assembly Test .3 2, 3 B, G

Rem/Inst .5 .5 2, 3 B, C
Repair .5 .5 2, 3 B, C
020202 Connecting Assembly Test .3 2, 3 B, G

Rem/Inst .5 2, 3 B
Repair .5 B
0203 Control Cabinet Inspect .1 I

Preheating Board Test 5 8 2, 3 B, C, G
Rem/lnst 1.5 1, 5 2, 3 B, C
Repair 15 2, 0 2, 3 B, C, L
020301 Relay Assembly Test .5 2, 3 C

Rem/lnst .5 2, 3 C
Repair .5 2, 3 C
020302 Time Relay Assembly Test .5 2, 3 C

Rem/Ins! .5 2, 3 C
Adjust .3 2, 3 C, E
Repair .5 2, 3 C
020303 Circuit Breaker Assembly Rem/lnst .3 2, 3 B

Repair .3 2, 3 B
B-5
TM 9-6115-668-13
(1) (2) (3) (4) (5) (6)
MAINTENANCE TOOLS
NUMBER COMPONENT/ASSEMBLY FUNCTION O F H EQUIPMENT REMARKS
020304 Resistor Assembly Rem/lnst .3 2, 3 B

Repair .3 2, 3 B
020305 Wiring, Preheating Board Test 1.5 2, 3 C

Replace 3.0 2, 3 C
Repair 1.5 2, 3 C
0204 Control Cabinet. DYNA II Rem/Inst .5 2, 3 C

Installation Repair .5 2, 3 C
020401 DYNA II, Power Control Rem/lnst .5 2, 3 C

Assembly Repair .5 2, 3 C
020402 DYNA II Digital Module Test .5 2, 3 C

Replace .5 2, 3 C
Repair 2.0 2, 3 D
0205 Cabinet Assembly Test .5 .5 2, 3 B, C

Rem/lnst 1.5 2.0 2, 3, 12, 13, 15 B, C
Repair 1.5 2.0 2, 3, 12, 13, 15 B, C, L
020501 Key Assembly Rem/lnst .3 2, 3 B

Repair .3 2, 3 B
020502 Cabinet lllumination Test .3 2, 3 B

Rem/lnst .3 2, 3 B
Repair .3 2, 3 B
020503 Diode Assembly Rem/lnst .3 2, 3 B

Repair .3 2, 3 B
020504 Time Relay Assembly Test .5 2, 3 C, G

Adjust .3 2, 3 C
Rem/lnst .5 2, 3 C
Repair .5 2, 3 C
020505 Transformer Assembly Test .5 2, 3 B, G

Rem/Inst .5 2, 3 B
Repair .5 2, 3 B
020506 Resistor Assembly, Mounted Rem/lnst .5 2, 3 C

Repair .5 2, 3 C
020507 Automatic Voltage Regulator Test .5 2, 3 C, G

Adjust 1.0 2, 3, 16 C
Repair 1.0 2, 3 C
B-6
TM 9-6115-668-13
(1) (2) (3) (4) (5) (6)
MAINTENANCE TOOLS
02050701 Printed Circuit Card Replace 1.0 2.0 2, 3 C

Assembly Repair 2, 3 D
020508 Equipment Protection Test .5 2, 3 C, G

Adjust 1.0 2, 3 C, M
Repair 1.0 2, 3 C
02050801 Printed Circuit Card Replace 1.0 2, 3 C

Assembly Repair 2.0 2, 3 D
020509 Relay Assembly Rem/lnst .5 2, 3, 16 B

Repair .5 .5 2, 3 B, C
020510 Contactor Assembly Rem/lnst 1.0 2, 3 C

Repair 1.0 2, 3 C
020511 Filter Box Assembly Test 1.0 2, 3 C

Rem/lnst 1.0 2, 3 C
Repair 1.0 2, 3 C
0206 Housing, Control Cabinet Rem/lnst 1.0 2, 3 B

Repair 1.0 1.0 2, 3 B, C, L
03 Fuel Tank Assembly Inspect .2 I

Service .5 2, 3 A, B
Rem/lnst 1.5 2, 3 B
Repair 2.0 2.5 2, 3 B, C, L
0301 Fuel Hose Assembly Inspect .2 I

Replace 2.0 2, 3 B
Repair 2.0 2, 3 C
0302 Hose Assembly, Inspect .2

Fuel Rem/lnst 1.5 2, 3 I
Repair 1.5 2.0 2, 3 B
04 Battery Set Assembly Inspect .1 I

Test .3 2, 3 B
Rem/lnst 1.5 2, 3 B
Repair 1.0 2, 3 B, L
05 Air Filter Assembly Inspect .1 I

Rem/lnst 1.0 2, 3 B
B-7
TM 9-6115-668-13
(1) (2) (3) (4) (5) (6)
MAINTENANCE TOOLS
06 Engine Preheating Assembly Inspect .1 I

Rem/lnst 2.0 2, 3 B
0601 Gas Exhaust Assembly Inspect .2 I

Rem/lnst 3.0 2, 3 B
Repair 3.0 2, 3 B
0602 Hose Assembly, Oil Inspect .2 I

Rem/lnst 2.5 2, 3 C
Repair 3.0 2, 3 C
0603 Mounting Plate Inspect .2 I

Rem/lnst 3.0 2, 3 B
07 Muffler Assembly Inspect .2 I

Rem/lnst 3.0 2, 3 B
08 Scavenge Pump Assembly Inspect .2 I

Rem/lnst 1.0 2, 3 B
0801 Scavenge Pump Replace 1.0 2, 3 B

Repair 1.5 2, 3 C
09 Synchronous Alternator Inspect .1 I

Assembly Service .3 2, 3 A, B
Test .5 2, 3 C, K
Replace 10.0 2, 3, 8, 17 C
Rem/lnst 10.0 2, 3, 8, 17 C
Repair 10.0 1 0 0 2, 3, 8, 17 C, L
Overhaul 1 thru 20 D
0901 Bearing Assembly, Test .5 2, 3

