ARMY TM 9-6115-730-24

AIR FORCE TO 35C2-3-520-2

MARINE CORPS TM 11598A-OI
NAVAIR 19-50-29
TECHNICAL MANUAL
FIELD AND SUSTAINMENT MAINTENANCE
FOR
GENERATOR SET, SKID MOUNTED, TACTICAL QUIET
200 kW, 50/60 Hz, MEP-809A
NSN 6115-01-296-1462 (EIC: VK7)
GENERATOR SET, TRAILER MOUNTED, TACTICAL QUIET
200 kW, 50/60 Hz, PU-809A
NSN 6115-01-471-7085 (EIC: TBS)

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

NAVAIR STATEMENT - Published by Direction of Commander, Naval Air Systems Command

HEADQUARTERS, DEPARTMENT OF THE ARMY, AIR FORCE,

NAVY, AND HEADQUARTERS U.S. MARINE CORPS
1 OCTOBER 2006
PCN 184 115981 00
 TM 9-6115-730-24

WARNING SUMMARY
This warning summary contains general safety warnings and hazardous materials warnings that must be
understood and applied during operation and maintenance of this equipment. Failure to observe these
precautions could result in serious injury or death to personnel. Also included are explanations of safety
and hazardous material icons used within the technical manual.

FIRST AID

For first aid, refer to FM 4-25.11.

a
 TM 9-6115-730-24

WARNING SUMMARY - Continued

SAFETY AND HAZARDOUS MATERIAL

This manual describes physical and chemical processes that may require the use of chemicals, solvents, paints,
or other commercially available material. Users of the manual should obtain the material safety data sheets
(Occupational Safety and Health Act (OSHA) Form 20 or equivalent) from the manufacturers or suppliers of
materials to be used. Users must be completely familiar with manufacturer/supplier information and adhere to
their procedures, recommendations, warnings, and cautions for safe use, handling, storage, and disposal of these
materials.

EXPLANATION OF SAFETY WARNING ICONS

ELECTRICAL - electrical wire to hand with electricity symbol running through hand
shows that shock hazard exists.

HOT AREA - hand over object radiating heat shows that part or area is hot and can
burn.

EAR PROTECTION - headphones over ears shows that noise level will harm ears.

HEAVY OBJECT - human figure stooping over heavy object shows physical injury
potential from improper lifting technique or failure to share lifting task with other
persons.

HEAVY PARTS - hand with heavy object on top shows that heavy parts can crush and
harm if dropped.

HEAVY PARTS - foot with heavy object on top shows that heavy parts can crush and
harm if dropped

b
 TM 9-6115-730-24

WARNING SUMMARY - Continued

EXPLANATION OF SAFETY WARNING ICONS - Continued

MOVING PARTS - hand with figures caught between gears shows that the moving
parts of the equipment present a danger to life or limb.

SHARP OBJECT - pointed object in hand shows that a sharp object presents a danger
to limb.

HEAVY OBJECT - falling object shows that a heavy item can fall and crush.

EXPLOSION - flame and burst shows that material can explode if subjected to high
temperatures, sources of ignition, or high pressure.

EYE PROTECTION - human figure with goggles shows that material can injure eyes.

CRYOGENIC - hand in block of ice shows that the material is extremely cold and can
injure human skin or tissue.

c
 TM 9-6115-730-24

WARNING SUMMARY - Continued

GENERAL SAFETY WARNINGS DESCRIPTION

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

WARNING
DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

WARNING
High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

WARNING
High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

WARNING
High voltage is produced when the generator set is in operation. Never attempt to connect or
disconnect load cables while the generator set is running. Failure to comply can cause injury or
death to personnel.

WARNING
If necessary to move a generator set which has been operating in parallel with another generator
set, shut down both generator sets prior to removing load cables or ground. Failure to comply
can cause injury or death to personnel by electrocution.

WARNING
Before making any connections for parallel operation or moving generator set which has been
operating in parallel, ensure there is no input to the load output terminal board and the generator
sets are shut down. Failure to comply can cause injury or death to personnel by electrocution.

d
 TM 9-6115-730-24

WARNING SUMMARY - Continued

GENERAL SAFETY WARNINGS DESCRIPTION - Continued

WARNING
High voltage power is available when the main contactor is closed. Avoid accidental contact with
live components. Ensure load cables are properly connected and the load cable door is shut
before closing main contactor. Ensure load is turned off before closing main contactor. Ensure
that soldiers working with/on loads connected to the generator set are aware that main contactor
is about to be closed before closing main contactor. Failure to observe this warning can result in
severe personal injury or death by electrocution.

WARNING
A qualified technician must make the power connections and perform all continuity checks. The
power source may be a generator or commercial power. Failure to comply with this warning can
result in injury or death to personnel.

WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

WARNING
Slave receptacle (NATO connector) is electrically live at all times and is unfused. The Battery
Disconnect Switch does not remove power from the slave receptacle. NATO slave receptacle has
24 VDC even when Battery Disconnect Switch is set to OFF. This circuit is only dead when the
batteries are fully disconnected. Disconnect batteries before performing maintenance on the
slave receptacle. Failure to comply can cause injury or death to personnel.

WARNING
Ensure power is off before performing troubleshooting procedures. Failure to comply can cause
injury to personnel.

WARNING
A strong electrical shock hazard is present if the electrical power is not removed from the ECM.
The electronic unit injector system uses 90-120 volts.

WARNING
Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET. Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF.) Failure to comply can cause injury or death to personnel.

e
 TM 9-6115-730-24

WARNING SUMMARY - Continued

GENERAL SAFETY WARNINGS DESCRIPTION - Continued

WARNING
Lethal voltages up to 440 Vac are present on wiring any time the generator set is operating or
paralleled with other generator sets that are operating. Be very careful when working around these
wires and making measurements during troubleshooting. Failure to comply can cause serious
injury or death to personnel.

WARNING
High voltages may be present at the generator terminals when the unit is rotating. Tools,
equipment, clothing, and your body must be kept clear of rotating parts and electrical connections.
Special precautions must be taken during troubleshooting since protective covers and safety
devices may be removed or disabled to gain access and perform tests. Be extremely careful.
Failure to comply can cause serious injury or death to personnel.

WARNING
Dangerously high voltage can exist across current transformer (CT) output with engine running.
CT could explode if disconnected from load with engine running. Do not disconnect CT with
generator rotating. Failure to comply can cause serious injury or death to personnel.

WARNING
When disconnecting or removing batteries, disconnect the negative lead that connects directly
to the grounding stud first; disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply can cause serious injury
to personnel.

WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set, and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply can
cause injury or death to personnel.

WARNING
Exhaust system can get very hot. Shut down generator set, and allow system to cool before
performing checks, services and maintenance. Failure to comply can cause severe burns and
injury or death to personnel.

f
 TM 9-6115-730-24

WARNING SUMMARY - Continued

GENERAL SAFETY WARNINGS DESCRIPTION - Continued

WARNING
The muffler blanket heat insulation material can cause skin and eye irritation and deteriorate after
continued use. Avoid breathing and eye and skin contact with the insulation particles. Wear dust
mask, safety goggles, gloves and long sleeve clothes when working on muffler blanket. Failure to
comply can cause injury to personnel.

WARNING
Top housing panels can get very hot. Allow panels to cool down before performing maintenance.
Failure to comply can cause injury or death to personnel.

WARNING
When running, winterization heater has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow heater to cool before performing maintenance. Wear gloves and
additional protective clothing as required. Failure to comply can cause injury or death to
personnel.

WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
components have been heated. Wear additional protective clothing as required. Failure to comply
can cause injury to personnel.

WARNING
Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool
before performing checks, services, and maintenance. Failure to comply can cause injury or
death to personnel.

WARNING
In extreme cold weather, skin can stick to metal. Avoid contacting metal items with bare skin in
extreme cold weather. Failure to comply can cause injury or death to personnel.

WARNING
Operating the generator set exposes personnel to a high noise level. Hearing protection must be
worn when operating or working near the generator set when the generator set is running. Failure
to comply can cause hearing damage to personnel.

WARNING
Many components require a two-person lift. Lifting heavy components can cause back strain.
Ensure proper lifting techniques are used when lifting heavy components. Failure to comply can
cause injury to personnel.

g
 TM 9-6115-730-24

WARNING SUMMARY - Continued

GENERAL SAFETY WARNINGS DESCRIPTION - Continued

WARNING
Each battery weighs more than 70 pounds (32 kg) and requires a two-person lift. Lifting batteries
can cause back strain. Ensure proper lifting techniques are used when lifting batteries. Failure to
comply can cause injury to personnel.

WARNING
Flywheel weighs more than 125 pounds (57 kg) and requires a two-person lift. Lifting flywheel can
cause back strain. Ensure proper lifting techniques are used when lifting flywheel. Failure to
comply can cause injury to personnel.

WARNING
The generator set, engine, and generator are extremely heavy and require an assistant and a
lifting device (forklift, overhead lifting device) with sufficient capacity. Failure to comply can cause
serious injury or death to personnel.

WARNING
Be extremely careful when working near the generator set as it is being positioned on the trailer.
Failure to comply can cause injury to personnel.

WARNING
Support components when removing attaching hardware or component may fall. Failure to
comply can cause injury to personnel and equipment damage.

WARNING
Retaining rings and springs are under tension and can act as projectiles when being removed.
Use eye protection when removing retaining rings or springs. Failure to comply can cause injury
to personnel.

WARNING
Oil filter base and housing springs are under tension and can act as projectiles when being
removed. Use eye protection when removing springs. Failure to comply can cause injury to
personnel.

WARNING
Do not use the engine starter to turn the flywheel. Failure to comply can cause injury to personnel.

WARNING
Fan has sharp blades. Use caution and wear gloves when removing or installing belts. Failure to
comply can cause injury to personnel.

h
 TM 9-6115-730-24

WARNING SUMMARY - Continued

EXPLANATION OF HAZARDOUS MATERIALS ICONS

EYE PROTECTION - human figure with goggles shows that material can cause injury
to eyes.

CHEMICAL - drops of liquid on hand shows that material can cause burns or
irritation to human skin or tissue.

VAPOR - human figure in a cloud shows that material vapors present danger to life
or possible death.

FIRE - flames show that material is flammable.

EXPLOSION - flame and burst shows that material can explode if subjected to high
temperatures, sources of ignition, or high pressure.

RADIATOR - steam in face and body shows that escaping steam and hot water exist.

i
 TM 9-6115-730-24

WARNING SUMMARY - Continued

HAZARDOUS MATERIALS DESCRIPTION

WARNING
Batteries give off a flammable gas. Do not smoke or use open flame when performing mainten-
ance. Failure to comply can cause injury or death to personnel and equipment damage due to
flames and explosion.

WARNING
The connection of any electrical equipment and the disconnection of any electrical equipment
may cause an explosion hazard which may result in injury or death. Do not connect any electrical
equipment or disconnect any electrical equipment in an explosive atmosphere.

WARNING
Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Personnel are to wash exposed skin and change chemical soaked clothing
promptly if exposed to fuel. Failure to comply can cause injury or death to personnel.

WARNING
Cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protec-
tion are required when working in contact with cleaning solvent. Avoid repeated or prolonged
contact. Work in ventilated area only. Failure to comply can cause injury or death to personnel.

WARNING
Carbon removing compound is flammable and toxic to eyes, skin, and respiratory tract. Skin and
eye protection are required when working in contact with carbon removing compound. Avoid
repeated or prolonged contact. Work in ventilated area only. Failure to comply can cause injury or
death to personnel.

WARNING
Fuels used in the generator set are flammable. Do not smoke or use open flames when performing
maintenance. Failure to comply can result in flames and possible explosion and can cause injury
or death to personnel and damage to the generator set.

WARNING
Fuels used in the generator set are flammable. When filling the fuel tank, maintain metal-to-metal
contact between filler nozzle and fuel tank opening to eliminate static electrical discharge. Failure
to comply can result in flames and possible explosion and cause injury or death to personnel and
damage to the generator set.

j
 TM 9-6115-730-24

WARNING SUMMARY - Continued

HAZARDOUS MATERIALS DESCRIPTION - Continued

WARNING
Hot exhaust gases can ignite flammable materials. Allow room for safe discharge of hot gases and
sparks. Failure to comply can cause injury or death to personnel.

WARNING
High pressure steam can blow particles or chemicals into eyes, can cause severe burns, and
creates hazardous noise levels. Wear protective eye, skin, and hearing protection when using high
pressure steam. Failure to comply can cause serious injury to personnel.

WARNING
Eye protection is required when working with compressed air. Compressed air can propel
particles at high velocity and injure eyes. Do not exceed 15 psi pressure when using compressed
air. Failure to comply could cause serious injury to personnel.

WARNING
Cleaning compound is toxic. Avoid prolonged breathing of vapors. Use only in a well-ventilated
area. Failure to comply can cause serious injury to personnel.

WARNING
Breathing ether fumes can cause fainting. Do not manually discharge or deliberately inhale ether.
Failure to comply can cause injury to personnel.

WARNING
Avoid breathing fumes generated by soldering. Eye protection is required. Good general ventila-
tion is normally adequate. Failure to comply can cause injury to personnel.

WARNING
CARC paint is a health hazard, and is irritating to eyes, skin, and respiratory system. Wear
protective eyewear, mask, and gloves when applying or removing CARC paint. Failure to comply
can cause injury to personnel.

k
 TM 9-6115-730-24

WARNING SUMMARY - Continued

HAZARDOUS MATERIALS DESCRIPTION - Continued

WARNING

Exhaust discharge contains deadly gases including carbon monoxide. Do not operate generator
set in an enclosed area unless exhaust discharge is properly vented outside. Failure to comply
can cause injury or death to personnel.

Engine exhaust fumes contain deadly poisonous gases.

Severe exposure can cause death or permanent brain damage.

Exhaust gases are most dangerous in places with poor airflow. Best defense against exhaust
gas poisoning is very good airflow.

To protect yourself and your partners, always obey the following rules:

x DO NOT run engine indoors unless you have VERY GOOD AIRFLOW.

x DO NOT idle engine for a long time unless there is VERY GOOD AIRFLOW.

x Be alert at all times. Check for smell of exhaust fumes.

x REMEMBER: Best defense against exhaust gas poisoning is VERY GOOD AIRFLOW.

x Exhaust gas poisoning causes dizziness, headache, loss of muscle control, sleepiness,
coma, and death. If anyone shows signs of exhaust gas poisoning, get ALL PERSONNEL
clear of HMEE. Make sure they have lots of fresh air. KEEP THEM WARM, CALM, AND
INACTIVE. GET MEDICAL HELP. If anyone stops breathing, give artificial respiration. See
FM 4-25.11 for first aid.

l
 TM 9-6115-730-24

Change HEADQUARTERS
DEPARTMENTS OF THE ARMY,
N O. 1
AIR FORCE, NAVY and
HEADQUARTERS, U.S.
MARINE CORPS
Washington, DC, 31 July 2009
TECHNICAL MANUAL

FIELD AND SUSTAINMENT MAINTENANCE

FOR
GENERATOR SET, SKID MOUNTED, TACTICAL QUIET
200 kW, 50/60 Hz, MEP-809A
NSN 6115-01-296-1462 (EIC: VK7)
GENERATOR SET, TRAILER MOUNTED, TACTICAL QUIET
200 kW, 50/60 Hz, PU-809A
NSN 6115-01-471-7085 (EIC: TBS)

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

TM-9-6115-730-24, dated 1 October 2006, is updated as follows:

1. File this sheet in front of the manual for reference.

2. This change is the result of adding Engineering Change Proposals (ECPs)
3. New or updated text is indicated by a vertical bar in the outer margin of the page.
New or updated illustrations are indicated by a vertical bar in the outer margin of the page
or by a miniature pointing hand.
4. Remove old pages and insert new pages as indicated below:

Remove Pages Insert Pages

Cover/(Blank) Cover/(Blank)
A and B A and B
i through xii i through xii
Index 1 through 4 Index 1 through 4

5. Replace the following work packages with their revised version.

Work Package Number
WP 0002
WP 0014
WP 0032
WP 0041
WP 0042
WP 0045
WP 0047
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6. Add the following work packages.

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Distribution Statement A: Approved for public release; distribution is unlimited.

By Order of the Secretary of the Army:
al:
GEORGE W. CASEY JR.
General, United States Army
JOYCE E. MORROW
Chief of Staff
Administrative Assistant to the
Secretary of the Army
0921706

By Order of the Sec retary of the Air Force:

NORTO N A. S CHWARTZ
General, United States Air Force
Chief of Staff
Official:

DONALD J. HOF F MAN

General, United States Air Force
Commander, AFMC

By Order of the Secretary of the Navy:

WALTER H. C ANTRELL
Rear Admiral, United States Navy
Commander, Space and Naval Warfare
Systems Command

By Order of the Marine Corps:

G. W . TAY LO R
Product Group Director, PG-15
Ground Transportation Engineer S ystems
Marine Corps Systems Command

Army Distribution:

To be distributed in accordance with t he init ial distribution number (IDN) 256 917 requirements
for TM 9-6115-730 -24.

Marine Corps Distribution:

To be distributed in accordance with PCN 184 115981 00.

 TM 9-6115-730-24

LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE: Zero in the "Change No." - column indicates an original page or work package.

Dates of issue for the original manual are:

Original .. 0 .. 1 October 2006
Change .. 1 .. 31 July 2009
TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 64 AND TOTAL
NUMBER OF WORK PACKAGES IS 125, CONSISTING OF THE FOLLOWING:

Page/WP No. Change No. Page/WP No. Change No. Page/WP No. Change No.