Rotor side Rem/lnst 5.0 2, 3
Repair 5.0 2, 3
0902 Excitor Stator Assembly Test .5 2, 3

Rem/lnst 5.0 2, 3
Replace 5.0 2, 3
Repair 3.0
B-8
TM 9-6115-668-13
(1) (2) (3) (4) (5) (6)
MAINTENANCE TOOLS
NUMBER COMPONENT/ASSEMBLY FUNCTION C O EQUIPMENT REMARKS
0903 Bearing Assembly, Test 5 2, 3 C

Excitor Side Rem/lnst 5.0 2, 3 C
Repair 5.0 2, 3 C
0904 Rotor Assembly Test .5 2, 3 C

Rem/lnst 5.0 2, 3 c
Replace 5.0 2, 3 C
Repair 3.0 2, 3 D
0905 AC-Stator Assembly Test .5 2, 3 C

Rem/lnst 5.0 2, 3 C
Replace 5.0 2, 3 C
Repair 3.0 2, 3 D
10 Engine Assembly Inspect .1 I

Test .5 2, 3 CK
Rem/lnst 10.0 2, 3, 8, 16-18 C
Repair 10.0 2, 3, 8, 16-18 C, L
Overhaul 150 2, 3, 8, 16 D, H
1001 Preffilter Assembly, Fuel Inspect .1 I

Rem/lnst .5 2, 3 B
Replace .5 2, 3 B
1002 Two Step Fuel Filter Inspect .1 I

Assy Service .5 2, 3 B
Rem/lnst .5 2, 3 B
Replace .5 2, 3 B
1003 Pick Up Cable Assy Inspect .1 I

Rem/lnst 5 2, 3 C
Repair .5 2, 3 C
1004 Actuator Cable Assy Inspect .1 I

Rem/lnst 5 2, 3 C
Repair .5 2, 3 C
1005 Engine Inspect .2 I

Test 1.5 2, 3 C, K
Replace 27.0 2, 3, 8,16-20 C
Rem/lnst 27.0 2, 3, 8,16-20 C
Repair 30.0 2, 3, 8,16-20 C, L
Overhaul 1 5 0 2, 3, 8,16-20 D, H
B-9
TM 9-6115-668-13
(2) (3) (4) (5) (6)
MAINTENANCE TOOLS
NUMBER COMPONENT/ASSEMBLY FUNCTION O F H D EQUIPMENT REMARKS
100501 Engine Cable Harness Test 3.0 2, 3 C, G

Assy Rem/lnst 2.0 2, 3 C
Replace 10.0 2, 3 C
Repair 2.0 2, 3 C
100502 Cable Harness Assy Test .5 C, G

Rem/lnst 2.0 C
Replace 1.0 C
Repair 2.0 C
100503 Connecting Elbow Assy. Air Rem/lnst 1.0 2, 3 C

Repair 2.0 2, 3 C
100504 Air Shielding Assy, Rem/lnst 1.0 2, 3 C

Turbo Repair 2.0 2, 3 C
100505 Oil Tube Assy, Turbo LH Rem/lnst 1.0 2, 3 C

Repair 2.0 2, 3 C
100506 Oil Tube Assy, Turbo RH Rem/lnst 1.0 2, 3 C

Repair 2.0 2, 3 C
100507 Oil Tube Assy, Turbo Return Rem/lnst 1.0 2, 3 C

Repair 2.0 2, 3 C
100508 Turbocharger Assy Rem/lnst 1.0 2, 3 C

Repair 2.0 2, 3 C, L
B-10
TM 9-6115-668-13
(1) (2) (3) (4) (5) (6)
MAINTENANCE TOOLS
100509 Suction Pipe Assy Rem/lnst 1.0 2, 3 C

Repair 2.0 2, 3 C
100510 Breather Pipe Assy Rem/lnst 1.0 2, 3 C

Repair 2.0 2, 3 C
100511 Breather Pipe Assy, Rem/lnst 1.0 2, 3 C

Crankcase Repair 2.0 2, 3 C
100512 Exhaust Pipe Assy, LH Rem/lnst 1.0 2, 3 C

Repair 2.0 2, 3 C
100513 Exhaust Pipe Assy, RH Rem/lnst 1.0 2, 3 C

Repair 2.0 2, 3 C
100514 Breather Assy, Crankcase Rem/lnst 1.0 2, 3 C

Repair 2.0 2, 3 C
100515 Oil Return Tube Assy. Rem/lnst 1.0 2, 3 C

Breather Repair 2.0 2, 3 C
100516 Cover Plate Assy, Rem/lnst 1.0 2, 3 C

Oil Cooler Repair 2.0 2, 3 C
100517 Cooling Blower Assy Rem/lnst 1.0 2, 3 C

Repair 2.0 2, 3 C
100518 Linkage Assy Rem/lnst 1.0 2, 3 C

Repair 2.0 2, 3 C
100519 Cooling Air Duct Assy, Rear Rem/lnst 1.0 2, 3 C

LH Repair 2.0 2, 3 C
100520 Cooling Air Duct Assy, Rear Rem/lnst 1.0 2, 3 C

RH Repair 2.0 2, 3 C
100521 Cooling Air Duct Assy, Front Rem/nst 1.0 2, 3 C

RH Repair 2.0 2, 3 C
100522 Valve Drive Assy Rem/lnst 1.0 2, 3 C

Repair 2.0 2, 3 C
B-11
TM 9-6115-668-13
(1) (2) (3) (4) (5) (6)
MAINTENANCE TOOLS
100523 Fuel Injector Assy Rem, lnst 1.0 2, 3 C

Replace 1.0 2, 3 C
Repair 1.0 2, 3 D
100524 Cylinder Head Assy Replace 5.0 2, 3 D

Repair 5.0 2, 3 D
100525 Drive Coupling Assy Rem/lnst 1.0 2, 3 C

Repair 2.0 2, 3 C
100526 Two Wheel Drive Gear Assy Replace 5.0 2, 3 D

Repair 5.0 2, 3 D
100527 Timing Device Assy Replace 5.0 2, 3 D

Repair 5.0 2, 3 D
100528 Blower Drive Assy Replace 5.0 2, 3 D

Repair 5.0 2, 3 D
100529 Oil Pan Assy Rem/lnst 1.0 2, 3 C

Repair 2.0 2, 3 C
100530 Oil Line Assy Rem/lnst 1.0 2, 3 C

Repair 2.0 2, 3 C
100531 Piston Assy Replace 5.0 2, 3 D

Repair 5.0 2, 3 D
100532 Connecting Rod Assy Replace 5.0 2, 3 D

Repair 5.0 2, 3 D
100533 Crankshaft Assy Replace 5.0 2, 3 D

Repair 5.0 2, 3 D
100534 Block, Engine Replace 5.0 2, 3 D

Repair 5.0 2, 3 D
11 Wiring Harness, Electrical Inspect .2 I

Generator 150KW Test 1.0 2, 3 C, G
Rem/lnst 2.5 2, 3 C
Repair 2.5 2, 3 C
12 Base Frame Assy Inspect .2 I

Service 5 2, 3 A, B
Rem/lnst 3.0 3.0 2, 3 B, C
Repair 3.5 2, 3 C, L
B-12
TM 9-6115-668-13
(1) (2) (3) (4) (5) (6)
MAINTENANCE TOOLS
1201 Subcurrent Filter Assy Service 5 2, 3 A, B

Rem/lnst .8 2, 3 B
Repair .8 2, 3 B
1202 Slave Receptacle Assy Rem/lnst .8 2, 3 B

Repair .8 2, 3 B
1203 Frame Replace 10 2, 3 C

Repair 10 2, 3 D, F
B-13
TM 9-6115-668-13
Section III, Tool and Test Equipment Requirements

FOR
GEN SET 150 KW
Tool or Mainte-
Test nance National Stock Tool
Equipment Level Nomenclature Number Number
1 O, F Lamp Extractor 3SB1902-2AD
2 O, F Tool kit, Auto 5180-00-177-7033 SC-5180-90-CL-N26-1
3 O, F Tool kit, Fuel/Elec 5180-00-754-0655 SC5180-91-CL-R13-HR-1
4 O, F Wrench, Oil Filter 67.600.47.111
5 F Watch Stop
6 F Resistor, 1000 OHMS .25 Watt 525.17.0301
7 O, F Mandrel 190200
8 F Wrench, Shop Manufactured 505.09.0063
9 F Fork-Head, Screwdriver 505.38.0011
10 F Removal Tool 5210-00-177-6966 MS27495R20
11 F Installation Tool 5210-00-177-6967 MS27495A20
12 F Removal Tool 5210-00-409-5206 M81969/8-08
13 F Installation Tool 5210-00-018-0529 M81969/8-07
14 F Crimp Tool, Hydraulic 505.38.0003
15 F Wrench, Socket, Shop 505.38.0010
Manufactured
16 F X/Y Printer 6625-01-438-6968 RS 3200
17 F Eyebolt 02417150
18 F Eyebolt 02417148
19 F, D Load Bank, 150KW Avtron K675a
20 F, D Engine Stand 13230E6806
21 F, D Shop Set, Automotive 4910-00-754-0654 SC4910-95-CLA47-HR
22 F, D Shop Set, Electrical
B-14
TM 9-6115-668-13
Section IV, REMARKS

FOR
GEN SET 150 KW
Reference
Code Remarks
A Preventative Maintenace Checks and Services (PMCS)
B Unit Maintenance Instructions
C Direct Support Maintenance Instructions
D Depot Maintenace Work Requirement (DMWR)
E In Accordance with Procedures in applicable TM
F Weld and Straighten
G Continuity Test
H Test Pressure Output
I Visual inspection
J Voltage Test
K Operation Test
L Repair by Replacement of Sub-Assemblies/Components
M Adjust to Specifications in Applicable TM
B-15/(B-16 blank)
TM 9-6115-668-13
APPENDIX C
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII)

LISTS
C.1 SCOPE.
This appendix lists components of the end item and basic issue items for the generator set 150 kW to
help you inventory the items for safe and efficient operation of the equipment.
C.2 GENERAL.
The Components of End Item (COEI) and Basic Issue Items (Bll) Lists are divided into the following sections:
C.2.1 Section II. Components of End Item. This listing is for information purposes only, and is not
authority to requisition replacements. There are no components of end item for the generator set 150 kW.
C.2.2 Section Ill. Basic Issue Items. These essential items are required to place the (enter name
of end item) in operation, operate it, and to do emergency repairs. Although shipped separately pack-
aged, Bll must be with the generator set 150 kW during operation and when it is transferred between
property accounts. Listing these items is your authority to request/requisition them for replacement based
on authorization of the end item by the TOE/MTOE. Illustrations are furnished to help you find and iden-
tify the items.
C.3 EXPLANATION OF COLUMNS.
C.3.1 Column (1). lllus Number. Column (I), lllus Number, gives you the number of the item illustrated.
C.3.2 Column (2). National Stock Number. Column (2), National Stock Number, identifies the
stock number of the item to be used for requisitioning purposes.
C.3.3 Column (3). Description and Usable On Code. Column (3), Description and Usable On
Code, identifies the Federal item name (in all capital letters) followed by a minimum description when
needed. The last line below the description is the CAGEC (Commercial and Government Entity Code) (in
parenthesis) and the part number.
C.3.4 Column (4). U/M (unit of measure). Column (4), U/M (unit of measure), indicates how the
item is issued for the National Stock Number shown in column two.
C.3.5 Column (5). Qty Rgr (quantity rewired). Column (5), Qty Rqr, indicates the quantity re-
quired.
C-1
TM 9-6115-666-13
Section II. COMPONENTS OF END ITEM
(1) (2) (3) (4) (5)
lllus National Description U/M Qty