Cover 1 WP 0036 (3 pages) 0 WP 0077 (3 pages) 0

Warning Summary (12 pgs) 0 WP 0037 (3 pages) 0 WP 0078 (3 pages) 0
Title page 1 WP 0038 (3 pages) 0 WP 0079 (4 pages) 0
LOEP (2 pages) 1 WP 0039 (2 pages) 0 WP 0080 (3 pages) 0
i - xii 1 WP 0040 (3 pages) 0 WP 0081 (3 pages) 0
Chp 1 title page (2 pages) 0 WP 0041 (11 pages) 1 WP 0082 (3 pages) 0
WP 0001 (9 pages) 0 WP 0042 (13 pages) 1 WP 0083 (27 pages) 1
WP 0002 (12 pages) 1 WP 0043 (3 pages) 0 WP 0084 (3 pages) 0
WP 0003 (32 pages) 0 WP 0044 (2 pages) 0 WP 0085 (4 pages) 0
Chp 2 title page 0 WP 0045 (3 pages) 1 WP 0086 (1 pages) 0
WP 0004 (10 pages) 0 WP 0046 (5 pages) 0 WP 0087 (4 pages) 0
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WP 0006 (5 pages) 0 WP 0048 (4 pages) 0 Chp 4 title page 0
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WP 0010 (13 pages) 0 WP 0052 (5 pages) 0 WP 0092 (4 pages) 0
WP 0011 (61 pages) 0 WP 0053 (3 pages) 0 WP 0093 (3 pages) 0
WP 0012 (8 pages) 0 WP 0054 (4 pages) 1 Chp 5 title page 0
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WP 0014 (3 pages) 1 WP 0057 (8 pages) 1 WP 0096 (5 pages) 1
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WP 0033 (3 pages) 0 WP 0076 (3 pages) 0 WP 0115 (3 pages) 0
WP 0034 (5 pages) 0
WP 0035 (3 pages) 0

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Page/WP No. Change No. Page/WP No. Change No.

WP 0116 (3 pages) 0 FP-9 0

WP 0117 (3 pages) 0 FP-10 Blank 0
WP 0118 (3 pages) 0 FP-11 0
WP 0119 (9 pages) 0 FP-12 Blank 0
WP 0120 (5 pages) 0 FP-13 0
Chp 6 title page 0 FP-14 Blank 0
Chp 7 title page 1 FP-15 0
WP 0121 (3 pages) 0 FP-16 Blank 0
WP 0122 (4 pages) 0 FP-17 0
WP 0123 (7 pages) 0 FP-18 Blank 0
WP 0124 (5 pages) 0 FP-19 0
WP 0125 (32 pgs) Added..1 FP-20 Blank 0
Glossary-1 0 FP-21 0
Glossary-2 0 FP-22 Blank 0
Index-1 0 FP-23 0
Index-2 0 FP-24 Blank 0
Index-3 1 FP-25 0
Index-4 0 FP-26 Blank 0
FP-1 0 FP-27 0
FP-2 Blank 0 FP-28 Blank 0
FP-3 0 FP-29 0
FP-4 Blank 0 FP-30 Blank 0
FP-5 0 The Metric System
FP-6 Blank 0 And Equivalent 0
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B
 ARMY TM 9-6115-730-24
AIR FORCE TO 35C2-3-520-2
MARINE CORPS TM 11598A-OI
NAVAIR 19-50-29
__________________________________________________________________________________________
HEADQUARTERS,
DEPARTMENTS OF THE
ARMY, AIR FORCE, NAVY, AND
HEADQUARTERS, U.S. MARINE CORPS
Washington, D.C., 1 OCTOBER 2006
TECHNICAL MANUAL

FIELD AND SUSTAINMENT MAINTENANCE

FOR
GENERATOR SET, SKID MOUNTED, TACTICAL QUIET
200 kW, 50/60 Hz, MEP-809A
NSN 6115-01-296-1462 (EIC:VK7)

GENERATOR SET, TRAILER MOUNTED, TACTICAL QUIET

200 kW, 50/60 Hz, PU-809A
NSN 6115-01-471-7085 (EIC:TBS)

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 the
procedures, please let us know. Reports, as applicable by the requiring Service, should be submitted as
follows:

(a) (A) Army - Mail your letter or DA Form 2028 (Recommended Changes to Publications and
Blank Forms) located in the back of this manual, directly to: Commander, U.S. Army CECOM
Life Cycle Management Command (LCMC) and Fort Monmouth,
ATTN: AMSEL-LC-LEO-E-CM, Fort Monmouth, NJ 07703-5006. You may also send in your
recommended changes via electronic mail or by fax. Our fax number is 732-532-1556, DSN
992-1556. Our e-mail address is MONM-AMSELLEOPUBSCHG@conus.army.mil. Our online
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(b) (MC) Marine Corps - Submit notice of discrepancies or suggest changes on a NAVMC 10772.
The NAVMC may be submitted via the Internet using website https://www.ala.usmc.mil, click
on Publications, Technical Publications, follow the instructions, and then click on NAVMC
10772. It may also be submitted by electronic mail to smb.log.tech.pubs.fct@usmc.mil, or by
mailing a paper copy NAVMC 10772 in an envelope addressed to Commander, Marine Corps
Systems Command, ATTN: Assistant Commander Acquisition and Logistics (AC LCL/TP),
814 Radford Blvd, Suite 20343, Albany, Georgia 31704-0343. In addition, forward an
information copy to the Project Officer at the following address: Commander, Marine Corps
Systems Command (GTES-EPS), 2200 Lester Street, Quantico, VA 22134-6050.

(c) (N) Navy - By letter directly to Commander, Space and Naval Warfare Systems Command,
ATTN: SPAWAR 8122, Washington, DC 20363-5100.

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directly to prime ALC/MST.
A reply will be furnished to you.

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

i Change 1
 TM 9-6115-730-24

TABLE OF CONTENTS
WP Sequence No.
Page No.

Warning Summary
How to Use This Manual

CHAPTER 1 - General Information, Equipment Description, and Theory of Operation

General Information.................................................................................................................... WP 0001
Table 1. Manufacturer’s Warranties for 200 kW Generator Set ............. 0001-4
Equipment Description and Data ............................................................................................... WP 0002
Figure 1. 200 kW Tactical Quiet Generator Location of Components .... 0002-2
Table 1. 200 kW TQG Equipment Data .................................................. 0002-10
Theory of Operation ................................................................................................................... WP 0003
Figure 1. Engine Starting System ........................................................... 0003-4
Figure 2. Fuel System ............................................................................. 0003-5
Figure 3. Fuel Supply and Injection ........................................................ 0003-7
Figure 4. Engine Cooling System ........................................................... 0003-9
Figure 5. Engine Lubrication System ...................................................... 0003-10
Figure 6. Air Inlet and Exhaust System................................................... 0003-11
Figure 7. AC Power Output ..................................................................... 0003-13
Figure 8. DC Power Distribution ............................................................. 0003-14
Figure 9. Generator Set Control.............................................................. 0003-22
Table 1. GSC Display Relay Identification .............................................. 0003-24
Figure 10. Digital Voltage Regulator ....................................................... 0003-25
Figure 11. DVR Startup Profile ............................................................... 0003-26
Figure 12. DVR Loading and Stopping Profile........................................ 0003-27
Figure 13. Generator............................................................................... 0003-30
Figure 14. Winterization Kit ..................................................................... 0003-31
CHAPTER 2 - Field Level Troubleshooting Procedures
Introduction ................................................................................................................................. WP 0004
Figure 1. Generator Set Control (GSC) Displays and Dedicated
Alarm Indicators.................................................................... 0004-3
Troubleshooting Index ............................................................................................................... WP 0005
GSC Alarm Indicators and Fault Code Troubleshooting Procedures......................................... WP 0006
SP Fault Code Troubleshooting Procedures.............................................................................. WP 0007
AL Fault Code Troubleshooting Procedures .............................................................................. WP 0008
GSC Fault Code Troubleshooting Procedures........................................................................... WP 0009
DVR Fault Code Troubleshooting Procedures ........................................................................... WP 0010
Failures Without a Fault Code Troubleshooting Procedures ..................................................... WP 0011
Figure 1. SMMS Relay Location ............................................................. 0011-2
Electronic Technician (ET) Troubleshooting Software Installation ............................................ WP 0012
Figure 1. Connecting Caterpillar Communication Adapter ..................... 0012-2
Figure 2. Caterpillar ET Opening Screen................................................ 0012-5
Table 1. Caterpillar ET Tool Navigation Icons ........................................ 0012-6
Figure 3. Cat ET Diagnostic Tests .......................................................... 0012-8

ii
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TABLE OF CONTENTS - Continued

WP Sequence No.
Page No.
CHAPTER 2 - Field Level Troubleshooting Procedures - Continued
Electronic Technician (ET) Troubleshooting Procedures........................................................... WP 0013
Figure 1. 24 Vdc Electrical Circuits ......................................................... 0013-4
Table 1. ECM Supply Voltage Test Points.............................................. 0013-6
Table 2. + Battery Voltage Input to ECM Test Points ............................. 0013-7
Figure 2. Engine Timing Circuit............................................................... 0013-8
Figure 3. Timing Sensors ........................................................................ 0013-10
Figure 4. Ether Injection System Circuit.................................................. 0013-12
Figure 5. Injector Solenoid Circuit........................................................... 0013-16
Table 3. Injector Solenoid Harness Terminals........................................ 0013-20
Figure 6. Speed Control Circuits............................................................. 0013-23
Table 4. Speed Control Circuit Test Points............................................. 0013-24
Table 5. Required Special Tools............................................................. 0013-28
Figure 7. Timing Calibration Plug............................................................ 0013-29
CHAPTER 3 - Unit (Field) Level Maintenance Instructions
Service Upon Receipt................................................................................................................. WP 0014
Figure 1. Reconnection Terminal Board Voltage Setting........................ 0014-3
PMCS Introduction................................................................................................................ WP 0015
PMCS, Including Lubrication Instructions ............................................................................. WP 0016
Table 1. Preventive Maintenance Checks and Services ........................ 0016-1
Table 2. PMCS Mandatory Replacement Parts List ............................... 0016-6
Table 3. Engine Oil.................................................................................. 0016-8
Table 4. Engine Coolant.......................................................................... 0016-8
Table 5. Fuel ........................................................................................... 0016-8
Table 6. Lubrication Requirements ......................................................... 0016-9
General Maintenance Instructions ......................................................................................... WP 0017
Right Battery Access Door Assembly Maintenance................................................................ WP 0018
Figure 1. Right Battery Access Door Assembly...................................... 0018-2
Left Battery Access Door Assembly Maintenance .................................................................. WP 0019
Figure 1. Left Battery Access Door Assembly ........................................ 0019-2
Control Box Door Assembly Maintenance.............................................................................. WP 0020
Figure 1. Control Box Door Assembly..................................................... 0020-3
Left Front Door Assembly (Latch) Maintenance ..................................................................... WP 0021
Figure 1. Left Front Door Assembly (Latch)............................................ 0021-2
Left Rear Door Assembly Maintenance...................................................................................... WP 0022
Figure 1. Left Rear Door Assembly......................................................... 0022-2
Left Rear Door Assembly (Latch) Maintenance ...................................................................... WP 0023
Figure 1. Left Rear Door Assembly (Latch) ............................................ 0023-2
Load Board Door Assembly Maintenance ................................................................................. WP 0024
Figure 1. Load Board Door Assembly..................................................... 0024-2
Right Front Door Assembly (Latch) Maintenance ..................................................................... WP 0025
Figure 1. Right Front Door Assembly (Latch) ......................................... 0025-2
Right Front Door Assembly Maintenance and Storage Box Assembly Maintenance ................ WP 0026
Figure 1. Right Front Door Assembly...................................................... 0026-2
Figure 2. Storage Box Assembly ............................................................ 0026-5
Right Rear Door Assembly Maintenance ................................................................................... WP 0027
Figure 1. Right Rear Door Assembly ...................................................... 0027-2

iii
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TABLE OF CONTENTS - Continued

WP Sequence No.
Page No.
CHAPTER 3 - Unit (Field) Level Maintenance Instructions - Continued
Right Rear Door Assembly (Latch) Maintenance ....................................................................... WP 0028
Figure 1. Right Rear Door Assembly (Latch) .......................................... 0028-2
Access Covers Maintenance ..................................................................................................... WP 0029
Figure 1. Access Covers ......................................................................... 0029-3
Front Roof Section Housing Assembly Maintenance ................................................................ WP 0030
Figure 1. Front Roof Section Housing Assembly.................................... 0030-3
Rear Roof Section Housing Assembly Maintenance ................................................................. WP 0031
Figure 1. Rear Roof Section Housing Assembly .................................... 0031-2
Engine Generator Compartment Ceiling Assembly Maintenance ............................................. WP 0032
Figure 1. Engine Generator Compartment Ceiling Assembly................. 0032-3
Generator Access Cover Assembly Maintenance ..................................................................... WP 0033
Figure 1. Generator Access Cover Assembly......................................... 0033-3
Front Section Housing Assembly Maintenance ......................................................................... WP 0034
Figure 1. Front Section Housing Assembly............................................. 0034-2
Rear Section Housing Assembly Maintenance ......................................................................... WP 0035
Figure 1. Rear Section Housing Assembly ............................................. 0035-2
Left Center Panel Assembly Maintenance ................................................................................. WP 0036
Figure 1. Left Center Panel Assembly .................................................... 0036-2
Right Center Panel Assembly Maintenance .............................................................................. WP 0037
Figure 1. Right Center Panel Assembly.................................................. 0037-2
Right Rear Panel Assembly Maintenance.................................................................................. WP 0038
Figure 1. Right Rear Panel Assembly..................................................... 0038-3
Left Rear Panel Assembly Maintenance ................................................................................... WP 0039
Figure 1. Left Rear Panel Assembly ....................................................... 0039-2
Door Support Assembly Maintenance ....................................................................................... WP 0040
Figure 1. Door Support Assembly........................................................... 0040-2
Control Box Panel Assembly Maintenance ............................................................................... WP 0041
Table 1. WP 0041 Guide ........................................................................ 0041-2
Figure 1. Control Box Panel Assembly ................................................... 0041-3
Control Box Assembly Maintenance........................................................................................... WP 0042
Figure 1. Control Box .............................................................................. 0042-2
Table 1. WP 0042 Guide ........................................................................ 0042-3
Figure 2. Control Box Assembly ............................................................. 0042-5
Resistor Assembly A7 Maintenance .......................................................................................... WP 0043
Figure 1. Resistor Assembly A7.............................................................. 0043-2
Control Box Harness Assembly Maintenance ........................................................................... WP 0044
Reconnection Terminal Board Assembly Maintenance ............................................................ WP 0045
Figure 1. Reconnection Terminal Board Assembly ................................ 0045-2
Load Terminal Board Assembly Maintenance ........................................................................... WP 0046
Figure 1. Load Terminal Board Assembly............................................... 0046-2
Battery Cable Assemblies Maintenance .................................................................................... WP 0047
Figure 1. Battery Cable Assemblies........................................................ 0047-3
Power Cable Assemblies Maintenance ..................................................................................... WP 0048
Figure 1. Power Cable Assemblies......................................................... 0048-2
Main Load Contactor Maintenance ............................................................................................ WP 0049
Figure 1. Main Load Contactor ............................................................... 0049-2
Batteries Maintenance ............................................................................................................... WP 0050
Figure 1. Batteries................................................................................... 0050-3

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TABLE OF CONTENTS - Continued

WP Sequence No.
Page No.
CHAPTER 3 - Unit (Field) Level Maintenance Instructions - Continued
Battery Disconnect Switch Maintenance ................................................................................... WP 0051
Figure 1. Battery Disconnect Switch ....................................................... 0051-3
Current Transformers Maintenance............................................................................................ WP 0052
Figure 1. Current Transformers .............................................................. 0052-3
Potential Transformer Maintenance .......................................................................................... WP 0053
Figure 1. Potential Transformer .............................................................. 0053-2
Slave Receptacle Maintenance ................................................................................................. WP 0054
Figure 1. Slave Receptacle ..................................................................... 0054-3
Electrical Installation Maintenance ............................................................................................ WP 0055
Table 1. WP 0055 Guide ........................................................................ 0055-2
Figure 1. Electrical Installation ................................................................ 0055-3
Fuel Level Switch Assembly Maintenance ................................................................................ WP 0056
Figure 1. Fuel Level Switch Assembly .................................................... 0056-2
Fuel Hoses Maintenance ........................................................................................................... WP 0057
Figure 1. Fuel Hoses............................................................................... 0057-3
Fuel Pickup Tube Assembly Maintenance ................................................................................ WP 0058
Figure 1. Fuel Pickup Tube Assembly .................................................... 0058-2
Auxiliary Fuel Pump Assembly Maintenance ............................................................................. WP 0059
Figure 1. Auxiliary Fuel Pump Assembly ................................................ 0059-3
Fuel Cooler Maintenance .......................................................................................................... WP 0060
Figure 1. Fuel Cooler .............................................................................. 0060-3
Water Separator Filter and Bracket Maintenance ..................................................................... WP 0061
Figure 1. Water Separator Filter and Bracket ......................................... 0061-3
Fuel Level Sender Maintenance ................................................................................................ WP 0062
Figure 1. Fuel Level Sender.................................................................... 0062-2
Fuel Tank Maintenance ............................................................................................................. WP 0063
Figure 1. Fuel Tank ................................................................................. 0063-3
Coolant Recovery System Maintenance ................................................................................... WP 0064
Figure 1. Coolant Recovery System ....................................................... 0064-3
Surge Tank Maintenance ........................................................................................................... WP 0065
Figure 1. Surge Tank .............................................................................. 0065-3
Fan and Fan Guards Maintenance............................................................................................. WP 0066
Table 1. WP 0066 Guide......................................................................... 0066-2
Figure 1. Fan and Fan Guards................................................................ 0066-3
Coolant Hose Assemblies Maintenance..................................................................................... WP 0067
Figure 1. Coolant Hose Assemblies........................................................ 0067-3
Radiator Assembly Maintenance ............................................................................................... WP 0068
Figure 1. Radiator Assembly................................................................... 0068-3
Exhaust System Maintenance ................................................................................................... WP 0069
Figure 1. Exhaust System ....................................................................... 0069-3
Crankcase Ventilation Filter Maintenance ................................................................................. WP 0070
Figure 1. Crankcase Ventilation Filter..................................................... 0070-3
Air Cleaner Filter Maintenance .................................................................................................. WP 0071
Figure 1. Air Cleaner Filter ...................................................................... 0071-3
Air Cleaner System Maintenance .............................................................................................. WP 0072
Figure 1. Air Cleaner System.................................................................. 0072-3

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TABLE OF CONTENTS - Continued

WP Sequence No.
Page No.
CHAPTER 3 - Unit (Field) Level Maintenance Instructions - Continued
Ether Injection Assembly Maintenance ...................................................................................... WP 0073
Figure 1. Ether Injection Assembly ......................................................... 0073-3
Alternator Maintenance ............................................................................................................. WP 0074
Figure 1. Alternator ................................................................................. 0074-3
Alternator Belt Maintenance ....................................................................................................... WP 0075
Figure 1. Alternator Belt .......................................................................... 0075-3
Starter Maintenance .................................................................................................................. WP 0076
Figure 1. Starter ...................................................................................... 0076-3
Tensioner Maintenance .............................................................................................................. WP 0077
Figure 1. Tensioner ................................................................................. 0077-3
Fuel Priming Pump Maintenance .............................................................................................. WP 0078
Figure 1. Fuel Priming Pump .................................................................. 0078-3
Oil Filter Maintenance and Oil Change ...................................................................................... WP 0079
Figure 1. Oil Filter Maintenance and Oil Change.................................... 0079-3
Fuel Filter Maintenance .............................................................................................................. WP 0080
Figure 1. Fuel Filter ................................................................................. 0080-2
Thermostat Maintenance............................................................................................................ WP 0081
Figure 1. Thermostat............................................................................... 0081-3
Engine Control Module Maintenance ........................................................................................ WP 0082
Figure 1. Engine Control Module ............................................................ 0082-3
Reprogramming ......................................................................................................................... WP 0083
Table 1. 200 kW TQG DVR Voltage and Frequency Programming
Parameter and Setpoints...................................................... 0083-1
Table 2. 200 kW TQG DVR Programming Parameters .......................... 0083-4
Table 3. 200 kW TQG GSC Programming Setpoints ............................. 0083-7
Table 4. 200 kW OP5-0 Engine/Generator Setpoint Programming........ 0083-11
Table 5. OP5-1 Protective Relaying Setpoint Programming................... 0083-16
Table 6. OP5-3 Synchronization Setpoint Programming ........................ 0083-22
Table 7. OP6 Spare Input/Output Setpoint Programming ...................... 0083-24
Table 8. OP8 Voltmeter Ammeter Programming .................................... 0083-27
Installation of Generator Set on Trailer ...................................................................................... WP 0084
Figure 1. Installation of Generator Set on Trailer.................................... 0084-2
Preparation for Storage or Shipment ......................................................................................... WP 0085
Figure 1. Preparation for Storage or Shipment....................................... 0085-3
Illustrated List of Manufactured Items......................................................................................... WP 0086
Table 1. Index of Manufactured Items .................................................... 0086-1
Torque Limits .............................................................................................................................. WP 0087
Figure 1. Measuring Screw ..................................................................... 0087-1
Figure 2. Capscrew Head Markings........................................................ 0087-1
Table 1. Standard Dry Torque Limits ...................................................... 0087-2
Table 2. Metric Dry Torque Limits........................................................... 0087-3

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TABLE OF CONTENTS - Continued

WP Sequence No.
Page No.
CHAPTER 3 - Unit (Field) Level Maintenance Instructions - Continued
Wire Lists ................................................................................................................................... WP 0088
Figure 1. Engine Sensors ....................................................................... 0088-6
Figure 2. Wire Harness Connectors........................................................ 0088-8
Table 1. Control Panel Wire List ............................................................. 0088-11
Table 2. Generator Set Harness (Generator, Engine, Control Panel)
Wire List................................................................................ 0088-33
Table 3. ECM to EMCP Harness Wire List ............................................. 0088-45
Table 4. Engine Harness Wire List ......................................................... 0088-51
Table 5. Engine Harness to Unit Injectors Wire List ............................... 0088-57
Table 6. Winterization Control Panel Wire List ....................................... 0088-59
Table 7. Winterization Kit Heater Cable Wire List................................... 0088-62
Table 8. Winterization Kit Power Cable Wire List ................................... 0088-64
CHAPTER 4 - Unit (Field) Level Maintenance Instructions Winterization Kit
Winterization Heater Control Box Assembly Maintenance ........................................................ WP 0089
Figure 1. Winterization Heater Control Box Assembly............................ 0089-2
Winterization Heater Assembly Maintenance ............................................................................ WP 0090
Figure 1. Winterization Heater Assembly................................................ 0090-3
Winterization Heater Hoses Maintenance ................................................................................. WP 0091
Figure 1. Winterization Heater Hoses ..................................................... 0091-3
Winterization Thermostat, Resistors, and Diode Maintenance ................................................. WP 0092
Figure 1. Winterization Thermostat, Resistors, and Diode ..................... 0092-3
Winterization Wiring Harnesses Maintenance ........................................................................... WP 0093
Figure 1. Winterization Wiring Harnesses............................................... 0093-2
CHAPTER 5 - Direct Support (Field) Level Maintenance Instructions
Generator Repair ....................................................................................................................... WP 0094
Figure 1. Generator ................................................................................ 0094-3
Generator Replacement ............................................................................................................. WP 0095
Figure 1. Generator................................................................................. 0095-3
Engine Replacement .................................................................................................................. WP 0096
Figure 1. Engine...................................................................................... 0096-3
Engine/Generator Base Assembly Repair ................................................................................. WP 0097
Engine Electrical System Repair ............................................................................................... WP 0098
Table 1. WP 0098 Guide......................................................................... 0098-2
Figure 1. Engine Electrical System Repair ............................................. 0098-3
Fan Pulley Maintenance ............................................................................................................ WP 0099
Figure 1. Fan Pulley ................................................................................ 0099-2
Valve Cover and Base Maintenance ......................................................................................... WP 0100
Figure 1. Valve Cover and Base ............................................................. 0100-3
Fuel Filter Base and Manifold Maintenance .............................................................................. WP 0101
Figure 1. Fuel Filter Base and Manifold .................................................. 0101-3
Fuel Transfer Pump Maintenance ............................................................................................. WP 0102
Figure 1. Fuel Transfer Pump ................................................................. 0102-2
Turbocharger Maintenance ....................................................................................................... WP 0103
Figure 1. Turbocharger ........................................................................... 0103-3
Crankshaft Vibration Damper and Pulley Maintenance ............................................................. WP 0104
Figure 1. Crankshaft Vibration Damper and Pulley ................................ 0104-3

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TABLE OF CONTENTS - Continued

WP Sequence No.
Page No.
CHAPTER 5 - Direct Support (Field) Level Maintenance Instructions - Continued
Crankshaft Front Seal Maintenance .......................................................................................... WP 0105
Figure 1. Crankshaft Front Seal.............................................................. 0105-3
Front Cover Maintenance .......................................................................................................... WP 0106
Figure 1. Front Cover .............................................................................. 0106-3
Oil Filter Base Maintenance ...................................................................................................... WP 0107
Figure 1. Oil Filter Base .......................................................................... 0107-3
Oil Cooler Maintenance ............................................................................................................. WP 0108
Figure 1. Oil Cooler ................................................................................. 0108-3
Oil Pump Maintenance .............................................................................................................. WP 0109
Figure 1. Oil Pump .................................................................................. 0109-2
Water Pump Maintenance ......................................................................................................... WP 0110
Figure 1. Water Pump ............................................................................. 0110-2
Flywheel Maintenance................................................................................................................ WP 0111
Figure 1. Flywheel................................................................................... 0111-3
Crankshaft Rear Seal Maintenance .......................................................................................... WP 0112
Figure 1. Crankshaft Rear Seal .............................................................. 0112-2
Flywheel Housing Maintenance.................................................................................................. WP 0113
Figure 1. Flywheel Housing .................................................................... 0113-3
Crankshaft Rear Seal Carrier Maintenance ............................................................................... WP 0114
Figure 1. Crankshaft Rear Seal Carrier .................................................. 0114-3
Exhaust Manifold Maintenance .................................................................................................. WP 0115
Figure 1. Exhaust Manifold ..................................................................... 0115-3
Inlet Manifold Maintenance......................................................................................................... WP 0116
Figure 1. Inlet Manifold............................................................................ 0116-3
Oil Pan Maintenance .................................................................................................................. WP 0117
Figure 1. Oil Pan ..................................................................................... 0117-3
Unit Injector Maintenance ...................................................................................................... WP 0118
Figure 1. Unit Injector.............................................................................. 0118-3
Rocker Shaft and Pushrod Maintenance................................................................................ WP 0119
Figure 1. Rocker Shaft and Pushrod Removal and Installation .............. 0119-3
Figure 2. Rocker Shaft Inspection........................................................... 0119-4
Figure 3. Valve Lash Check.................................................................... 0119-6
Table 1. Crankshaft Positions for Valve Lash Setting.............................. 0119-7
Table 2. Check for Valve Lash................................................................. 0119-7
Table 3. Valve Lash Settings ................................................................... 0119-8
Cylinder Head Maintenance .................................................................................................. WP 0120
Figure 1. Cylinder Head .......................................................................... 0120-3
CHAPTER 6 - General Support - Moved to Sustainment (NMWR)
CHAPTER 7 - Supporting Information
References............................................................................................................................ WP 0121
Maintenance Allocation Chart (MAC) Introduction.................................................................. WP 0122
Maintenance Allocation Chart (MAC) ..................................................................................... WP 0123
Table 1. MAC .......................................................................................... 0123-1
Table 2. Tools and Test Equipment Requirements ................................ 0123-5
Table 3. Remarks.................................................................................... 0123-6
Expendable and Durable Items List ....................................................................................... WP 0124
Table 1. Expendable and Durable Items List.......................................... 0124-1
Laminates............................................................................................................................... WP 0125

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TABLE OF CONTENTS - Continued

WP Sequence No.
Page No.
Foldout Figures
FO-1. 200 kW TQG Electrical Power Schematic Diagram ..................... FP-1
FO-2. 200 kW Engine Harnesses - Schematic Diagram ........................ FP-13
FO-3. Generator Set Wiring Diagram ..................................................... FP-17
FO-4. Control Box Wiring Diagram ......................................................... FP-21

Glossary

Index

ix
 TM 9-6115-730-24

HOW TO USE THIS MANUAL

This manual contains maintenance instructions for the 200 kW Tactical Quiet Generator (TQG) Skid-Mounted
MEP-809A and for the TQG, Trailer-Mounted PU-809A. The skid-mounted TQG can be mounted on a 5-ton trailer,
Model XM1061E1 and is designated PU-809A in that configuration. Detailed operation and maintenance for the trailer
can be found in TM 9-2330-376-14&P.

This maintenance manual is part of a family of manuals which includes an Operator’s Manual (TM 9-6115-730-10) and
a Repair Parts and Special Tools Lists (RPSTL) Manual (TM 9-6115-730-24P).

Refer to References work package WP 0121, located in Chapter 7, for a listing of other related manuals.

This manual implements the Army Maintenance Transformation and changes the Maintenance Allocation Chart (MAC)
to support Field and Sustainment Maintenance under the new two-level maintenance concept.

This manual is written in Work Package (WP) format.

Table of Contents: The table of contents will help you understand the organization of the manual. The overall table of
contents in the front of the manual directs you to the Chapters and lists all of the work packages in the manual with
tables and figures identified for each work package. The chapters contain descriptive information, maintenance
procedures organized by maintenance level, and supporting data. Each chapter contains its own chapter index
that lists all the work packages within the chapter to help you find information. Each chapter is divided into work
packages with titles that describe the information or procedure in the work package. An alphabetical index at the end of
the manual can also be used to find work packages.
NOTE
The generator end of the TQG is referred to as the REAR of the TQG. The control panel is also
located on the generator end (REAR) of the TQG. Figure 1 (Sheets 1-6) in WP 0002 shows where
TQG components are located.

GENERAL INFORMATION AND EQUIPMENT DATA WORK PACKAGES

Chapter 1 contains general information work packages including required maintenance forms, records, and reports;
safety, care, and handling information and directions for finding warranty information. General information includes a
list of abbreviations and acronyms. Other WPs in the chapter describe the equipment, and include location of major
components, theory of operation, and equipment data.

FIELD LEVEL TROUBLESHOOTING WORK PACKAGES

Chapter 2 Field Level Troubleshooting Work Packages contains Field Level Troubleshooting work packages.

The TQG features electronic troubleshooting that allows you to diagnose problems with the engine and generator by
using special indicators and code readouts displayed on the Electronic Modular Control Panel (EMCP).

Before you begin troubleshooting, read the introduction to troubleshooting WP 0004 carefully and familiarize yourself
with the operation and meaning of the codes and indicators. You should also use the Operator Manual,
TM 9-6115-730-10, so you know how controls and indicators work.

WP 0004 contains an overview of the troubleshooting that tells how the Generator Set Control (GSC) indicator lights
and Alarm Module lights work and describes the use of Component Identification (CID) codes and Failure Mode
Identifier (FMI). It contains directions for viewing the fault log of recorded controller and engine control module (ECM)
faults and engine event codes. The WP also explains the use of the Digital Voltage Regulator (DVR) failure codes
and indicators.

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 TM 9-6115-730-24

HOW TO USE THIS MANUAL - Continued

WP 0005 contains a Field level troubleshooting index. This index is followed by the troubleshooting procedures in a
series of related WPs.

WP 0006 contains troubleshooting procedures to be followed for dedicated GSC shutdown indicator lights.

WP 0007 contains troubleshooting procedures for SP Fault Codes.

WP 0008 contains troubleshooting procedures for AL Fault Codes.

WP 0009 contains troubleshooting procedures for GSC Fault Codes based on generator set and engine monitoring
electronics for identify operating problems. These procedures contain all the CID FMI fault code combinations that
you will see displayed on the GSC display and directs you to the appropriate fault isolation procedure.

WP 0010 contains troubleshooting procedures DVR Fault Codes.

WP 0011 contains troubleshooting for generator set failures without fault codes.

WP 0012 tells you how to prepare the TQG for use with the Maintenance Support Device (MSD), if available, for using
Caterpillar Electronics Technician (Cat ET) engine diagnostic software. A laptop or SPORT running with MS Windows
2000 or higher can also be used. The WP describes how to load all software required for proper operation of
diagnostics software on your computer in a logical sequence. This includes the software for Caterpillar
Communications Adapter II that you must preload on your computer before using the diagnostics software. It also
includes instructions for loading the ET software and other necessary instructions or documentation onto your
computer.

WP 0012 also contains instructions required for obtaining software license for the Cat ET tool and maintaining the
assigned registration number for the ET tool license. It also includes instructions for loading the ET software and
other necessary documentation onto your computer.

WP 0013 contains troubleshooting procedures using the Cat ET tool for Field level troubleshooting.

Before using the MSD and the Cat ET, software for Caterpillar Communication Adapter II should also be preloaded as
described in WP 0012. Refer to Caterpillar Service Tool Hardware and Software/User’s Manual Communication
Adapter II, Ver 1.93 (1.9-B4) and CD NEHS0758.

UNIT (FIELD) LEVEL MAINTENANCE WORK PACKAGES

Chapter 3 Unit (Field) Level Maintenance Instructions contains Unit (Field) Level Maintenance Instructions work
packages for the Generator Set.

Read the INITIAL SETUP section of each maintenance work package carefully before you start any maintenance
procedure. Get the tools and supplies listed and the personnel needed.

Chapter 4 Unit (Field) Level Troubleshooting Work Packages for Winterization Kit contains Unit (Field) Level
Troubleshooting work packages for the optional winterization kit installation.

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HOW TO USE THIS MANUAL - Continued

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE WORK PACKAGES

Chapter 5 Direct Support (Field) Level Maintenance Instructions contains Direct Support (Field) Level
Maintenance Instructions work packages for the Generator Set.

Read the INITIAL SETUP section of each maintenance work package carefully before you start any maintenance
procedure. Get the tools and supplies listed and the personnel needed.

Chapter 6 General Support Level Maintenance Instructions. These instructions have been moved to Sustainment
(NMWR) in accordance with Implementation of Two Level Maintenance.

Chapter 7 contains Supporting Information, including References WP, Introduction and Two-Level MAC work
packages, Expendable and Durable Items List WP, Tool Identification List WP, Mandatory Replacement Parts WP,
and any additional support items WPs.

Rear Matter. At the rear of your manual, you will find a Glossary, Alphabetical Index, Foldout schematics, DA Form
2028s.

While performing the procedures in this manual, you may find that you are able to make suggestions that will improve
the manual. At the back of this manual, you will find copies of DA Form 2028 that invite you to submit your
suggestions.

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
TITLE
CRANKSHAFT VIBRATION DAMPER AND PULLEY MAINTENANCE
TOOLS AND INITIAL SETUP:
SPECIAL TOOLS
Tools and Special Tools Personnel Required PERSONNEL
Tool Kit, General Mechanic’s One
(WP 0123, Item 5)
REQUIRED
References
Materials/Parts TM 9-6115-730-10 REFERENCES
MATERIALS/ Marker tag
PARTS (WP 0124, Item 6) Equipment Condition
Drive belt removed (WP 0068)
EQUIPMENT
CONDITION

LEGEND:

TITLE The name of the procedure.

TOOLS AND SPECIAL TOOLS The tools and equipment needed to do the procedures.

MATERIALS/PARTS The supplies and parts needed to do the procedures.

PERSONNEL REQUIRED The personnel needed to do the procedures.

REFERENCES Other work packages, manuals, and publications needed to do the procedure.

EQUIPMENT CONDITION Special equipment condition(s) or procedures to be performed before starting the
procedure.

xii
 TM 9-6115-730-24

CHAPTER 1

GENERAL INFORMATION, EQUIPMENT

DESCRIPTION AND THEORY OF OPERATION
 TM 9-6115-730-24

CHAPTER 1

FIELD AND SUSTAINMENT MAINTENANCE

GENERAL INFORMATION, EQUIPMENT DESCRIPTION AND THEORY OF OPERATION

WORK PACKAGE INDEX

Title WP Sequence No.

GENERAL INFORMATION ..................................................................................................................... 0001

EQUIPMENT DESCRIPTION AND DATA .................................................................................................. 0002
THEORY OF OPERATION ......................................................................................................................... 0003
 TM 9-6115-730-24 0001

FIELD AND SUSTAINMENT MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
GENERAL INFORMATION

SCOPE

This technical manual (TM) contains instructions for Unit and Direct Support (Field), General Support
(Sustainment), Preventive Maintenance Checks and Service (PMCS), maintenance, checks and adjustments,
theory of operation, troubleshooting, and corrective maintenance for the 200 kW Tactical Quiet Generator Set,
MEP-809A and PU-809A.