Number Stock CAGEC and Part Number Rqr
Number
This section is not applicable to the generator set

150 kW
C-2
TM 9-6115-668-13
Section Ill. BASIC ISSUE ITEMS
(1) (2) (3) (4) (5)
Illus National Description QtY

Number Stock CAGEC and Part Number Rqr
Number
1 Manual, Technical TM 9-6115-668-13 EA 1
C-3(C-4blank)
TM 9-6115-668-13
APPENDIX D
ADDITIONAL AUTHORIZATION LIST
D.1 SCOPE.
This appendix lists additional items you are authorized for the support of the generator set 150 kW.
D.2 GENERAL.
This list identifies items that do not have to accompany the equipment and that do not have to be turned in with it.
These items are all authorized to you by CTA, MTOE, TDA, or JTA.
D.3 EXPLANATION OF LISTING.
National stock numbers, descriptions, and quantities are provided to help you identify and request the additional
items you require to support this equipment. The items are listed in alphabetical sequency by item name. If the item
you require differs between serial numbers of the same model, effective serial numbers are shown in the last line of
the description. If item required differs for different models of this equipment, the model is shown under the “Usuable
on” heading in the description column.
D-1
TM 9-6115-668-13
Section II. ADDITIONAL AUTHORIZED ITEMS LIST
(1) (2) (3) (4)
National Description
Stock Qty
Number CAGEC and Part Number Usuable on Code U/I Recm
7240-00-222-3088 CAN, GASOLINE, MILITARY (80372) 42-D-1280 EA 1
D-2
TM 9-6115-666-13
APPENDIX E
EXPENDABLE AND DURABLE ITEMS LIST
E.1 SCOPE.
This appendix lists expendable and durable items that you will need to operate and maintain the genera-
tor set 150 kW. This listing is for information only and is not authoriy to requisition the listed items. These
items are authorized to you by CTA 50-790, Expendable/Durable Items (exept medical, class V repair
parts, and heraldic items), or CTA 8-100, Army Medical Department Expendable/Durable Items.
E.2 EXPLANATION OF COLUMNS.
E.2.1 Column 1, Item number. This number is assigned to the entry in the listing and is referenced
in the narrative instructions to identify the item (e.g., “Use cleaning cloth, Item 3, Appendix E”).
E.2.2 Column 2. Level. This column identifies the lowest level of maintenance that requires the item.
E.2.3 Column 3. National stock number. This is the national stock number assigned to the item
which you can use to requisition it.
E.2.4 Column 4. Item name, description. Commercial and Government Entity Code (CA-
GEC) and part number. This provides the other information you need to identify the item.
E.2.5 Column 5. Unit of Measure. This code shows the physical measurement or count of an item,
such as gallon, dozen, gross, etc.
E-1
TM 9-6115-668-13
Section II. EXPENDABLE AND DURABLE ITEMS LIST
(1) (2) (3) (4) (5)

NATIONAL
ITEM STOCK ITEM NAME, DESCRIPTION
NUMBER LEVEL NUMBER CAGEC, PART NUMBER U/M
1 C 9150-00-152-4117 Lubricating Oil, Engine, MIL-L-2104,
15/40w
2 C Lubricating Oil, Engine, 5/30W
3 C, O 7920-01-338-3329 Cloth, Cleaning, TX-250
4 O Bearing grease
5 O Talc, technical grade
6 O, F Lubricant
7 O Light-duty detergent, commercial
8 O Kerosene
9 O Lubricating grease
10 F Cable ties
11 F Adhesive
12 F 3439-00-974-1873 Solder, Tin Alloy, SN60WRAP2, 1 Lb.
Spool
13 F Thermoconductive Paste
14 F Heat-shrink tubing
15 F Hylomar
16 F Loctite 243
17 F Adhesive tape
18 F Heat-shielding tape
19 F Sealing tape
20 F Double-sided Adhesive Tape
21 F Plastic Bags
22 F Rubber Bands
E-2
TM 9-6115-668-13
APPENDIX F
OPERATOR’S LUBRICATION INSTRUCTIONS
F.1 GENERAL.
This appendix is not applicable to the generator set 150 kW.
F-1 (F-2 blank)

TM 9-6115-668-13
APPENDIX G
TORQUE LIMITS
G.1 BOLTS.
Bolt alloy: K18-8(A4)-70, DIN 931/933, in lengths up to 8 x nominal thread diameter (d) at room tem-
perature, strength class 70 (normal), work-hardened.
NOTE
Coefficient of friction µ = 0.16
Coarse-pitch thread Tightening torque,

ft-lb (Nm)
M5 3.5 (4.7)
M6 6 (8.2)
M8 14.5 (19.6)
M10 28.8 (39)
M12 49.4 (67)
M14 78.2 (106)
M16 119.5 (162)
M18 166 (225)
M20 233 (3 16)
M22 174 (236)
M24 224 (304)
M27 327 (443)
M30 446 (605)
G.2 STUDS.
Stud alloy: A1Mg 3
Coarse-pitch thread Tightening torque,

ft-lb (Nm)
M3 0.6 (0.8)
M4 1.5 (2.0)
M5 2.6 (3.5)
G-1 (G-2 blank)

TM 9-6115-668-13
GLOSSARY
Section I. ABBREVIATIONS
COMMON ABBREVIATIONS.
The common abbreviations used in this manual are in accordance with MIL-STD-12D.
SPECIAL OR UNIQUE ABBREVIATIONS.

The following are abbreviations and symbols that are used in this manual and not listed in MIL-STD-12D.
AAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . additional authorization list
Bll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . basic issue
°C .......................................................................... degrees Celsius
CAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . commercial and government entity
CAGEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . commercial and government entity code
COEl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . components of end item
CPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . corrosion prevention and control
CTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . common table of allowance
DOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Department of Defense
EIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . equipment improvement recommendation
° F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . degrees Fahrenheit
Hz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hertz
JTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . joint table of allowances
k g ................................................................................. Kilogram
kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kilowatt
m ...................................................................... meter (metric measure)
MAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . maintenance allocation chart
MTOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . modification table of organization and equipment
N m. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . newton meter
N S N. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . national stock number
PMCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . preventive maintenance checks and services
RPSTL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . repair parts and special tools list
SMR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . source, maintenance, and recoverability
TAMMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Army Maintenance Management System
TDA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . table of distribution and allowances
TMDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . test, measurement, and diagnostic equipment
UOC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . usable on code
Glossary - 1
TM 9-6115-668-13
Section II. DEFINITION OF UNUSUAL TERMS
UNUSUAL TERMS.
The following are terms that are used in this manual and not listed in the Army dictionary (AR 310-25).
None.
Glossary - 2
TM 9-6115-668-13
INDEX
Subject Paragraph
A
Abbreviations, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
Actuator Assembly Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.41
Actuator Cable Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.42
Adjustments, Initial, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Air Cooling Inlet Grate Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
Air Filter Cartridge Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29
Air Filter Dust Collector Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Air Filter Housing and Piping Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
Air Flap Puller Magnet Maintenance, .............................................. 5.36
Air Leading Duct Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
Air-Oil Heat Exchanger Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.38
Army Materiel, Destruction of to Prevent Enemy Use, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Auxiliary Contactor K109 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
Auxiliary Contactor Maintenance, ................................................. 5.7
Auxiliary Contactor with Semiconductor Device Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
B
Battery Charging Alternator Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.89
Battery Charging Alternator Regulator N6 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.75
Battery Charging Alternator V Belt, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.34
Battery Charging Alternator V Belt Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.35
Battery Set Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.74
Battle Short Switch S21 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.48
Brightness Control N5 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.59
Bulb in Illuminated Switch Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25
Bulb in INdicator Lamp Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
Burner Monitoring Temperature Switch Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.32
C
Cabinet Illumination H7 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.57
Characteristics, Capabilities and Features of Equipment, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
Circuit Breaker Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.63, 4.68
Clutch Assembly Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.52
INDEX - 1
TM 9-6115-666-13
Subject Paragraph
Common Tools and Equipment, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1, 5.1
Connector J9 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.69
Connector Receptacle L1 to L3 and N Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
Construction, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
Contactor K1 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.66
Control Cabinet Assembly Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.43
Controls and Indicators, Operator’s, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Cover and Case for Connection Panel Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . 4.19
Cross-Reference List, Nomenclature, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
Current Transformer Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
Data, Equipment, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