Type of Manual: Field and Sustainment Maintenance.

Model Number and Equipment Name: Generator Set, Tactical Quiet, Skid Mounted, 200 kW, 50/60 Hz, MEP-809A.

Purpose of Equipment: The 200 kW TQG provides 120/208 Vac or 240/416 Vac, 50/60 Hz, 3-phase power for a
wide variety of military applications, offering the mobility and operational characteristics demanded by modern
armed forces. Operational characteristics include the ability to operate at all possible humidity levels, at ambient
temperature levels from -25°F to +120°F (-32°C to +49°C) down to -50°F (-46°C) with winterization kit, and at
altitudes up to 10,000 feet.

CONSOLIDATED INDEX OF ARMY PUBLICATIONS AND BLANK FORMS

Refer to the latest issue of DA PAM 25-30 to determine whether there are new additions, changes, or additional
publications pertaining to the equipment.

MAINTENANCE FORMS, RECORDS, AND REPORTS

a. Army Reports of Maintenance and Unsatisfactory Equipment. Department of the Army forms and procedures
used for equipment maintenance will be those prescribed by DA PAM 738-750, as contained in the current
Maintenance Management Update (The Army Maintenance Management System (TAMMS). Fill out and
forward to the TAMMS clerk, DD Form 5988-E, automated form in the Unit Level Logistics System (ULLS),
generated Equipment Maintenance and Inspection Worksheet.

Air Force Personnel will use AFR 66-1 for maintenance reporting and TO 00-35D-54 for unsatisfactory
equipment reporting.

b. Reporting of Item and Packaging Discrepancies. Army and Air Force users fill out and forward SF 364
(Supply Discrepancy Report (SDR)) as prescribed in AR 735-11-2/DLAR 4140.55/SECNAVINST
4355.18/AFR 400-54/MCO 4430.3J.

c. Transportation Discrepancy Report (TDR) (SF 361). Army users fill out and forward Transportation Discrep-
ancy Report (TDR) (SF 361) as prescribed in AR 55-38/NAVSUPINST 4610.33C/AFR 75-18/MCO
P4610.19D/DLAR 4500.15.

0001-1
 TM 9-6115-730-24 0001

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

If your 200 kW Tactical Quiet Generator Set needs improvement, let us know. Send us an EIR. You, the user, are
the only one who can tell us what you don't like about your equipment. Let us know why you don't like the design
or performance. Put it on an SF Form 368, Product Quality Deficiency Report (PQDR). EIRs should be mailed
directly to:
Commander
U.S. Army Communications and Electronics Life Cycle Management Command
ATTN: AMSEL-LC-LEO-D-E-ED
Fort Monmouth, New Jersey 07703-5000

EQUIPMENT DEFICIENCY REPORTING

USAF Deficiency Reporting and Investigating System, TO 00-35D-54, Appendix A procedures will be used for
electronic submission. Submit mailed SF 368 forms to:

Warner-Robins AFB
WRALC/LGMTC
375 Perry Street
Robins, AFB GA 31098-1865

A reply will be furnished to you.

CORROSION PREVENTION AND CONTROL (CPC)

CPC of materiel is a continuing concern. It is important that any corrosion problems with this item be reported so
that the problem can be corrected and improvements can be made to prevent the problem in future systems.
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 Deficiency Report. Use of key words such as “corrosion,” “rust,” “deterioration,” or “cracking” will ensure
that the information is identified as a CPC problem. The form should be submitted to the address specified in DA
PAM 738-750. Air Force personnel will use TO 25-1-3.

DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE

Refer to TM 750-244-2 for demolition procedures when equipment destruction is required.

PREPARATION FOR STORAGE OR SHIPMENT

Requirements for packaging and administrative storage are contained in TM 9-6115-730-10. Requirements for
short and long term storage are in WP 0085.

0001-2
 TM 9-6115-730-24 0001

WARRANTY INFORMATION

This section provides information of manufacturer’s warranties for generator set components.
See Table 1 for list of warranted components (this work package).

NOTE
Check the Insp Date on the end-item data plate on the generator set. If the Insp Date is prior to
09/06, the (12) month Warranty period shall begin on 08/31/06.

If the Insp Date on the data plate is 09/06 or after, the standard (12) month Warranty begins on
the date stamped.

Warranty service may be obtained through two methods.

1. a. (ARMY ONLY) Fill out the preferred warranty claim SF 368, Product Quality Deficiency Report, or fill out a
warranty claim per DA PAM 738-750. The DA Form 2407, Maintenance Request, is also acceptable. Mail
completed form to Commander, US Army, Communications-Electronics Command, ATTN: AMSEL-LC-CCS-
G-GN, 1200 Nealis Avenue, Fort Monmouth, New Jersey 07703-5043. At a minimum, the end item NSN,
serial number, and date of shipment to the government, and the defective component part number/CAGE
must be included in the documentation.

b. (OTHER SERVICES) TBD

2. Warranty service can be obtained by contacting the actual warranted component manufacturer listed in
column 1. Each manufacturer will provide instructions on filing the claim.

3. Troubleshooting should be performed to the level of warranted component, but no further unless directed by
the warranted component manufacturer. Troubleshooting to the failed part inside warranted components may
invalidate the warranty.

4. There are some components with short warranty periods that may not be listed in Table 1. Warranty
coverage may be available for these components. Submit warranty claims in accordance with DA PAM 738-
750 to determine if the components are covered.

5. If you have difficulty with or questions about the warranty process, contact your local CECOM LAR or the
CECOM Generator Branch, DSN 992-1313, (732) 532-1313.

0001-3
 TM 9-6115-730-24 0001

MANUFACTURER WARRANTY INFORMATION

Column (1)  MANUFACTURER. This column gives you the name and address of the manufacturer of a
component under warranty. Telephone numbers, fax numbers, and internet addresses are listed where available.
Column (2)  COMPONENT UNDER WARRANTY. This column describes the component under warranty with
part number (PN) and vendor part number VPN where available.
Column (3) WARRANTY PERIOD. This column lists the length of the warranty period.

Table 1. Manufacturer’s Warranties for 200 kW Generator Set.

(1) (2) (3)

WARRANTY
MANUFACTURER COMPONENT UNDER WARRANTY PERIOD
Caterpillar, Inc Diesel Engine 12 Months
Defense Products Engine Service (PN: 0116-2110, VPN: 212-3802)
Engineer
PO Box 470 Digital Control System Components
Mossville, IL 61552-0470
GSC+P Controller
Phone: 309-578-4562 (PN: 0116-1201-41, VPN: 198-9253)
Fax: 309-578-3739
Alarm Module
CAGE: 11083 (PN: 0116-1201-34, VPN: 130-3324)

Caterpillar, Inc. – Continued Digital Voltage Regulator

(PN: 0116-1201-37, VPN: 155-3832)
Warranty repairs can also be
obtained through any Caterpillar
Load Sharing Module
dealer. Nearest dealer can be
(PN: 0116-1201-39, VPN: 161-0797)
located at www.cat.com
Transformer
(PN: 0116-1201-32, VPN: 118-0175)

Transformer
(PN: 0116-1201-40, VPN: 169-4701)

Harness Assembly
(PN: 0116-1201-43, VPN: 212-8737)

Marathon Electric Generator 12 months from date

P.O. Box 8003 (PN: 0116-2120, VPN: 571PSL4800) of startup or 18
Wausau, WI 54402-8003 months from date of
shipment whichever
Phone: 715-675-8237 period shall expire
first.

0001-4
 TM 9-6115-730-24 0001

Table 1. Manufacturer’s Warranties for 200 kW Generator Set - Continued.

(1) (2) (3)

WARRANTY
MANUFACTURER COMPONENT UNDER WARRANTY PERIOD
Signal Transformer Transformer 1250 VA 12 Months
500 Bayview Avenue (PN: 0116-1257, VPN: HP1-12)
Inwood, NY 11096-1792

Phone: 516-239-5777

Derema Group Switch, Battery Disconnect 12 Months

46 Acorn Drive (PN: 0116-1298, VPN: 2304-A)
Westbrook, CT 06498

Phone 860-399-5669

Madison Company Fuel Level Switch 12 Months

27 Business Park Drive (PN: 0116-2304, VPN: M3863 )
Branford, CT 06405

Phone: 203-488-4477

Technology Research Co Relay, Overload/Short Circuit 12 Months

140th Avenue North (PN: 0116-1219, VPN: 19970)
Clearwater, FL 33760

Phone: 727-535-0572
Rwood@TRCI.net

G & O Manufacturing Co. Radiator Assembly 18 months from

100 Gando Drive (PN: 0116-2400, VPN: X6635-00-50) shipment or 12
New Haven, CT 60513 months in service

Phone: 601-366-1423

Parker Hannifin Corporation Filter, Crankcase Ventilation 12 Months

Racor Division (PN: 0116-1607-02, VPN: CCV6000-08L)

Phone: 209-575-7651
hbrizuela@parker.com

Donaldson Company, Inc. Muffler, Exhaust 36 Months

Minneapolis, MN 55440-1299 (PN: 0116-2500, VPN: WOM12-0744)

Phone: 800-374-1374 Air Cleaner Assembly 12 Months

www.donaldson-filters.com (PN: 0116-2600, VPN: FVG16-0587)

0001-5
 TM 9-6115-730-24 0001

NOMENCLATURE CROSS REFERENCE LIST

See TM 9-6115-730-24 for nomenclature for common names listed alphabetically with a cross-reference to the
official nomenclature (i.e., Maintenance Allocation Chart (MAC), Repair Parts and Special Tools Lists (RPSTL)).

Common Name Official Nomenclature

200 kW TQG Generator Set, Skid Mounted Tactical Quiet, 200 kW, 50/60 Hz,
MEP-809A

Generator Set, Trailer Mounted, Tactical Quiet, 200 kW,

50/60 Hz, PU-809A

LIST OF ABBREVIATIONS AND ACRONYMS

Abbreviation/Acronym Definition
AAL Additional Authorization List
AC Alternating Current
AFPV Auxiliary Fuel Pump Solenoid Valve
AFPS Auxiliary Fuel Pump Switch
AGM Absorbed Glass Mat
ASR Air Shut Off Relay
ATB AC Transformer Box
BAT Battery
BDS Battery Disconnect Switch
BII Basic Issue Items
BIT Built-in-Test
BRT Brightness
BLK Black
BSS Battle Short Switch
BTB Bus Transformer Box
CAGE Commercial and Government Entity
CBR Chemical, Biological, and Radiological
CCA Circuit Card Assembly
CCM Customer Communication Module
CCS Contractor Control Switch
CCW Counterclockwise
CDR Cool Down Relay
CID Component Identifier
COEI Components of End Item
CPU Computer Processing Unit
CRFF Diode Field Flash
CT Current Transformer

0001-6
 TM 9-6115-730-24 0001

LIST OF ABBREVIATIONS AND ACRONYMS - Continued

Abbreviation/Acronym Definition

CTA Common Table of Allowances

CTR Crank Termination Relay
CW Clockwise
DBHI Dead Bus Relay High Sensing
DBLO Dead Bus Relay Low Sensing
DC Direct Current
DCS Dead Crank Switch
DESCP Description
DVR Digital Voltage Regulator
ECM Engine Control Module
ECS Engine Control Switch
EGR Electronic Governor Relay
EMCP Electronic Modular Control Panel
EMI Electromagnetic Interference
ESD Electrostatic Discharge
ESPB Emergency Stop Pushbutton
UI Electronic Unit Injector
FCR Fuel Control Relay
FMI Failure Mode Indicator
GFCI Ground Fault Circuit Interrupter
GFE Government Furnished Equipment
GFR Generator Fault Relay
GND Ground
GSC Generator Set Control
IETM Interactive Electronic Technical Manual
KFF Relay Field Flash
kPa Kilo Pascal
KR Main Contactor Relay
kVa Kilovolt-ampere
KVAR Kilovolt-ampere-reactive
KVARHr Kilovolt-ampere-reactive hour
kW Kilowatt
kWh Kilowatt hour
JTA Joint Table of Allowances
LCD Liquid Crystal Display
LED Light Emitting Diode

0001-7
 TM 9-6115-730-24 0001

LIST OF ABBREVIATIONS AND ACRONYMS - Continued

Abbreviation/Acronym Definition

LSM Load Sharing Module

MAC Maintenance Allocation Chart
MSD Maintenance Support Device
MTOE Modified Table of Organization and Equipment
NATO North Atlantic Treaty Organization
NBC Nuclear, Biological, and Chemical
NSN National Stock Number
OL/SC Overload and Short Circuit Module
OSHA Occupational Safety and Health Act
PAR Paralleling Relay
PF Power Factor
PMCS Preventive Maintenance Checks and Services
PN Part Number
PQDR Product Quality Deficiency Report
PRMTR Parameter
PSR Programmable Spare Relay
PW Pulse Width
PWM Pulse Width Modulation
RPSTL Repair Parts and Special Tools Lists
RR GSC Run Relay
SCR Silicon Controlled Rectifier
SDR Supply Discrepancy Report
SMMS Starter Motor Magnetic Switch
SMR Starter Motor Relay
SMS Sync Mode Switch
SP Spare Input
SR Slave Receptacle
SRY Slave Relay
SSP Speed Setting Potentiometer
TAMMS The Army Maintenance Management System
TDA Table of Distribution and Allowances
TDC Top Dead Center
TDR Transportation Discrepancy Report
TM Technical Manual
TMDE Test, Measurement, and Diagnostic Equipment
TPI Threads per Inch

0001-8
 TM 9-6115-730-24 0001

LIST OF ABBREVIATIONS AND ACRONYMS - Continued

Abbreviation/Acronym Definition

TQG Tactical Quiet Generator

ULLS Unit Level Logistics System
U/M Unit of Measure
Vac Volts Alternating Current
Vdc Volts Direct Current

SAFETY, CARE, AND HANDLING INFORMATION

The TQG contains no radioactive components or parts or radioactive material requiring special handling or
consideration. The TQG contains no electronic modules or components requiring special handling to protect them
from electrostatic discharge (ESD).

This manual describes physical and chemical processes that may require the use of chemicals, solvents, paints, or
other commercially available material. Users of the manual should obtain the material safety data sheets
(Occupational Safety and Health Act (OSHA) Form 20 or equivalent) from the manufacturers or suppliers of
materials to be used. Users must be completely familiar with manufacturer/supplier information and adhere to
their procedures, recommendations, warnings, and cautions for safe use, handling, storage, and disposal of these
materials.

REPAIR PARTS

Repair parts are listed in the Repair Parts and Special Tools List (RPSTL) TM 9-6115-730-24P.

SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT

Special Tools; Test, Measure, and Diagnostic Equipment (TMDE); and support equipment are needed for Field
maintenance. They are listed in the RPSTL, TM 9-6115-730-24P, and in the Maintenance Allocation Chart (MAC)
in WP 0123.

COMMON TOOLS AND TEST EQUIPMENT

For authorized common tools and equipment, refer to the Modified Table of Organization and Equipment (MTOE),
Common Table of Allowances (CTA) 50-970, Expendable/Durable Items (Except: Medical, Class V, Repair Parts,
and Heraldic Items), or Army Medical Department Expendable/Durable Items CTA 8-100, as applicable to your
unit.

END OF WORK PACKAGE

0001-9/10 blank
 TM 9-6115-730-24 0002

FIELD LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
EQUIPMENT DESCRIPTION AND DATA

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

The 200 kW Tactical Quiet Generator (TQG) is skid-mounted and is designated MEP-809A. When the 200 kW
TQG is mounted on a trailer, it is designated PU-809A. The 200 kW TQG consists of a diesel engine that can
operate using diesel fuel, or aviation fuel, a brushless alternating current (AC) generator, a digital voltage
regulator (DVR), an electronic governing system, a fuel system, a 24 Vdc cranking system, a control system, a
protection system, and other devices as described below to achieve a complete engine-driven generator set. The
system uses the Caterpillar C-12 engine and a Marathon generator model DOD 751 FR. The engine is
electronically controlled. The electronic control is essential to meeting U.S. Environmental Protection Agency
(USEPA) and fuel consumption requirements. All the electrical components and assemblies (including the voltage
regulator) that provide the required instrumentation and control functions are contained in the Electronic Modular
Control Panel (EMCP) located on the generator end (rear) of the TQG. The generator end of the TQG is
considered the rear of the generator in the following descriptions. Opening the EMCP and side access panels
gives accessibility to all the electrical components and essential engine components. Paralleling receptacles are
used to connect the paralleling cable between generator sets of the same family. The generator set family
includes a 100 kW TQG. The 100 kW TQG is skid-mounted and is designated MEP-807A. When the 100 kW
TQG is mounted on a trailer, it is designated PU-807A. These generator sets use the same control system as the
MEP-809A and PU-809A 200 kW TQG and can operate in parallel to share an electrical load.

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

ENGINE

The engine for the 200 kW TQG is the Caterpillar C-12 engine (Figure 1, Sheet 1, Item 1). The engine is
electronically controlled. The engine control module (ECM) controls the amount of fuel that is injected by the unit
injectors. The EMCP provides frequency (speed) control, controls long and short-term stability, and regulates load
conditions. High injection pressures help to reduce fuel consumption and emissions. Precise injection timing
optimizes the engine’s performance for starting, emissions, noise and fuel consumption.

MUFFLER

The muffler/exhaust system (Figure 1, Sheet 1, Item 2) and exhaust tubing are connected to the engine exhaust
manifold. This system reduces engine exhaust noise. Exhaust gases are exhausted upward from the top of the
generator set.

TURBOCHARGER

The turbocharger (Figure 1, Sheet 1, Item 3) is located on the right side of the engine. Powered by engine
exhaust gases, the turbocharger compresses air from the air filter to provide pressurized air to the engine for
combustion.