Description, Functional, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
Description, General, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
Description, Major Components, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
Destruction of Army Materiel to Prevent Enemy Use, . . . . . . . . . . . . . . . . . . . 1.3
Diesel Engine and Synchronous Generator Maintenance, . . . . . . . . . . . . . . . . . . . . . 5.47
Diesel Engine Cylinder Cooling Fins and Oil Cooler Maintenance, . . . . . . . . . . . . 4.36
Diesel Engine Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50
Diesel Engine Shock Absorbers Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . 5.48
Digital lsochronous Load Sharing Module N4 Maaintenance, . . . . . . . . . . . . . . . . . . 5.11
Diode Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.61, 5.19
Diode V3 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.62
Door Contact Switch S3 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . 4.58
E
EHG Temperature Sensor Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.45
EHG Regulator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.76
Electric Oil Pump Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.37
Electrical Fuel Pump Assembly Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.78
Emergency Procedures, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Engine Preheating Assembly Maintenance, . . . . . . . . . . . . . . . . . . . . 5.31
Engine Preheating Assembly Wiring Diagram . . . . . . . . . . . . . . . . . . . . FO-2
Engine Preheating Control Board Maintenance, . . . . . . . . . . . . . . . . . . . . 4.67
INDEX - 2
TM 9-6115-668-13
Subject Paragraph
Equipment
Characteristics, Capabilities, and Features, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
Data, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.12
Preliminary Servicing and Adjustment, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6
Equipment Improvement Recommendation, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
F
Filter Box FK Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
Flame Glowplug System Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30
Flap Mount Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22
Forms and Records, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Frequency Adjust R4 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.52
Frequency Meter P5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.55
Fuel Level Sensor 2R4 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.81
Fuel Line Assembly Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.42
Fuel Lines and Prefilter Assembly Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.38
Fuel tines and Two Step Fuel Filter Assembly Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.39
Fuel Prefilter Assembly Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40
Fuel Prefilter Cartridge Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32
Fuel Tank Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.77
FunctionalDescription, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
G
Gas-Cylinder and Prop Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
Generator Set 150 kW, Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-1
Generator Set 150 kW, Engine Preheating Assembly Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . FO-1
Generator Wiring Harness Maintenance , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46
Glossary, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Glowplug Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33
Glowplug/Start Switch S2 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.50
I
Improvement Recommendation, Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
Initial Adjustments, Checks, and Self Test, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Installation Instructions, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.5
INDEX - 3
TM 9-6115-668-13
Subject Paragraph
Interference Suppression Components, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
Interlock Switch Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
J
J1/120 V 406 HZ Double Connector Receptacle Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.70
J2/24 V Connector Receptacle Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.71
J3 Slave Receptacle 24 Volts Connector Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
L
Light indicator Assembly Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23
List of Abbreviations, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
List, Nomenclature Cross-Reference, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
Load Bank Procedures, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.53
Location of Major Components, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
Lower Fuel Level Switch Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.80
Lubrication
Operator, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Synchronous Generator Assembly, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
M
Maintenance
Forms and Records, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Operator, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Maintenance of
Actuator Assembly, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.41
ActuatorCable, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.42
Air Coding Inlet Grate, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
Air Fitter Cartridge, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29
Air Filter Dust Collector, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Air Filter Housing and Piping, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
Air Flap Puller Magnet, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.36
Air Leading Duct, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
Air-Oil Heat Exchanger, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.38
Auxiliary contactor, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
Auxiliary Contactor K109, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
Auxiliary Contactor with Semiconductor Device, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Battery Charging Alternator, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.89
Battery Charging Alternator Regulator N6, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.75
INDEX - 4 Change 1
PIN: 074795-001
TM 9-6115-668-13
Subject Paragraph
Battery Charging Alternator V Belt, .............................................. 4.35
Battery Set, .................................................................. 4.74
Battle Short Switch S21, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.48
Brightness Control N5, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.59
Bulb in Illuminated Switch, ..................................................... 4.25
Bulb in Indicator, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
Burner Monitoring Temperature Switch, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.32
Cabinet Illumination H7, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.57
Circuit Breaker, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.63, 4.68
Clutch Assembly, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.52
Connector J9, ................................................................ 4.69
Connector Receptacle L1 to L3 and N, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
Contactor K1, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.66
Control Cabinet Assembly, ..................................................... 4.43
Cover and Case for Connection Panel, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
Current Transformer, .......................................................... 5.17
Diesel Engine, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50
Diesel Engine and Synchronous Generator, ...................................... 5.47
Diesel Engine Cylinder Cooling Fins and Oil Cooler, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.36
Diesel Engine Shock Absorbers, ................................................ 5.48
Digital lsochronous Load Sharing Module N4, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
Diode, ....................................................................... 4.61, 5.19
Diode V3, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.62
Door Contact Switch S3, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.58
EHG Temperature Sensor, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.45
Electric Oil Pump, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.37
Electrical Fuel Pump Assembly, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.78
Engine Preheating Assembly, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.31
Engine Preheating Control Board, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.67
Filter Box FK, ................................................................ 5.16
Flame Glowplug System, ...................................................... 5.30
Flap Mount, .................................................................. 4.22
Frequency Adjust R4, ......................................................... 4.52
Frequency Meter P5, .......................................................... 4.55
Fuel Level Sensor 2R4, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.81
Fuel Line Assembly, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.42
Fuel Lines and Prefilter Assembly, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.38
Fuel Lines and Two Step Fuel Filter Assembly, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.39
INDEX - 5
TM 9-6115-668-13
Subject Paragraph
Fuel Prefilter Assembly, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40
Fuel Prefilter Cartridge, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32
Fuel Tank, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.77
Gas-Cylinder and Prop, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
Generator Wiring Harness, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46
Glowplug, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33
Glowplug/Start Switch S2, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.50
Interlock Switch, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
J1/120 V 400 HZ Double Connector Receptacle, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.70
J2/24 V Connector Receptacle, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.71
J3 Slave Receptacle 24 Volts Connector, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
Light Indicator Assembly, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23
Lower Fuel Level Switch, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.80
Master Switch S1, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.51
Meter, ..................................................................... 4.56
Miniature Relay, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
Oil Hose, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39
Oil Line Assembly, .......................................................... 4.86
Oil Outlet Pipe Assembly, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.85
Oil Temperature Switch, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40
Overtemperature Switch, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.34