AIR CLEANER ASSEMBLY

The air cleaner assembly (Figure 1, Sheet 1, Item 4) is located on the left side of the engine inside the rear
access doors. The air cleaner filters intake air used for engine combustion. The air cleaner is equipped with a
restriction indicator (refer to TM 9-6115-730-10, WP 0012/WP 0014).

0002-1 Change 1
 TM 9-6115-730-24 0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued

Figure 1. 200 kW Tactical Quiet Generator Location of Components (Sheet 1 of 6).

Change 1 0002-2
 TM 9-6115-730-24 0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued

Figure 1. 200 kW Tactical Quiet Generator Location of Components (Sheet 2 of 6).

0002-3 Change 1
 TM 9-6115-730-24 0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued

Figure 1. 200 kW Tactical Quiet Generator Location of Components (Sheet 4 of 6).

0002-5 Change 1
 TM 9-6115-730-24 0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued

Figure 1. 200 kW Tactical Quiet Generator Location of Components (Sheet 5 of 6).

Change 1 0002-6
 TM 9-6115-730-24 0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued

Figure 1. 200 kW Tactical Quiet Generator Location of Components (Sheet 6 of 6).

ALTERNATOR

The alternator (Figure 1, Sheet 1, Item 5) is located on the right side of the engine. The alternator maintains the
batteries in a state of full charge. The alternator also provides 24 Vdc voltage for TQG control circuits and to the
NATO slave receptacle.

RADIATOR

The radiator (Figure 1, Sheet 1, Item 6) located at the front of the TQG eliminates engine heat via circulated
coolant and air. The radiator and engine fan are the primary heat exchanger for cooling engine coolant and
turbocharged engine intake air.

WATER PUMP

The water pump (Figure 1, Sheet 1, Item 7) located on the right side of the engine circulates coolant through the
engine block and radiator to cool the engine.

0002-7 Change 1
 TM 9-6115-730-24 0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued

LOAD BOARD

The load board (Figure 1, Sheet 2, Item 8) connects load cables to the TQG with heavy duty connector lugs and
nuts.

RECONNECTION BOARD

The reconnection board (Figure 1, Sheet 2, Item 9) allows the operator to change the TQG generator output
voltage for different load applications. The TQG can be configured for 120/208 Vac or 240/416 Vac operation for
50 Hz or 60 Hz.

MAIN LOAD CONTACTOR

The main load contactor K1 (Figure 1, Sheet 2, Item 10) connects/disconnects generator load output to the load
board.

AC GENERATOR

The generator (Figure 1, Sheet 2, Item 11) used in the 200 kW TQG is designed to meet military applications for
the TQG. The generator is a brushless, single bearing, rotating-rectifier generator. It is close-coupled to the
engine via flexible drive disks. Each generator consists of five major components: main stator (armature), main
rotor (field), exciter stator (field), exciter rotor (armature), and rotating rectifier assembly.

ELECTRONIC MODULAR CONTROL PANEL

The TQG EMCP (Figure 1, Sheet 3, Item 12) contains controls and indicators for monitoring TQG operation.
Located at the rear end of the generator set, the EMCP contains the Generator Set Control (GSC) (Figure 1,
Sheet 3, Item 13), an alarm module (Figure 1, Sheet 3, Item 14), and a digital voltage regulator (DVR) (Figure 1,
Sheet 3, Item 15). EMCP displays and indicators allow the user to monitor all engine and generator functions with
alarms and identification of malfunctions. Malfunction/Symptom Indices in Troubleshooting work packages identify
the malfunctions. The Malfunction/Symptom indices in the Troubleshooting work packages list off of the alarm
codes and fault codes for TQG malfunctions. The GSC monitors the output frequency of the generator and
controls the engine speed to maintain a constant output frequency, regardless of load. The PUSH TO STOP
EMERGENCY STOP pushbutton (Figure 1, Sheet 3, Item 16) shuts down the TQG immediately when it is
pushed.

PARALLELING RECEPTACLES

The PARALLELING RECEPTACLES panel is located to the left of the Electronic Modular Control Panel (EMCP).
The paralleling receptacles (Figure 1, Sheet 3, Item 17) are used to connect the paralleling cable between
100/200 kW generator sets.

CONVENIENCE RECEPTACLES

Two convenience receptacles (Figure 1, Sheet 3, Item 18) are located to the left of the Electronic Modular Control
Panel (EMCP) on the PARALLELING RECEPTACLES panel. The receptacles rated 120 Vac, 15A are available
at all times during generator operation. The receptacles are protected by a GROUND FAULT CIRCUIT
INTERRUPTER with TEST and RESET (Figure 1, Sheet 3, Item 19) functions. The frequency at the convenience
receptacle outlets is set by generator frequency and will be 50 Hz or 60 Hz.

Change 1 0002-8
 TM 9-6115-730-24 0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued

DEAD CRANK SWITCH

The dead crank switch (Figure 1, Sheet 4, Item 21) is located inside the generator housing at the left rear. During
maintenance, the dead crank switch allows the engine to be cranked without starting the engine.

NATO SLAVE RECEPTACLE

The NATO slave receptacle (Figure 1, Sheet 4, Item 22) is located on the left side (front) of the TQG. It is used for
24 Vdc slave starting.

BATTERIES

Four 12 Vdc batteries (Figure 1, Sheet 4, Item 23) located at the front of the generator are connected in series
and parallel. The batteries provide power for EMCP controls, engine starting, and to the NATO slave receptacle.
These batteries can be disconnected with the Battery Disconnect Switch (Figure 1, Sheet 4, Item 24).

WINTERIZATION KIT (ISSUED TO SELECTED UNITS ONLY)

The winterization kit consists of a fuel-fired heater (Figure 1, Sheet 4, Item 25) to heat engine coolant. The kit also
includes resistor heaters located in EMCP. The fuel-fired heater is controlled with the winterization kit control
panel (Figure 1, Sheet 3, Item 20).

STARTER

The engine starter motor (Figure 1, Sheet 5, Item 26) is located on the right rear side of the engine. The electric
starter engages the flywheel mechanically to start the diesel engine.

SKID BASE

The skid base (Figure 1, Sheet 5, Item 27) provides the main structural support for the engine generator set. The
skid base consists primarily of two formed side rails, cross members, mounting pads, fork lift openings, and a
bottom plate. Main cross members complete the primary skid base structure to support the engine and generator
mounting pads and vibration isolators and reinforce the fork lift openings (Figure 1, Sheet 5, Item 28). Four 25,000
lb (11,400 kg) capacity LIFT/TIEDOWN rings (Figure 1, Sheet 5, Item 29) are attached to the skid weldment. In
addition to supporting the engine generator assembly, housing, battery and other components, the skid base
has provisions for engine oil drain (Figure 1, Sheet 5, Item 30), coolant drain (opposite side), a water separator
drain (Figure 1, Sheet 5, Item 31), and fuel tank drain (Figure 1, Sheet 5, Item 32). The skid base also serves as a
support and protective enclosure for the fuel tank.

FUEL TANK

The fuel tank (Figure 1, Sheet 5, Item 33) is a 128 gallon (485L) molded tank located below the diesel engine
between the skid assembly side members.

ENGINE CONTROL MODULE

The engine control module (ECM) (Figure 1, Sheet 5, Item 34) monitors most of the engine sensors and controls
the amount of fuel that is injected by the unit injectors as well as engine timing functions.

0002-9 Change 1
 TM 9-6115-730-24 0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued

GENERATOR HOUSING

The housing (Figure 1, Sheet 6, Item 35) is fabricated from sheet steel and attaches directly to mating flanges on
the skid base. The housing is thus removable for unscheduled maintenance and engine or generator removal.
Access openings and doors (Figure 1, Sheet 6, Item 36) allow engine, generator, and other component servicing.
Each side of the rear housing has a set of double doors and the large doors at the front of the housing provide
accessibility. The housing structure incorporates acoustic damping foam and internal baffle structures to reduce
engine noise. The rugged design of the housing includes reinforced corners and access openings to meet
transportability, operational, and handling requirements of a mobile military generator set.

TRAILER-MOUNTED CONFIGURATION (PU-809A)

The skid-mounted TQG can be mounted on a model XM1061 E1 5-ton trailer (Figure 1, Sheet 6, Item 37). In this
configuration, the TQG can be towed and positioned as required. In the power-unit configuration, the trailer-
mounted TQG has an accessory box (Figure 1, Sheet 6, Item 38) and two fire extinguishers (Figure 1, Sheet 6,
Item 39). The TQG skid is bolted directly to the trailer bed and frame.

EQUIPMENT DATA

Table 1 lists equipment data for the 200 kW TQG.

Table 1. 200 kW TQG Equipment Data.

EQUIPMENT DATA

200 kW Tactical Quiet Generator Set MEP-809A /PU-809A

Overall length 114 in. (290 cm)

Width 50 in. (127 cm)
Height 75 in. (191 cm)
Weight
Wet (includes fuel) 9,300 lb (4218 kg)
Dry 8,200 lb (3719 kg)

Engine
Manufacturer Caterpillar
Model C-12, serial number BCY series
Type Six cylinder, in-line, four cycle, turbocharged diesel
Horsepower 395 hp @ 1800 rpm (60 Hz)
329 hp @ 1500 rpm (50 Hz)
Displacement 732 cu. in (12.0L)
Valves per cylinder Four (two inlet, two exhaust)
Valve lash setting (cold engine) Inlet: 0.015 in. (0.38 mm)
Exhaust: 0.025 in. (0.64 mm)
Cooling system
Type Pressurized radiator and coolant pump
Capacity 42 qt (39.7L)
Normal operating temperature 170°F to 200°F (77°C to 93°C)
Temperature indicating system voltage 24 Vdc, range programmable

Change 1 0002-10
 TM 9-6115-730-24 0002

EQUIPMENT DATA - Continued

Table 1. 200 kW TQG Equipment Data - Continued.

EQUIPMENT DATA

Lubricating system
Type Full flow, circulating pressure
Pump type Positive displacement gear
Capacity 36 qt (34.1L)
Normal operating pressure 25 to 70 psi (241 to 483 kPa)
Fuel system
Fuel type DF-1, DF-2, (1-D/2-D), JP5, JP8
Fuel tank capacity 128 gal (485L)
Consumption rate 8 hour tank capacity at full load (8.25 GPH)
Auxiliary fuel pump
Manufacturer Walbro Corp.
Voltage rating 24 Vdc (16 to 30 Vdc)
Delivery rate 34 gph at 30 Vdc; 17 gph at 24 Vdc

Fuel level switch

Manufacturer Madison
Type Float
Model 0116-2303
Voltage 18-32 Vdc

Engine starting system

Batteries
Manufacturer Optima
Voltage 12 Vdc, qty 4 (sealed units)

Starter
Manufacturer Caterpillar
Model 207-1556
Voltage rating 24 Vdc
Drive type Direct

Alternator
Manufacturer Caterpillar
Model 4N3986
Voltage rating 24 Vdc, 50A
Drive type Belt
Generator
Manufacturer Marathon
Model 571PSL4800
Type Alternating current, synchronous, brushless

0002-11 Change 1
 TM 9-6115-730-24 0002

EQUIPMENT DATA - Continued

Table 1. 200 kW TQG Equipment Data - Continued.

EQUIPMENT DATA

Load capacity 200 kW at 60 Hz 166 kW at 50 Hz

(1,800 rpm) (1,500 rpm)
Current ratings
120/208 Vac connection 694A at 60 Hz 578A at 50 Hz
240/416 Vac connection 347A at 60 Hz 289A at 50 Hz
Power factor 0.8
Cooling Fan cooled
Drive type Direct coupling
Duty classification Continuous

Governing system

Load measuring unit

Manufacturer Caterpillar
Model 161-0797

Engine control module

Manufacturer Caterpillar
Model 198-9253

GSC Protective Relay Setpoint Values

Low oil pressure shutdown 26 psi (179 kPa)
High water (coolant) temperature shutdown 230°F (110°C)
Engine overspeed 2120 rpm
Overcrank (total cycle crank time) 90 seconds
High oil temperature shutdown 253°F (123°C)
Overvoltage alarm threshold 125% overvoltage for programmed voltage
Generator overvoltage shutdown threshold 125% of nameplate voltage
Generator undervoltage alarm threshold 82% of programmed voltage
Generator undervoltage shutdown threshold 75% of nameplate voltage
Generator overfrequency alarm threshold 63 Hz for 60 Hz operation; 53 Hz for 50 Hz operation
Generator overfrequency shutdown threshold 66 Hz for 60 Hz operation; 55 Hz for 50 Hz operation
Generator underfrequency alarm threshold 57 Hz for 60 Hz operation; 48 Hz for 50 Hz operation
Generator underfrequency shutdown 57 Hz for 60 Hz operation; 45 Hz for 50 Hz operation
Generator phase overcurrent alarm threshold 160% of nameplate current
Generator total overcurrent alarm threshold 160% of nameplate current
Generator phase overcurrent shutdown threshold 160% of nameplate current
Generator total overcurrent shutdown threshold 160% of nameplate current
Reverse power shutdown 15% to 17%

END OF WORK PACKAGE

Change 1 0002-12
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FIELD LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
THEORY OF OPERATION

GENERAL

This work package contains functional descriptions of the generator set and explains how TQG functional
systems interact with one another.

ENGINE OVERVIEW

The 200 kW TQG is powered by an in-line six cylinder diesel engine. The engine firing order is 1-5-3-6-2-4. The
engine rotation is counterclockwise when the engine is viewed from the flywheel end (rear) of the engine. The
engine uses a turbocharger and an air-to-air aftercooler. The engine cylinder bore is 5.12 inch (130 mm) with
stroke of 5.91 inch (150 mm). Total displacement is 732 cu. in. (12.0L). The engine electronic unit injector system
(EUI) eliminates mechanical components that are used in a pump-and-line system. The EUI provides increased
control of the timing and increased control of the fuel air mixture. The timing advance is achieved by precise
control of the unit injector timing. Adjusting injection duration controls engine rpm. An engine speed sensor
provides information to the Engine Control Module (ECM) for detection of cylinder position and engine rpm. The
engine has built-in diagnostics to ensure that all of the components are operating properly. In the event of a system
component failure, the operator will be alerted via the Generator Set Control (GSC) component of the TQG
Electronic Modular Control Panel (EMCP). Numerical codes of the faulty component or condition are displayed on
the GSC. Intermittent faults are logged and stored in the ECM memory.

Engine Control Module

The Engine Control Module (ECM) automatically provides the correct amount of fuel in order to start the engine.
The ECM is integrated with the engine fuel system and the engine air inlet and exhaust system to control the fuel
delivery and the injection timing electronically. The ECM provides timing control and fuel air ratio control. Injection
timing is achieved by the precise control of the injector firing time. Adjusting the injection duration controls engine
rpm. ECM energizes unit injector solenoids to start the injection of fuel and de-energizes the unit injector
solenoids to stop the injection of fuel.

Electronic Components

The engine uses three types of electronic components: input, control, and output. Input components send variable
electrical signals (voltage, frequency, or pulse width (PW)) to the ECM. ECM interprets input signals about the
condition, environment, or operation of the TQG. ECM firmware evaluates input data to control engine
components such as fuel injector solenoids or to log and relay information to EMCP.

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ENGINE SENSORS

Boost Pressure

Boost is defined as the difference between the inlet and outlet pressures of the turbocharger. The atmospheric
pressure sensor on the air inlet to the turbocharger is used to reduce smoke emissions at high altitudes and as
the reference for calculating turbocharger boost pressure. Boost pressure measurements are used to reduce
smoke emissions during acceleration. The outlet pressure sensor is located at the turbocharger outlet and
measures pressure from 3 to 49 psi (20 to 340 kPa).

Oil Pressure

The ECM monitors oil pressure following engine start up and may display a low oil pressure alarm diagnostic
code. The code will not be logged for 15 seconds following start up. The output of the oil pressure sensor is pulse
width modulated. The base frequency is 500 ±150 Hz. The duty cycle varies from 13 to 85% corresponding to 0 to
100 psi (0 to 690 kPa).

Coolant Level Sensor

A sensor in the coolant detects dangerously low levels of coolant in the system. The output of this sensor is
connected to the GSC for display and control.

Crankshaft (bottom or primary) and Camshaft (top or secondary) Engine Speed/Timing Sensors

Two timing sensors determine engine timing. The primary sensor monitors crankshaft rotation and is used to
determine both engine rpm and fuel injection timing. The other sensor senses rotation of the camshaft. With these
redundant sensors, the probability of a failure shutting down the engine is greatly reduced. All of the timing for fuel
injection is based on the output of these sensors. If one fails, timing can continue based on the output of the other
sensor.

Fuel Pressure Sensor

The ECM monitors fuel pressure at the fuel pump between 0 and 100 psi (0 and 690 kPa).

Intake Manifold Air Temperature Sensor

The ECM monitors air manifold inlet temperature and uses this information to adjust ignition timing.

Coolant Temperature Sensor

The coolant temperature is used to determine whether to operate the engine in cold mode and to notify the
operator of excessive engine temperature. If the coolant temperature is below 63°F (17°C) and the engine is not
in the cranking phase of starting, the timing is advanced and fuel delivery is reduced to improve cold engine
performance. Cold mode remains active until the coolant temperature rises above 63°F (17°C) or until the engine
has been running five minutes.

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ENGINE SENSORS - Continued

Speed Input

The speed input signal to the ECM is a pulse width modulated control signal which eliminates the mechanical
throttle and governor linkages along with their adjustments. The nominal frequency is 500 ±200 Hz. The pulse
width varies from 10% to 90% corresponding to idle and maximum speed of the engine. Signals outside of this
range are considered a failure and a fault code is logged.

Fuel Temperature Sensor

Fuel temperature is monitored and used to adjust fuel rate calculations and for fuel temperature power correction.
When fuel temperature exceeds 86°F (30°C), fuel rates are corrected to provide consistent power. Maximum
power correction is achieved at 158°F (70°C). Fuel temperatures exceeding 176°F (80°C) for 30 seconds cause a
diagnostic code to be logged.

TDC Probe Input

A connector on the engine harness is used to calibrate engine timing. A special probe is inserted into the engine
and this extra connector is connected to the probe. This special probe is used to determine how long after the
speed/timing sensor(s) sense top dead center (TDC) it actually occurs. This data is programmed into the engine
ECM at calibration.