Panel Dimmer S16/R2, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.54
Panel Illumination H6, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.46
Pick-Up Assembly, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43
Pick-Up Cable, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.44
Power Relay K101, K102, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
Power Supply NT2 24 V, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9, 5.21
Preheating Resistor R1, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.47
Priming Pump, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.37
Pushbutton Switch, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.45
Pushbutton Switch and Indicator Assembly, ...................................... 4.44
Relay K19 and K20 with Relay Socket and Contact Bushings, . . . . . . . . . . . . . . . . . . . . . . . 5.12
Resistor R100 to R102, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.65
Safety Device N3, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
Scavenge Pump Assembly, .................................................... 4.84
INDEX - 6
TM 9-6115-668-13
Subject Paragraph
Service Switch, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.72
Shunt R11, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.73
Silencer Assembly, Left Side, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.82
Silencer Assembly, Right Side, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.83
Speed Governor Assembly N1, ................................................. 5.13
Starter, ...................................................................... 4.90
Subcurrent Filter Assembly, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28
Subcurrent Filter Cartridge, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31
Subcurrent Filter Oil Lines, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29
Supply Air Duct, .............................................................. 4.16
Synchronous Generator, ....................................................... 5.51
Synchronous Generator Shock Absorbers, ....................................... 5.49
Thermistor Relay F12, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
Time Relay, .................................................................. 5.20
Time Relay K3, K10, K13, K17, K25, K26, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
True Power Measuring Transformer P4A, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.64
Twist Grip and Lock, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
Two Step Fuel Filter Assembly, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.41
Two Step Fuel Filter Cartridge, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.33
Unit Hood - Base Frame Ground Strap, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
Unit Hood Assembly, .......................................................... 4.14
Unit Hood Flap Ground Strap, .................................................. 4.13
Upper Fuel Level Switch, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.79
Voltage Adjust R3, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.53
Voltage Regulator N2, ......................................................... 5.14
Voltage Selector Switch S11, ................................................... 4.49
Major Components, Description of, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
Major Components, Location of, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
Manuals, Related Technical, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
Master Switch S1 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.51
Materiel, of to Prevent Enemy Use, ............................................... 1.3
Materiel, Service Upon Receipt of, ................................................ 4.4
Meter Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.56
Miniature Relay Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
Movement, Preparation for, ...................................................... 2.7
N
Nomenclature Cross-Reference List, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
INDEX - 7
TM 9-6115-668-13
Subject Paragraph
O
Oil Filter Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.30
Oil Hose Maintenance, ................................................ 5.39
Oil Line Assembly Maintenance, ........................................ 4.86
Oil Outlet Pipe Assembly Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.85
Oil Temperature Switch Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40
Operating Procedures, ................................................ 2.5
Operation Under Unusual Conditiones, Flame Glowplug System, . . . . . . . . . . . . . . . . . . . . 2.9
Operation Under Unusual Conditions, Extreme Cold, . . . . . . . . . . . . . . . . . . . . . . 2.10
Operations Under Unusual Conditions, Engine Preheating Assembly, . . . . . . . . . . . . . . 2.8
Operator
Controls and Indicators, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Lubrication, ........................................................ 3.1
Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
PMCS Table, Introduction to, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Troubleshooting, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Overtemperature Switch Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.34
P
Panel Dimmer S16/R2 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.54
Panel Illumination H6 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.46
Parts, Repair, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3, 5.3
Pick-Up Assembly Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43
Pick-Up Cable Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.44
PMCS
Operator Table, Introduction to, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Unit Table, Introduction to, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Power Relay K101, K102 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
Power Supply NT2 24 V Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9, 5.21
Preheating Assembly Cable, ........................................ 5.35
Preheating Resistor R1 Maintenance, .................................. 4.47
Preliminary Servicing and Adjustment of Equipment, . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
Preparation for Movement, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
Preparation for Storage and Shipment, ..................................... 1.4
Priming Pump Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.37
Procedures, Emergency, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
INDEX - 8
TM 9-6115-668-13
Subject Paragraph
Procedures, Operating, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
Pushbutton Switch and Indicator Assembly Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.44
Pushbutton Switch Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.45
R
Recommendation, Equipment Improvement, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
Records and Forms, Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Related Technical Manuals, ...................................................... 1.15
Relay K19 and K20 with Relay Socket and Contact Bushings Maintenance, . . . . . . . . . . . . 5.12
Repair Parts, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3, 5.3
Replace Bulb in Cabinet Light H7, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.28
Replace Bulb in Illuminated Meter, ................................................ 4.27
Replace Bulb in Panel Light H6, .................................................. 4.26
Resistor R100 to R102 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.65
S
Safety Device N3 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
Scavenge Pump Assembly Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.84
Scope, ........................................................................ 1.1
Service Switch Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.72
Service Upon Receipt of Materiel, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Shunt R11 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.73
Silencer Assembly, Left Side Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.82
Silencer Assembly, Right Side Maintenance, ....................................... 4.83
..................................................................
Special Tools, 4.2, 5.2
Speed Governor Assembly N1 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
Starter Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.90
Subcurrent Filter Assembly Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28
Subcurrent Filter Cartridge Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31
Subcurrent Filter Oil Lines Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29
Supply Air Duct Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
Support Equipment, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2, 5.2
Synchronous Generator Assembly, Lubrication, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
Synchronous Generator Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.51
Synchronous Generator Shock Absorbers Maintenance, ............................. 5.49
T
Technical Manuals, Related, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
INDEX - 9
TM 9-6115-668-13
Subject Paragraph
Test, Measurement, and Diagnostic Equipment, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2, 5.2
Thermistor Relay F12 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
Time Relay K3, K10, K13, K17, K25, K26 Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
Time Relay Maintenance, ........................................................ 5.20
Tools and Equipment
Common, .................................................................. 4.1, 5.1
Special, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2, 5.2
Transformer Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.60
Troubleshooting, Direct Support, General, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
Troubleshooting, Operator, General, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Troubleshooting, Unit, General, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
True Power Measuring Transformer P4A Maintenance, .............................. 4.64
Twist Grip and Lock Maintenance, ................................................ 4.20
Two Step Fuel Filter Assembly Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.41
Two Step Fuel Filter Cartridge Maintenance, ....................................... 4.33
U
Unit Hood - Base Frame Ground Strap Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
Unit Hood Assembly Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Unit Hood Flap Ground Strap Maintenance, ................................ 4.13
Unit PMCS, Table, Introduction to, ...................................... 4.8
Unusual Conditions, Operation Under
Engine Preheating Assembly, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
Extreme Cold, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
Flame Glowplug System, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
Upper Fuel Level Switch Maintenance, ...................................... 4.79
Voltage Adjust R3 Maintenance, .................................................. 4.53