ENGINE STARTING SYSTEM

The engine starting system (Figure 1) consists of four 12-volt batteries connected in series and parallel, a 24 Vdc
starter, a 24 Vdc battery charging alternator, a magnetic pickup (for sensing engine speed) and the related
switches and relays (described below) required for control of the starting system. The four 12 Vdc batteries are
configured in sets of two with each set consisting of two 12 Vdc batteries in parallel and the sets connected in
series to make a 24 Vdc system. The PUSH TO STOP EMERGENCY STOP pushbutton on the EMCP will
automatically disable the starting system and shut down the TQG if it is pushed in. For engine cranking, battery
power is supplied to the starter motor through the starter solenoid that in turn is controlled by the EMCP. The
starter engages the engine flywheel causing the engine to turn over. As the engine accelerates to above idle
speed (sensed by the magnetic pickup), the EMCP disengages the starter. Moving the ENGINE CONTROL switch
to COOL DOWN/STOP may also stop the starting sequence. The engine may be cranked without starting by
engaging the DEAD CRANK SWITCH. The DEAD CRANK SWITCH is a three-position switch. Up position is
CRANK, the center is OFF, and the lower position is NORMAL (operation). With the DEAD CRANK SWITCH in
CRANK, the starter motor is energized without activating any other starting or control function. With the switch in
the OFF center position, the system is off. With the switch in NORMAL (operation) position, the TQG may be
cranked and started. The belt-driven engine alternator charges the batteries. The battery charging alternator also
supplies GSC power. Normal operating indication depends on the state of charge in the batteries. A low charge,
such as exists immediately after engine starting, will cause a high reading. If the batteries are dead or inoperable,
external +24 Vdc power can be supplied to the TQG via the 24 Vdc NATO slave receptacle to start the generator
set engine. Cold outside temperatures make starting the engine difficult. The engine ECM controls the ether start
to improve the cold starting capability. The ether start is described in the Air Intake and Exhaust System
paragraph.

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ENGINE STARTING SYSTEM - Continued

Figure 1. Engine Starting System.

FUEL SYSTEM

The fuel system (Figure 2) consists of hoses, steel injector piping, fuel tank, fuel filter/water separator, fuel transfer
pump, and injectors. The fuel transfer pump draws fuel from the fuel tank through a fuel filter/water separator that
removes water and small impurities. The fuel is then pushed through the secondary fuel filter that removes even
smaller particles from the fuel. The fuel then enters a fuel manifold servicing unit injectors. Through the cam-
actuated injectors fuel enters the diesel engine combustion chamber, where it is mixed with air and ignited. The
fuel that is not used is cooled and returned to the fuel tank via an excess fuel return line. When the fuel level is
low, the fuel level switch will either supply power to the external auxiliary fuel pump for external fuel supply or shut
down the TQG to prevent it from completely running out of fuel. If a diesel engine runs out of fuel, it is
necessary to fill the fuel filters, purge all air from the lines and pumps, and bleed all injectors.

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FUEL SYSTEM - Continued

Figure 2. Fuel System.

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AUXILIARY FUEL SYSTEM

The auxiliary fuel system consists of an external fuel supply, a fuel hose, a 24 Vdc auxiliary fuel pump with
strainer and solenoid valve, fuel lines, and an auxiliary fuel pump relay. When the EMCP AUX FUEL switch is ON,
the auxiliary fuel pump can transfer fuel from an external fuel supply to the generator fuel tank. The fuel level float
in the fuel tank shuts off power to the auxiliary fuel pump via the auxiliary fuel pump relay when the TQG fuel tank
is full and reactivates the pump as the level drops. The fuel level indicator on the EMCP indicates the fuel level of
the fuel tank from the empty (E) to full (F).

ELECTRONIC UNIT INJECTOR FUEL SYSTEM

The engine uses an EUI in each cylinder. A solenoid on each injector controls the amount of fuel delivered by the
injector. An engine speed/timing sensor detects top dead center (TDC). All fuel injection is timed off the
occurrence of TDC. The ECM determines how much fuel is to be delivered based on the difference between
desired and actual speed. The ECM then sets the timing from TDC for each cylinder based on data received from
the coolant temperature sensor, inlet air manifold temperature, atmospheric pressure sensor, and turbocharger
outlet (boost) pressure sensor. The ECM adjusts timing and fuel delivery for best engine performance, fuel
economy, and white smoke control.

The EUI fuel system uses a mechanically actuated electronically controlled unit injector. All fuel systems for diesel
engines use a plunger and barrel to pump fuel under high pressure into the combustion chamber. Fuel is pumped
into the combustion chamber in precise amounts to control engine performance. The EUI uses a fuel injection
pump camshaft lobe to power the plunger.

Engine Control Module (ECM)

The ECM computer electronically controls engine performance. The ECM uses engine performance data
gathered by several sensors to make adjustments to the fuel delivery, injection pressure and injection timing. The
ECM contains programmed performance maps (software) to define horsepower, torque curves and rpm. This
software is commonly called the personality module. The ECM logs faults of engine performance. The ECM can
diagnose problems with itself and the sensors and sensed values input to the module. When a problem is
detected, a diagnostic code is generated and sent to the GSC where it is displayed. In most cases, the code is
also logged with the engine hour value indicating when the failure occurred. When diagnostic codes are
generated, they are referred to as active. They indicate a problem presently exists. These should be serviced first.
Diagnostic codes stored in memory are referred to as logged failures. The existence of a logged code does not
indicate a current failure. The failure may have occurred some time ago. The logged codes are useful when
troubleshooting an intermittent problem. Logged inactive codes require a generic password to clear as described
in WP 0004 and WP 0083. Codes not requiring a password are automatically deleted from memory after 100
engine operating hours.

Fuel Transfer Pump and Fuel Flow

The fuel supply and injection circuit (Figure 3) is a conventional design for unit injected engines. It uses a fixed-
clearance gear fuel transfer pump to deliver fuel from the fuel tank to the unit injectors. The fuel transfer pump is
driven by the lower accessory drive gear. Fuel is pulled from the fuel tank and through the fuel filter/water
separator into the pump. The pump incorporates a check valve to permit fuel flow around the gears for hand
priming. The pump has a pressure regulating valve to protect the system from extreme pressure. The excess fuel
flow provided by the fuel transfer pump cools and purges the air from the unit injectors. The fuel is pulled from the
tank through the fuel filter/water separator and then through a five micron fuel filter. A fuel priming pump is located
on the fuel filter base. If unit

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ELECTRONIC UNIT INJECTOR FUEL SYSTEM - Continued

injectors must be replaced, the priming pump can be used to fill the system after draining the fuel supply and
return manifolds. The fuel flows continuously from the fuel supply manifold through the unit injectors and excess
fuel is returned to the fuel tank by the fuel return manifold. A flow regulating orifice is located in the adapter
manifold to maintain sufficient back pressure in the system to fill the unit injectors. Optimal fuel flow is provided to
the unit injectors without excessive fuel tank heating. Each cylinder contains an electronically controlled,
mechanically actuated unit injector. A solenoid on each unit injector controls the amount of fuel delivered by the
unit injector. The ECM sends a signal to each unit injector solenoid, to provide complete control of the engine.

Figure 3. Fuel Supply and Injection.

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ELECTRONIC UNIT INJECTOR FUEL SYSTEM - Continued

Fuel Injection

The ECM controls the amount of fuel injected, by varying signals to the unit injectors. The unit injectors will inject
fuel only if the unit injector solenoid is energized. The ECM sends a 90 volt signal to the unit injector solenoid to
energize it. By controlling the timing and duration of the 90 volt signal, the ECM can control injection timing and
the amount of fuel injected. The ECM sets certain limits on the amount of fuel that can be injected. One limit
based on boost pressure controls the fuel/air ratio for emissions control purposes. When the ECM senses a higher
boost pressure (more air into cylinder), it increases the limit to allow more fuel into cylinder. A second limit is
based on the horsepower rating of the engine. (It is similar to the rack stops and torque spring on a mechanically-
governed engine and provides horsepower and torque curves for a specific engine rating.) Injection timing
depends on engine rpm, load, and other operation factors. The ECM knows where top center of cylinder number
one is from the signal provided by the engine Speed/Timing Sensor. It decides when injection should occur
relative to top center and provides the signal to the unit injector at the desired time.

Unit Injector Mechanism

The unit injector mechanism generates downward force to pressurize the fuel in the injector. At the precise time,
the unit injector injects fuel into the combustion chamber. The camshaft gear is driven by an idler gear which is
piloted in the cylinder block and bolted through the timing gear housing to the block. The idler gear is driven by
the crankshaft gear. Timing marks on the crankshaft gear, idler gear, and camshaft gear are aligned to define the
correct relationship between piston and valve movement. The camshaft has three cam lobes for each cylinder. Two
lobes operate the inlet and exhaust valves, and one operates the unit injector mechanism. Force is transmitted
from the unit injector lobe on the camshaft through a lifter to a pushrod. Force is transmitted from the pushrod
through the rocker arm assembly to the top of the unit injector.

ENGINE COOLING SYSTEM

The engine cooling system (Figure 4) consists of a radiator, hoses, thermostat, water pump, surge tank and
expansion bottle, a belt driven fan, and cooling jackets. The water pump forces coolant through passages (cooling
jackets) in the engine block and cylinder head and an engine oil cooler. The coolant absorbs heat from the engine
as it passes through these passages. A gear driven water pump located in the right hand side of the engine
supplies the coolant for the engine cooling system. The coolant is supplied to the engine oil cooler, cylinder head,
and cylinder liner. Coolant is pulled from the bottom of the radiator into the water pump by an impeller. The water
pump is gear driven at 1.17 times engine speed by an idler turned by the crankshaft gear. The water pump
impeller is an open-face, radial vane cast iron design. The coolant is pumped through an engine oil cooler and
into a supply manifold in the cylinder block. The supply manifold distributes coolant at each cylinder where coolant
flows around and cools the upper portion of the cylinder liner. Coolant flow from each liner enters the cylinder
head that is divided into single cylinder cooling sections. The coolant flow is split at each liner so that 60 percent
flows around the liner and the remainder bypasses the liner and flows directly to the cylinder head. In the cylinder
head coolant flows across the center of the cylinder and the injector seat boss. At the center of the cylinder, coolant
flows up around the injector sleeve over the exhaust port and exits into return manifold. The return manifold
collects the coolant from each cylinder and directs the flow to thermostat housing. With the thermostat closed,
coolant flows through the regulator, bypassing the radiator, and back to the water pump for recirculation. With the
thermostat open, the coolant is directed through the radiator and back to the water pump inlet. The full-flow
bypass coolant thermostat regulates the outlet temperature of the coolant. When the engine is cold the valve is
closed, and the coolant flows through the regulator, bypassing the radiator, to the water pump inlet for
recirculation. As the coolant temperature increases, the thermostat opens to direct some of the coolant to the
radiator, bypassing the remainder to the water pump inlet. At full operating temperature, the valve moves to the

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ENGINE COOLING SYSTEM - Continued

open position, and all the coolant flows to the radiator and then back to the water pump inlet to provide maximum
heat release. A shunt line extends from the top of the water pump to the surge tank. The shunt line must be
routed properly to avoid trapping any air. By providing a constant flow of coolant to the water pump, the shunt line
prevents cavitation. The cooling fan circulates air through the radiator where the coolant temperature is reduced. In
addition, the fan cools engine and generator set components within the TQG housing by drawing in air from outside
the housing through the baffles, circulating the air through the housing, and forcing the air through the radiator
and out through the housing exhaust vents on the roof. The housing is designed to operate with the doors closed
which ensures that the main alternator and other TQG components have access to a good flow of cooling air from
outside the generator set. The normal operating temperature of the generator set is 170° F to 200° F (77° C to 93°
C). A coolant temperature sensor provides automatic shut down in the event that coolant temperature exceeds
230°F (110°C). The lower GSC display indicates the engine coolant temperature.

Figure 4. Engine Cooling System.

LUBRICATION SYSTEM

The lubrication system (Figure 5) consists of an oil pan, dipstick, pump, oil pressure sensor, and filter. The oil pan
is a reservoir for engine lubricating oil. Engine oil lubricates, cleans, cools, seals, and preserves engine parts. The
dipstick indicates oil level in the oil pan. A pump draws oil from the oil pan and through a screen that blocks large
objects from entering the oil pump and oil cooler. The oil then passes through a spin-on type filter where small
impurities are removed. From the filter, oil enters the engine and is distributed to the engine's internal moving parts
through internal passageways. Oil is also supplied to the turbocharger. After passing through the engine, the oil
returns to the oil pan. The lower GSC display indicates oil pressure sensed by the oil pressure sensor in the
engine. The engine will shut off automatically if the oil pressure drops below 30 psi (207 kPa) and the red LOW
OIL PRESSURE indicator on the GSC will flash. The oil level can be checked with the engine running.

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LUBRICATION SYSTEM - Continued

Figure 5. Engine Lubrication System.

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LUBRICATION SYSTEM - Continued

Engine Lubrication

The engine oil pump is mounted to the bottom of the cylinder block inside the engine oil pan. The engine oil pump
pulls oil from engine oil pan and pushes the oil through the passage to the engine oil cooler and filter. The filtered
oil then enters the turbocharger oil supply line and main oil gallery. The main oil gallery distributes oil to main
bearings, piston cooling jets, and the camshaft bearing. Oil from the main oil gallery exits the front of the block
and enters a groove that is cast in the front housing. Oil enters the crankshaft through holes in the bearing surfaces
(journals) for the main bearing. Passages connect the bearing surface for the main bearing with the bearing
surface for the connecting rod. The front housing passage sends the oil flow in two directions. At the upper end of
the passage, oil is directed back into the block and up to cylinder head gallery through passage to the rocker arm
mechanism. Internal passages lubricate the oil pump idler gear bearing and camshaft idler gear bearing. Oil
passages in the crankshaft send oil from all the main bearings through the connecting rods to the connecting rod
bearings. The passages send oil from the camshaft bearing to pushrod lifters.

AIR INLET AND EXHAUST SYSTEM

The air inlet and exhaust system (Figure 6) consists of an air filter assembly, intake manifold, turbocharger,
exhaust manifold and muffler. Ambient air is drawn into the air filter assembly where it passes through the filter
elements. Airborne dirt is removed and trapped in the elements. Filtered air is drawn out of the air filter assembly
through air intake tubes to the turbocharger where it is pressurized and passed through an aftercooler coil in the
radiator. In cold weather, an ether starting aid is used to accelerate combustion The pressurized inlet air enters
the intake manifold to the combustion chambers and mixes with fuel from the fuel injectors. The engine exhaust
gases are released into the turbocharger, which is mounted on the exhaust manifold. The exhaust gases drive the
turbocharger, forcing large amounts of air into the intake manifold. After passing through the turbocharger, the
exhaust gases are channeled into a muffler to deaden the sound. The exhaust gases are vented upward from the
generator set housing.

Figure 6. Air Inlet and Exhaust System.

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AIR INLET AND EXHAUST SYSTEM - Continued

The components of the air inlet and exhaust system control the quality of the air that is available for combustion.
These components also control the amount of the air that is available for combustion. Inlet air is pulled through
the air cleaner. The inlet air is then compressed and heated by the compressor wheel of turbocharger to about
150°C (300°F). The inlet air is then pushed through the air-to-air aftercooler core and the inlet air is moved to air
inlet where the temperature about 110°F (43°C). Cooling the inlet air increases the combustion efficiency which
lowers fuel consumption and increases horsepower output. The aftercooler core is a separate cooler core
installed above the standard core of the engine radiator. The engine fan moves air at ambient temperature across
the aftercooler core to cool the turbocharged inlet air. From the aftercooler core the air is forced into the cylinder
head to fill the inlet ports. The inlet valves control air flow from the inlet port into the cylinder. There are two inlet
valves and two exhaust valves for each cylinder. Inlet valves open when the piston moves down on the inlet
stroke to pull air into the cylinder. The inlet valves close and the piston begins to move up on the
compression stroke. The air in the cylinder is compressed and fuel is injected into the cylinder. The fuel mixes
with the air and combustion starts. During the power stroke, the combustion force pushes the piston downward.
Then the piston moves upward in the exhaust stroke. During the exhaust stroke, the exhaust valve opens, and the
exhaust gases are pushed through the exhaust port into the exhaust manifold. After the piston completes the
exhaust stroke, the exhaust valves close and the cycle starts again. Exhaust gases from exhaust manifold enter
the turbine side of turbocharger to turn the turbine wheel. The turbine wheel is connected to a shaft that drives the
compressor wheel. Exhaust gases from the turbocharger pass through the exhaust outlet pipe, the muffler and
the exhaust stack.

Turbocharger

The turbocharger is installed on the center section of the exhaust manifold. All the exhaust gases from the engine
go through the turbocharger. The compressor side of the turbocharger is connected to the aftercooler by pipe. The
exhaust gases go into the turbine housing through the exhaust inlet. The exhaust gases spin the blades of a
turbine wheel connected by a shaft to a compressor wheel. The rotation of the compressor wheel pulls clean air
from the air filters through the compressor housing air inlet to compress the inlet air. Air compression increases
engine power by allowing the engine to burn more air and more fuel during combustion. When the load on the
engine increases, more fuel is injected into the cylinders producing more exhaust gases to increase the
turbocharger speed. As the compressor wheel turns faster, more air is forced into the cylinders. The increased flow
of air gives the engine more power by allowing the engine to burn the additional fuel with greater efficiency. The
turbocharger uses engine oil under pressure for lubrication. The oil comes in through an oil inlet port, lubricates
turbocharger bearings, and returns through an outlet port to the engine lubrication system.

Ether Starting Aid

The ECM uses the coolant temperature sensor signal to determine if ether should be injected. Ether will be
injected if the coolant temperature is between -40°F and 50°F (-40°C and 10°C) and engine rpm is between 30
and 1500 rpm. The time duration of the ether injection is a linear function of the temperature. The shortest
injection duration (15 seconds) is at the highest temperature and the longest duration (130 seconds) is at the
coldest temperature.

AC POWER OUTPUT

The AC output system (Figure 7) consists primarily of the AC generator, the output load terminal board, the
voltage reconnection terminal board, the main load contactor and the AC CIRCUIT INTERRUPTER switch on the
EMCP. Power created by the AC generator is supplied through the voltage reconnection terminal board and the
main load contactor to the output load terminals on the output load terminal board. The voltage reconnection
terminal board allows configuration of the generator set for 120/208 volt connections or 240/416 volt connections.
The DVR and GSC must be reprogrammed for voltage changes. The AC CIRCUIT INTERRUPTER switch
located on the EMCP closes and opens the main load contactor. This enables or interrupts the power flow
between the voltage reconnection terminal board and the output load terminals. The main load contactor is also
opened automatically during any of the specified set faults. The Digital Voltage Regulator (DVR) module in the

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AC POWER OUTPUT - Continued

EMCP senses AC generator output voltage and provides excitation voltage to the AC generator to maintain the
desired output voltage. The VOLTAGE adjust potentiometer is connected to the DVR to allow the user to make
minor voltage adjustments. The user can select which output load terminals to monitor for current and voltage
measurements with the GSC keypad AC METER key. The values and terminals are indicated on the upper and
lower displays. Refer to AC POWER DISTRIBUTION for a more detailed discussion.

Figure 7. AC Power Output.

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DC POWER DISTRIBUTION (FIGURE FO-1, SHEETS 2 AND 3)

The DC battery system (Figure 8) provides 24 Vdc for engine starting and TQG control circuits. The two sets of
12 Vdc batteries are charged by the engine alternator. The DC AMMETER on the EMCP indicates alternator
charging rate. Charge rate is shown from -25 to +50 A. Normal operating indication depends on the state of
charge in the batteries. A low charge, such as exists immediately after engine starting, will cause a high reading.
The battery system includes a manually operated Battery Disconnect Switch to isolate the batteries from the
engine. The Battery Disconnect Switch can be used to remove the DC power from the TQG. The batteries
connect directly to the 24 Vdc NATO slave receptacle.

Figure 8. DC Power Distribution.

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DC POWER DISTRIBUTION (FIGURE FO-1, SHEETS 2 AND 3) - Continued

Batteries

Batteries BT1 and BT3 are paralleled as are batteries BT2 and BT4. These two sets of 12 Vdc batteries are
connected in series to supply 24 Vdc for this system. The DC power distribution system operates on 24 Vdc. The
Slave Receptacle (SR) is the NATO connector on the generator set. This is useful for charging the batteries and
jumping the generator set with another if the batteries become discharged. The Battery Disconnect Switch
disconnects the batteries from everything except the slave receptacle. Battery power goes directly to the starter
solenoid (Labeled PS (pinion solenoid) on the schematic) for use when cranking or starting the engine. The
batteries are connected to the alternator through shunt R4 and circuit breaker CB-5. R4 generates a voltage for
the ammeter, which displays the amperage from the alternator when charging the batteries. Battery power is
connected to ECM A8 through circuit breaker CB-4 and relay contacts of slave relay (SRY). SRY is energized any
time power is applied to the GSC. Battery power goes through D1 to the common of the DEAD CRANK SWITCH.
In OFF, battery power is removed from the GSC, DVR, ECM, and Winterization Kit (if supplied). In NORMAL,
battery power is applied to the relay module of the GSC through circuit breaker CB1. Power is distributed to the
other equipment by the ECS. In CRANK, +24 Vdc is applied to the Starter Motor Magnetic Switch (SMMS) relay
coil. SMMS connects battery voltage to the starter solenoid through circuit breaker CB-2, causing the engine to
crank. Since power is not supplied to the electronics, the engine will not start.

Emergency Stop Push Button

The Emergency Stop Push Button (ESPB) (PUSH TO STOP EMERGENCY STOP on EMCP) is there to stop the
generator set in an emergency. When pushed, contacts 3 and 4 ground P7-38, which informs the GSC that the
switch is pressed. Contacts 1A and 2A remove the ground from the output to the engine controller, which enables
the engine to run. This will stop the engine. Contacts 1 and 2 open the circuit between the GSC and relay SMMS
so that the GSC will not be able to attempt to crank the engine.

When the ECS is set to START, starter motor relay (SMR) A1 K4 is energized. +24 Vdc is applied through the
ESPB (if it is not pressed) and D2 to relay SMMS which enables the starter and cranks the engine. D2 prevents
voltage from the DEAD CRANK SWITCH from applying power to Relay Field Flash (KFF) relay.

Field Flash Relay

Relay A1 K4 also applies +24 Vdc to the coil of KFF relay. The contacts of KFF apply the +24 Vdc, which is
across the coil of KFF, to the generator field coil input (see FO-1, sheet 4) through a 15 Ohm, 25W resistor and
diode CRFF (Diode Field Flash). Note that for the acronyms KFF and CRFF, the common reference designators
for a relay (K) and a diode (CR) were used. This excitation voltage starts the generator generating voltage. After
the process is started, it is self sustaining.

Electronic Governor Relay (EGR) Comm Data Links, MPU, CTR, and GFR

The Electronic Governor Relay (EGR) output of the GSC is connected to the engine controller. This output
enables the engine to run. P7-21 and 22 are the Communications Data Link between the GSC and the
Communication Module (CM). P7-1 and 2 are the inputs from the engine Magnetic Pickup Unit (MPU). This
pickup measures speed of rotation of the engine by detecting the starter ring gear teeth. This input is a frequency
proportional to engine speed. P7-19 and 20 are the Communications Data Link between the GSC and the
electronic control module on the engine. (This is also known as the CAT Data Link.) A1 F1 (Labeled F1 GSC on
schematic), and the GSC relay contacts labeled CTR are not used. P7-23 is a low fuel level input from the low fuel
level sensor connected to Alarm Module A2 (FO-1, sheet 3). This input is connected to ground when the fuel tank
is almost empty. The 10A fuse between RM-34 and RM-7 is A1 F5. The Generator Fault Relay (GFR) K2 in the
GSC closes when the GSC detects a generator fault. This energizes the GFR external to the GSC. The contacts
for the GFR are used to de-energize K1 and disconnect the load from Generator G1.

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DC POWER DISTRIBUTION (FIGURE FO-1, SHEETS 2 AND 3) - Continued

Engine Control Switch (ECS)

The ECS consists of two sections. One section consists of pins 1, 2, 3, 4, and 5; the other section consists of pins
6, 7, 8, 9 and 10 of the switch. There is a legend on the schematic that describes which contacts are closed in
which positions of the switch. Pins 6 thru 10 apply power to the GSC, Overload and Short Circuit (OL/SC) module,
and DVR whenever the switch is not in OFF. This allows the OFF position of this switch to reset any alarms that
have occurred. Shorting pins RM 1 and RM 2 on the GSC does this. Note the internal relay connections in the
GSC between pins RM 1 and RM 2. This is to ensure that power can not be removed from the GSC when the
Fuel Control Relay (FCR) A1 K7 is energized (signifying the engine is running) or the Crank Termination Relay
(CTR) A1 K3 is active (signifying that the engine is running and the starter can be released). Pins 1 thru 5 ground a
different input line to the GSC for each position of the switch, telling the GSC what to do.

Power to ECM, DVR, OL/SC, Fuel Gauge, Panel Lights, Winterization Kit

Fuse F10 shown between RM 1 and RM 10 is A1 F10 on the back of the GSC. This connects +24 Vdc to pin RM
39 whenever the ENGINE CONTROL switch is in any position other than OFF. Slave Relay (SRY) is connected to
RM 39 and is powered up any time the ECS is not in OFF. The contacts of SRY apply +24 Vdc from the battery to
ECM A8. Power to DVR A3 module also comes from RM 39. Power to the OL/SC module comes from RM 1
through a set of normally closed contacts on relay AR. AR is energized when the LAMP TEST button is pressed
on Alarm Module A2. The fuel gauge (FLG) is connected to RM 39 for power. The signal comes from the fuel
sending unit (FLSU) in the fuel tank. The panel lights get their power from RM2, which has power whenever the
DEAD CRANK SWITCH is set to NORMAL. Closing the PANEL LIGHT switch (PLS) applies power to the lights.

Power to the optional winterization system is applied whenever the DEAD CRANK SWITCH is set to NORMAL. If
the winterization kit is turned on at its control panel, +24 Vdc is output to TB5-15. This applies power to the two
resistor heaters used to keep the LCD displays in the GSC and the DVR from freezing. There is also a thermally
operated switch in the control panel that closes when the temperature falls below -20°F ±10°F (-28.9°C ±5.6°C).
This switch applies +24 Vdc from TB4-17 to the resistors used to keep the LCD displays in the GSC and the DVR
from freezing. Note that this power is only available when the ECS is not in OFF.

Coolant Low Sensor Interface

Pins P7-7, 8, 9, 13, 14, 24, 30, and 31 are connected between the GSC and connector J37. P7-9 is +8 Vdc power
for the Coolant Low sensor. P7-31 is power return. P7-13 is the Coolant Low signal from the sensor. This sensor
detects presence or absence of coolant in the engine and provides an output indicating that the coolant level is
dangerously low to allow an operator to add coolant before a forced shutdown occurs.

Load Sharing Module (LSM) A4

The LSM gets an input from the Speed Setting Potentiometer (SSP) (labeled FREQUENCY on the front panel).
This signal allows the generator frequency to be adjusted ±10% of nominal. There is a SYNC input on pins 24 and
25 from the GSC. This signal is output on LSM Pins 10 and 11 if this generator is connected to a dead load bus
and in AUTO or SEMI-AUTO sync mode. Otherwise, pins 10 and 11 are an input. Pins 10 and 11 are connected
to J32 and J33 through contacts on the paralleling relay (PAR). J32 and J33 are the paralleling cable connectors
on the rear of the generator set near the control panel. In parallel operation, cables interconnect all of the
paralleled generators and these ports are all in parallel. Pins 19 and 20 are a serial communication port to the
ECM via J37. Pins 15 and 16 are power and ground respectively.

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DC POWER DISTRIBUTION (FIGURE FO-1, SHEETS 2 AND 3) - Continued

Alarm Module A2

The alarm module monitors three conditions: Low Fuel, Overload (current), and Short Circuit (OL/SC). The Low
Fuel condition is monitored by fuel level switch FL1 in the fuel tank and a set of contacts close when the fuel tank
is almost empty. This lights a red lamp on the alarm panel and sounds the alarm buzzer. The lamp will flash at
two cycles per second. Pressing the Alarm Silence button on the alarm module will silence the buzzer. This Low
Fuel signal is also connected to the GSC at P7-23 (SP-1 input) to notify the GSC that the fuel tank is almost empty.
The OL/SC module monitors the Overload and Short Circuit conditions. (The AC Power Distribution discussion
describes the module functions.) A set of relay contacts for each condition is input to this panel and each lights a
yellow lamp. These conditions do not sound the buzzer. There is a relay coil (AR) connected to the LAMP TEST
input/output of the alarm panel. When the LAMP TEST button on the panel is pressed, this relay is energized. The
contacts (FO-1, sheet 2) remove power from the OL/SC module when the relay is energized. This resets the
output relays and any condition sensed by this module. Power for this module is on pins 1 and 7.

Dead Bus Hi/Lo Inputs

Spare input SP-4 at P7-29 is connected to ground through a set of contacts on Dead Bus High (DBHI) and a set of
contacts on Dead Bus Low (DBLO). If there is no voltage on the load bus, DBLO and DBHI will both be de-
energized and the contacts used here will both be closed, grounding P7-29. This input is monitored to verify the
condition of the load bus. A ground here indicates that there is no voltage on the load bus. This input is compared
against the AC voltage monitored at P7-17 and P7-18. If both signals indicate a dead bus, the AUTO mode will
close the load contactor onto the dead bus automatically.

BATTLE SHORT Switch (BSS) Input to ECM

One set of contacts on the BSS is connected to the ECM. This is to notify the ECM when the system is in the Battle
Short Mode. In this mode, shutdown conditions are locked out except for Short Circuit Over Speed.

Auxiliary Fuel Pump Circuit

The AUX FUEL switch on the control panel is labeled AFPS (Auxiliary Fuel Pump Switch) on the schematic. The
ON position is when terminal 1 and 2 are connected together. The OFF position is when terminals 2 and 3 are
connected together. When the AUX FUEL switch is ON, fuel level sensors FL2A and FL2B in the fuel tank control
the Auxiliary Fuel Pump Relay (AFPR). When the fuel level in the tank gets low, FL2A and FL2B will be closed,
applying power to relay AFPR. One set of contacts on AFPR latch, keeping AFPR energized. Another set of
contacts on AFPR apply 24 Vdc to the auxiliary fuel pump. The auxiliary fuel pump will transfer fuel from an
external tank to fill the internal tank in the generator set. As the fuel level rises in the tank, FL2B will open. The
pump will continue transferring fuel since a set of contacts on AFPR latches the relay to the ON condition. When
the fuel level gets to FL2A, those contacts will open. AFPR will drop out and the transfer pump will stop.

0003-17
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DC POWER DISTRIBUTION (FIGURE FO-1, SHEETS 2 AND 3) - Continued

SYNC MODE Switch (SMS)

The SYNC MODE switch has three sections and four positions for the four sync modes: OFF, SEMI-AUTO,
AUTO, and PERMISSIVE. OFF is used when not paralleling generator sets, the other modes are for paralleling.
The first section controls the AUTO SYNC input to the GSC. The AUTO SYNC input to the GSC is grounded in
AUTO and PERMISSIVE modes. When grounded, this input enables the automatic synchronization of Generator
G1 with the load bus. The second section controls the SYNC CHECK input to the GSC. The SYNC CHECK input
to the GSC is grounded in SEMI-AUTO and PERMISSIVE. When grounded, this input enables the synchroscope
function on the GSC. The third section is integrated with the opening and closing of the load contactor K1 and is
discussed more fully with K1 operation. Note that SEMI-AUTO and PERMISSIVE are wired together.

Load Contactor K1, K1 Relay (KR), and Contactor Control Switch (CCS) aka AC CIRCUIT INTERRUPTER
Switch

Load contactor K1 is controlled by K1 Relay (KR), GSC Run Relay (RR) A1 K5, and GSC Programmable Spare
Relay (PSR) A1 K8. GSC PSR (A1 K8) is programmed to close whenever there are no alarm conditions sensed by
the GSC. When the ENGINE CONTROL switch (ECS) is placed in START (or in AUTO and a remote start
command is received), the GSC closes RR (A1 K5). The fuse labeled F7GSC is actually A1 F6. Note that the GSC
checks to be sure there are no faults present prior to closing RR and verifies that all previous faults have been
reset, otherwise RR will not be closed. As long as no faults are detected, PSR will also be closed. The cool down
relay (CDR) is normally closed and opens at the start of Cool-down Mode. Under these conditions, +24 Vdc is
connected to relay KR. The SC contacts will be closed unless the OL/SC module detects a short circuit condition.
These contacts are reset to closed by turning the engine control switch to OFF/RESET or pushing the LAMP
TEST button on Alarm Module A2. The battle short switch shorts across the next two contacts to disable them in
Battle Short Mode. The Generator Fault Relay contacts are normally closed and open when the GSC detects a
generator fault condition. The OL contacts will be closed unless the OL/SC module detects an overload condition.
These contacts are reset to closed by turning the ENGINE CONTROL switch to OFF/RESET or pushing the
LAMP TEST button on Alarm Module A2.

If the PARALLEL/UNIT switch is set to UNIT, setting the AC CIRCUIT INTERRUPTER switch to CLOSED will
apply ground to KR, which will close Load Contactor K1, as long as DBHI and DBLO are closed. Auxiliary
contacts on K1 latches KR on after KR is energized. DBHI and DBLO are relays on the final generator output
(after the load contactor K1) which monitor the output for presence of voltage. If there is no voltage on the load bus,
these relay contacts will be closed. If either 208 or 416 Vac are detected by these relays, one or the other
contacts will be open and closing of the AC CIRCUIT INTERRUPTER switch will not apply ground to KR. This will
inhibit closing the Load Contactor K1. Note that DBHI and DBLO have no affect after KR is latched on.

NOTE
Electrically, if the SYNC MODE switch is in AUTO, it does not matter which position the
PARALLEL/UNIT switch is in.

If the PARALLEL/UNIT switch is set to PARALLEL and SYNC MODE switch set to AUTO, GSC can apply ground
to relay KR by grounding the CLOSE BREAKER output. Auxiliary contacts on K1 latch KR on after KR is
energized.

0003-18
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DC POWER DISTRIBUTION (FIGURE FO-1, SHEETS 2 AND 3) - Continued

If the PARALLEL/UNIT switch is set to PARALLEL and SYNC MODE switch is in SEMI-AUTO or PERMISSIVE,
the CLOSE BREAKER output (P7-37) becomes an enable signal. Closing the AC CIRCUIT INTERRUPTER
switch will not apply ground to KR unless the GSC has activated the CLOSE BREAKER output. Auxiliary contacts
on K1 latches KR on after KR is energized. A set of auxiliary contacts on KR energizes K1. During operation, run
relay (RR) A1 K5 is energized until after cool down mode when the GSC opens the electronic governor relay
(EGR) on the GSC to stop the engine, then RR is opened also. When ENGINE CONTROL is set to
COOL DOWN/STOP, the GSC spare output at P7-36 is grounded and relay CDR (cool down relay) is energized.
The contacts of CDR are in series with relay KR and drop out KR, which drops out K1. The generator set runs for
5 minutes (programmable) and then shuts down the engine by opening the electronic governor relay (EGR) on
the GSC.

The short circuit (SC) and overload (OL) contacts are part of the OL/SC module. In the event the output current
goes above 130% of maximum (overload condition) or 400% of maximum (short circuit condition) the appropriate
contacts will open, de-energizing KR and K1. This will disconnect the load. The GSC directly controls the
Generator Fault Relay (GFR). If the GSC detects a generator fault, the GFR output energizes the GFR relay and
KR and K1 are de-energized, disconnecting the load from Generator G1. The paralleling relay (PAR) is connected
to an auxiliary set of contacts on K1 only when the PARALLEL/UNIT switch is in PARALLEL. Contacts on the
paralleling relay connect Load Sharing Module (LSM) A4 to the paralleling connectors and hence to the LSM in all
other generators in parallel. The press-to-test lamp above the AC Interrupt switch is connected to a set of auxiliary
contacts from K1 to indicate when K1 is energized. A line from this connection goes to a spare input of the GSC
(P7-25) to tell it that K1 is closed.