Voltage Regulator N2 Maintenance, ............................................... 5.14
Voltage Selector Switch S11 Maintenance, .......................................... 4.49
INDEX - 10
DENNIS J. REIMER
General, United States Army
Official: Chief of Staff

Secretary of the Army
04898
Distribution:
To be distributed in accordance with the initial distribution number (IDN) 256400,

requirements for TM 9-6115-668-13
These are the instructions for sending an electronic 2028
The following format must be used if submitting an electronic 2028. The subject line must be exactly the
same and all fields must be included; however only the following fields are mandatory: 1, 3, 4, 5, 6, 7, 8,
9, 10, 13, 15, 16, 17, and 27.
From: “Whomever” <[email protected]>
To: [email protected]
Subject: DA Form 2028
1. From: Joe Smith
2. Unit: home
3. Address: 4300 Park
4. City: Hometown
5. St: MO
6. Zip: 77777
7. Date Sent: 19-OCT-93
8. Pub no: 5 5 - 2 8 4 0 - 2 2 9 - 2 3
9. Pub Title: TM
10. Publication Date: 04-JUL-85
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22. Reference: 6
23. Figure: 7
24. Table: 8
25. Item: 9
26. Total: 123
27. Text:
This is the text for the problem below line 27.
The Metric System and Equivalents
Linear Measure Liquid Measure
1 centimeter = 10 millimeters = .39 inch 1 centiliter = 10 milliliters = .34 fl. ounce
1 decimeter = 10 centimeters = 3.94 inches 1 deciliter = 10 centiliters = 3.38 fl. ounces
1 meter = 10 decimeters = 39.37 inches 1 liter = 10 deciliters = 33.81 fl. ounces
1 dekameter = 10 meters = 32.8 feet 1 dekaliter = 10 liters = 2.64 gallons
1 hectometer = 10 dekameters = 328.08 feet 1 hectoliter = 10 dekaliters = 26.42 gallons
1 kilometer = 10 hectometers = 3,280.8 feet 1 kiloliter = 10 hectoliters = 264.18 gallons
Weights Square Measure
1 centigram = 10 milligrams = .15 grain 1 sq. centimeter = 100 sq. millimeters = .155 sq. inch
1 decigram = 10 centigrams = 1.54 grains 1 sq. decimeter = 100 sq. centimeters = 15.5 sq. inches
1 gram = 10 decigrams = .035 ounce 1 sq. meter (centare) = 100 sq. decimeters = 10.76 sq. feet
1 dekagram = 10 gram = .35 ounce 1 sq. dekameter (are) = 100 sq. meters = 1,076.4 sq. feet
1 hectogram = 10 dekagrams = 3.52 ounces 1 sq. hectometer (hectare) = 100 sq. dekameters = 2.47 acres
1 kilogram = 10 hectograms = 2.2 pounds 1 sq. kilometer = 100 sq. hectometers = .386 sq. mile
1 quintal = 100 kilograms = 220.46 pounds
1 metric ton = 10 quintals = 1.1 short tons Cubic Measure
1 cu. centimeter = 1000 cu. millimeters = .06 cu. inch
1 cu. decimeter = 1000 cu. centimeters = 61.02 cu. inches
1 cu. meter = 1000 cu. decimeters = 35.31 feet
Approximate Conversion Factors

To change To Multiply by To change To Multiply by
inches centimeters 2.540 ounce-inches newton-meters .007062
feet meters .305 centimeters inches .394
yards meters .914 meters feet 3.280
miles kilometers 1.609 meters yards 1.094
square inches square centimeters 6.451 kilometers miles .621
square feet square meters .093 square centimeters square inches .155
square yards square meters .836 square meters square feet 10.764
square miles square kilometers 2.590 square meters square yards 1.196
acres square hectometers .405 square kilometers square miles .386
cubic feet cubic meters .028 square hectometers acres 2.471
cubic yards cubic meters .765 cubic meters cubic feet 35.315
fluid ounces milliliters 29.573 cubic meters cubic yards 1.308
pints liters .473 milliliters fluid ounces .034
quarts liters .946 liters pints 2.113
gallons liters 3.785 liters quarts 1.057
ounces grams 28.349 liters gallons .264
pounds kilograms .454 grams ounces .035
short tons metric tons .907 kilograms pounds 2.205
pound-feet newton-meters 1.356 metric tons short tons 1.102
pound-inches newton-meters .11296
Temperature (Exact)
°F Fahrenheit 5/9 (after Celsius °C
temperature subtracting 32) temperature
TM 9-6115-668-13
PIN: 074795-002
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What is the purpose of this technical manual?

What is the purpose of this technical manual?

What changes were made in Change No. 1 and Change No. 2?

What changes were made in Change No. 1 and Change No. 2?

TM 9-6115-668-13

SUPERSEDES TM 9-6116-668-13, 02 AUGUST 1996

OPERATOR, UNIT, AND DIRECT SUPPORT MAINTENANCE MANUAL

GENERATOR SET, DIESEL ENGINE DRIVEN,

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

HEADQUARTERS, DEPARTMENT OF THE ARMY

OPERATOR, UNIT, AND DIRECT SUPPORT MAINTENANCE MANUAL

GENERATOR SET, DIESEL ENGINE DRIVEN.

150 KW, 400 HZ, ALTERNATING CURRENT

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TM 9-6115-668-13, dated 01 June 1998, is changed as follows:

2. Retain this sheet in front of manual for reference purposes.

By Order of the Secretary of the Army:

OPERATOR, UNIT, AND DIRECT SUPPORT MAINTENANCE MANUAL

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

TM9-6115-668-13, dated 01 June 1998, is changed as follows:

Remove pages Insert pages

Remove pages Insert pages

2. Retain this sheet in front of manual for reference purposes.

By Order of the Secretary of the Army:

Official: ERIC K. SHINSEKI

To be distributed in accordance with the initial distribution number (IDN) 256400,

LIST OF EFFECTIVE PAGES

Dates of issue for original and changed pages are:

Original 01 Jun 1998 Change 1 20 Sep 1999

Cover................................0 4-42 and 4-44 ....................0

*Zero an this column indicates an original page.

5-3 ....................................0 5-227 and 5-228 ................1

*Zero in this column indicates an original page.

Dry cleaning solvent used to clean parts is potentially dangerous to per-

High voltage is produced when this Generator Set 150 kW is in operation.

Do not operate Generator Set 150 kW unless it is properly grounded and

Never attempt to disconnect control or power cables while Generator Set

l Potential 150 kW shock hazard with failure to adhere to this warning.

Always wear gloves when operating actuator. Failure to observe this

l Do not stand in the operating area of the crane or forklift.

To prevent personal injury, wear protective gloves when loosening nuts

Refer to FM 21-11 for first aid.

TECHNICAL MANUAL HEADQUARTERS

OPERATOR, UNIT, AND DIRECT SUPPORT MAINTENANCE MANUAL

GENERATOR SET, DIESEL ENGINE DRIVEN, SKID MOUNTED,

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

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

HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv

CHAPTER 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Section I. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Section II. Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Section III. Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

This manual supersedes TM 9-6115-668-13, 02 August 1996.

TABLE OF CONTENTS - continued

CHAPTER 2 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Section I. Description and Use of Controls and Indicators . . . . . . . . . . . . . . . . . . . . 2-2

Section III. Operation under Usual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Section IV. Operation under Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 63

CHAPTER 3 OPERATOR MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1