AC POWER DISTRIBUTION (FIGURE FO-1, SHEETS 4 AND 5)

Generator G1

Generator G1 is a three phase Y-connected generator with two sets of coils. When these coils are placed in
parallel, the generator is capable of 208 Vac phase-to-phase and 120 Vac any phase-to-ground. If connected in
series the generator will put out 416 Vac phase-to-phase and 240 Vac any phase-to-ground. The Reconnection
Board TB1 does this changeover from series to parallel connection. The reconnection board (FO-1, sheet 4) is
shown pictorially rather than schematically. Note that the references T3, T6, etc. relate to the numbers on the
generator output wires. They are labeled 3, 6, etc correlating with T3, T6, etc. Electrically, T3 is connected to
Reconnection Board TB1 terminal labeled 3, T6 is connected to Reconnection Board TB1 terminal labeled 6, etc.
There are metal bus bars riveted to Reconnection Board TB1 that short between the generator wires in order to
connect the generator coils in parallel for 120/208 mode or in series for 240/416 mode. The bus bars are shown in
dotted lines on the schematic. There is also a bus bar connecting terminals labeled 10, 11, 12, and 13. These are
all connected to the common wire #10 (Ground) and wire 110 coming in and going out of Reconnection Board
TB1.

The output of Reconnection Board TB1 goes through several current transformers, relay K1 (shown as a circuit
breaker) and then to Load Connection Board TB2. The coil of K1 is shown on the DC circuits (FO-1, sheet 2 and
sheet 3). There are filters and varisters connected between the outputs and chassis ground. A removable jumper
on the Load Connection Board TB2 connects the chassis ground (which will be externally connected to a
grounding rod) and the neutral line out of the generator.

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AC POWER DISTRIBUTION (FIGURE FO-1, SHEETS 4 AND 5) - Continued

Digital Voltage Regulator (DVR) A3

DVR A3 monitors the output of Generator G1 prior to Reconnection Board TB1 and regulates the output of the
generator according to the parameters programmed into it. The voltage from wires G1-7, G1-8, and G1-9 is
connected to the DVR. Also, PT2 measures the voltage between G1-7 and G1-8, divides the voltage in half, and
connects this to the DVR. PT3 is the same as PT2, except measures the voltage between G1-8 and G1-9. Fuses
F1, F2, and F3 protect PT2 and PT3. Whether the generator is connected for 208 or 416 Vac output, the DVR is
monitoring the same voltage. Current transformer CCCT monitors the current in wire G1-8 and G1-2 from the
generator. This total current will not change whether the generator is connected for 208 or 416 Vac output. CCCT
generates a voltage across a 1 ohm resistor A7R2 at a rate of 1.25 Vac per 200A. The voltage across this 1 ohm
resistor is input to the DVR. Rheostat VAR (Voltage Adjust Rheostat) is connected to the DVR to allow the
operator to adjust the voltage approximately ±10%. (This control is labeled VOLTAGE on the front panel.) Power
for the DVR comes from the battery (FO-1, sheet 2 and sheet 4 ). The DVR monitors the output voltage from the
generator and applies a voltage to the field coil (F+ and F-) on the generator in order to regulate the output voltage
of the generator. Essentially, the higher the voltage applied to the field, the higher the output voltage of the
generator. The nominal voltage across this coil is 4.6 Vdc at no load and approximately 14 Vdc at full load. The
voltage for the field coil actually comes from the generator output through PT2 and PT3. Because of this, a Field
Flash circuit provides an excitation at the initial startup of the generator set to start this process. The connections J
and K to the field coil circuit come from the Field Flash circuit (FO-1, sheet 2). This circuit provides an initial
voltage excitation to the field in order to get an initial output from the generator. Without this excitation the
generator will not produce power capable of supplying a load.

Load Sharing Module (LSM) A4

Three current transformers CT-7, CT-8, and CT-9, monitor the current from the generator and supply input signals
to LSM A4 and the overload (O/L) and short circuit (S/C) module. The output of each current transformer goes
through a resistance on LSM A4, then through a resistance on the O/L and S/C module. A voltage is generated
across the input of each module for control purposes. LSM A4 is also connected to lines G1-7, G1-8, and G1-9
from the generator and monitors the voltage out of Generator G1 before Reconnection Board TB1. The paralleling
input (pins 10, 11, and 12) is repeated completely in the DC circuits (FO-1, sheet 3) and was discussed there. The
ISOCHRONOUS/DROOP switch is connected to LSM A4 through an auxiliary set of contacts on relay K1.

Ground Fault Circuit Interrupter (GFCI)

The GFCI picks up one phase (G1-9) from Generator G1 before Reconnection Board TB1 and connects 120 Vac
to a standard 2 gang outlet on the rear of the generator set next to the control panel. This is for a trouble light or
other auxiliary components.

GSC Voltage and Current Monitoring

Three current transformers (CT1, CT2, and CT3) measure the current out of Generator G1 after Reconnection
Board TB1. The outputs of these current transformers are connected to three transformers located on AC
Transformer Box (ATB) A5. The outputs of these transformers go to the GSC for monitoring Generator G1 output
current. Lines G1-1, G1-2, and G1-3 from Generator G1 output, after Reconnection Board TB1, are connected to
transformers T1, T2, and T3 on ATB A5 through protection fuses. The outputs of these transformers are connected
to the GSC for monitoring the output voltage of Generator G1. There are two transformers (T1 and T2) on Bus
Transformer Box (BTB) A6. These monitor the load bus voltage on the output after load contactor K1; and their
outputs are connected to the GSC. The inputs are fused for protection.

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AC POWER DISTRIBUTION (FIGURE FO-1, SHEETS 4 AND 5) - Continued

Dead Bus Low (DBLO) and Dead Bus High (DBHI) Monitoring

Relay DBHI is connected after Load Contactor K1 between L1 and L3 (K1A2 to J31-19 and K1 B2 to J31-8) to
monitor for voltage on the load bus (the output of the generator set). DBLO energizes if 208 Vac is present on the
load bus. DBHI energizes if 416 Vac is detected on the load bus. R3 reduces the voltage seen by the 230 Vac coil
of DBHI so that it will only energize if it sees 416 Vac. DBHI will not energize at 208 Vac. One set of contacts on
DBHI is used to remove the 416 Vac from the coil of DBLO in order to protect the coil from excessive voltage. The
other contacts for DBLO and DBHI are discussed as part of the DC Power Distribution discussion.

Overload and Short Circuit (OL/SC) Module

The OL/SC module gets a current input from current transformers CT-7, CT-8, and CT-9, which are connected
before Reconnection Board TB1. This module monitors the output current and provides two sets of relay contacts
for overload condition and two relay contacts for short circuit condition. Overload condition is defined as an output
current over 130% of the maximum current rating of Generator G1. Short circuit is defined as an output current
over 400% of the maximum current rating of Generator G1. The relay outputs of the module latch after a condition
has been sensed. Setting ENGINE CONTROL to OFF/RESET will reset the latched relays on this module. Also
pressing the LAMP TEST button on Alarm Module A2 will reset the relays on this module. An overload or short
circuit condition causes an alarm on the alarm module and disconnects the load from Generator G1. The overload
condition is disabled in Battle Short mode. The relay contacts and the power input connections for the OL/SC
module are shown in the AC circuit, but the use is discussed as part of the DC Power Distribution discussion. In the
DC schematic, the OL/SC contacts are separate and labeled O/L and S/C respectively.

ELECTRONIC MODULAR CONTROL PANEL (EMCP)

The Electronic Modular Control Panel (EMCP) incorporates Generator Set Control A1 (GSC), Alarm Module A2,
Digital Voltage Regulator (DVR) A3, the Load Sharing Module (LSM) A4, Resistor Assembly A7, a relay module,
panel switches and controls, and various terminal boards.

GENERATOR SET CONTROL (GSC)

GSC Inputs

The GSC (Figure 9) is a microprocessor based control system which accepts programmed values, switch inputs,
data from ECM A8, and data from LSM A4 to control the speed of the engine. A constant engine speed maintains
the desired output frequency. The GSC inputs to the Central Processing Unit (CPU) include signals from panel
controls including touch pad inputs, ENGINE CONTROL switch settings, SYNC MODE switch setting, and the
PUSH TO STOP EMERGENCY STOP switch. External signals are input from engine sensors, generator output
voltage and current samples, load bus voltage samples and the ECM. LSM A4 interacts with the GSC as well.
The touch pad allows inputting parameters into the GSC to determine the desired output voltage and frequency,
and how the GSC reacts to various stimuli. The touch pad also allows the user to display all of the voltages,
currents, and calculated power levels, real and reactive as desired. The generator output voltage, current, and the
load bus voltage are all monitored and can be displayed as desired on the EMCP displays. LSM A4 monitors the
load that the generator powers and allows fine tuning of the load sharing via a speed setting potentiometer. The
LSM sends a speed correction signal to the GSC in order to fine tune the speed based on the load sharing of the
generator. This is utilized primarily when the generator set is in parallel with another generator. Most engine
sensors are connected to the engine control unit and their status transmitted to the GSC via the CAT Data Link.
One engine speed sensor and a low fuel level sensor are directly connected to the GSC. The engine speed
sensor provides positive feedback to the GSC that the engine is operating at the desired speed. The low fuel

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GENERATOR SET CONTROL (GSC) - Continued

sensor initiates a controlled shutdown before the engine runs out of fuel. The ENGINE CONTROL switch
determines whether the engine is to start, stop, or run. The SYNC MODE switch (called System Mode Switch
(SMS) in electrical descriptions) determines the mode of operation with regards to the paralleling capability. The
PUSH TO STOP EMERGENCY STOP pushbutton (also called Emergency Stop Push Button (ESPB))
immediately stops the engine and should only be used in an emergency. ECM sends alarm signals to the GSC for
any sensors that are directly connected to the ECM.

Figure 9. Generator Set Control.

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GENERATOR SET CONTROL (GSC) - Continued

GSC Outputs

The GSC outputs signals to the display, the ECM, Load Contactor K1, and the EMCP relay module. The GSC
display consists of an upper display, a lower display, and a column of indicators to the left of the upper and lower
displays. The upper display shows the average voltage, frequency, and total current the generator set is putting
out. By pressing the AC METER key on the touch pad, the upper display can display: line-to-line voltage,
generator frequency, and current for each phase; voltage line-to-line for all three phases; line current for all three
phases at once; or voltage line-neutral for all three phases at once. The upper display is also used to display any
fault codes identified by the GSC or by the ECM.

GSC Displays

The GSC lower display is capable of displaying one of the following:

Total Real Power (kW) Real Power Phase A (kW)

Total reactive power (KVAR) Real Power Phase B (kW)
Total apparent power (kVA) Real Power Phase C (kW)
Percentage of rated power (%kW) Power Factor Phase A
Power factor (average) Power Factor Phase B
Total energy output (kW/h) Power Factor Phase C
Total reactive energy output (kVARHr)

The lower display also has a series of arrows pointing downward to symbols printed below the display. These
arrows appear in order to indicate alarm conditions sensed by the GSC and/or ECM. The lower display also lights
up designations K1, K2, etc to indicate the condition of relays K1 through K8 in the relay module internal to the
GSC (Table 1). When a particular symbol appears, the associated relay is energized. This is strictly status and is
helpful when troubleshooting. An additional feature of the lower display is that of a synchroscope. When manually
synchronizing the generator output to another generator, the phase relationship between the generator and the
voltage on the load bus are shown graphically on the lower display. This allows the two systems to be brought in
sync before bringing the generator on line.

The column of indicators at the left side of the GSC indicate impending problems or what condition caused a
shutdown. The ECM resides on the engine and controls the operation of the engine, such as starting, stopping,
speed control through fuel control, ignition timing, and monitors various sensors on the engine. Problems
diagnosed by the ECM are sent via the CAT Data Link to the GSC and displayed on the GSC display with an E
suffix to identify them as engine diagnosed. The GSC sends a speed control signal and a governor on/off signal to
the ECM to control the speed of the engine, which determines the frequency of the output from the generator. The
GSC monitors various sensor outputs, plus the ECM sensors to enable or disable connecting the generator to the
load via Load Contactor K1. The GSC is also able to disconnect the generator from the load via Load Contactor
K1 in the event that the ECM or the GSC detects a failure that would keep the generator set from performing its
duty.

The GSC is a multi-purpose controller meant to be interfaced with a wide range of engine types and
configurations. The output from the GSC goes to a relay module inside the GSC and these relay outputs are
interconnected to the rest of the control system (refer to DC Power Distribution discussion for this interface). There
are also spare inputs and outputs described in the DC Power Distribution discussion. One of the purposes of the
GSC is to determine when the generator output is synchronized well enough with the voltage on the load bus in
order to connect the generator to the load. This can be done automatically or manually with the aid of the
synchroscope feature of the GSC.

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GENERATOR SET CONTROL (GSC) - Continued

Table 1. GSC Display Relay Identification.

RELAY NAME LIGHTS WHEN

K1 Electronic Governor Relay (EGR) On whenever ECM is enabled (engine is running).

(Output is not used) Internal connection shorts across
ENGINE CONTROL switch so that power can not be
removed from GSC while engine is running.

K2 Generator Fault Relay (GFR) On when a generator fault is detected. Engaged to

disconnect the load.

K3 Crank Termination Relay (CTR) On when the engine is running on its own (and the
starter should be released). Output is not used.

K4 Starting Motor Relay (SMR) After ENGINE CONTROL is set to START, K4 is on

while starter is cranking. Goes out after 10 seconds
or after engine is detected as running. If engine does
not start, light goes off for 10 seconds, then comes
back on for 10 seconds trying again to start the
engine.

K5 Run Relay (RR) On whenever the engine should be running.

K6 Air Shut Off Relay (ASR) On during fault shutdowns. Not used.

K7 Fuel Control Relay (FCR) On when engine should be running. Output not used.
Internal connection shorts across ENGINE CONTROL
switch so that power can not be removed from GSC
while engine is running.

K8 Programmable Spare Relay (PSR) On when alarm condition occurs that would cause the
GSC to disconnect the load.

0003-24
 TM 9-6115-730-24 0003

DIGITAL VOLTAGE REGULATOR (DVR A3) MODULE

DVR A3 (Figure 10) is a microprocessor based, digital voltage regulator. The regulator is specifically designed to
regulate the output voltage of a generator in an engine/generator set arrangement. The DVR consists of a touch
pad, digital display, CPU, voltage and current monitoring circuits and field drive circuits.

Figure 10. Digital Voltage Regulator.

Touch Pad and Digital Display

The touch pad allows the user to input operating and alarm parameters into the DVR and to check alarm conditions
past and present. When power is applied, :01 is displayed. This is the generator output Voltage Parameter. The
touch pad allows the user to access the following data, which is displayed on the digital display:

• Voltage • 3 Phase kVAR

• Frequency • Hours
• Current • Software ID
• Reactive Output Power • Latest Fault
• Generator Real Current • Previous Fault
• Exciter Field Current

CPU

The CPU contains the program which monitors generator output voltage and current, determines how much drive
current to supply the generator field in order to maintain desired output voltage, and monitors generator operation.
Alarm conditions are displayed on the digital display.

Voltage and Current Monitoring Circuits and Field Drive Circuits

The generator output is monitored for voltage and current. This data is input to the CPU where the data is
compared to the desired output from the generator. The field drive circuits provide field excitation current for the
generator, which regulates the output voltage of the generator.

0003-25
 TM 9-6115-730-24 0003

DIGITAL VOLTAGE REGULATOR (DVR A3) MODULE - Continued

Startup Profile

The DVR operates under one of two operational profiles. When the DVR senses that the generator is starting to
produce voltage, the Startup profile is used. When the output frequency has increased above the knee frequency
(programmable), the DVR will switch over to the Loading and Stopping profile.

In the Startup Profile (Figure 11) the DVR will follow a 1:1 V/Hz profile after generator frequency (engine speed)
has increased above the under frequency point (parameter: 10). This profile continues until the frequency reaches
the knee frequency (parameter :06). Once the knee frequency has been reached, the generator will be regulated
by the DVR to produce full rated voltage, as set by parameter :01. The DVR then switches to the loading and
stopping profile.

Figure 11. DVR Startup Profile.

0003-26
 TM 9-6115-730-24 0003

DIGITAL VOLTAGE REGULATOR (DVR A3) MODULE - Continued

Loading and Stopping Profile

Loading

The loading and stopping profile (Figure 12) defines how the DVR will react to a reduction in frequency below the
knee frequency. A drop in frequency from the generator is usually due to one of two occurrences: either a heavy
load was applied which will take the generator a few seconds to recover from, or the engine driving the generator
is shutting down. In either case, the DVR reduces the generator output voltage. The reduction in voltage reduces
the power requirement of the load, thus allowing the engine to recover faster for a given increase in load.

The rate at which the DVR reduces the output voltage is called Decreasing V/Hz Slope 1 and is set to 3 V/Hz by
parameter :07. This rate is effective when the generator frequency is no more than 5 Hz below the knee
frequency.

Figure 12. DVR Loading and Stopping Profile.

Stopping

If the frequency drops below 5 Hz below the knee frequency, the generator set is assumed to be shutting down.
The DVR will reduce the output voltage further using a parameter called Decreasing V/Hz Slope 2, which is set to
2 V/Hz by parameter :08. This rate is effective until the generator gets to the minimum voltage setpoint (parameter
:09). This is the lowest voltage the DVR will attempt to regulate. The voltage will attempt to regulate at this point
until the frequency gets to the under frequency point (parameter: 10) at which point the voltage will decrease to a
minimum value.

0003-27
 TM 9-6115-730-24 0003

DIGITAL VOLTAGE REGULATOR (DVR A3) MODULE - Continued

Voltage Droop When Connected In Parallel

When generators are operated in parallel, the engine speed regulator (i.e. GSC via LSM A4) controls the sharing
of the real power requirements (kW) of the total system load. The DVR controls the sharing of the reactive power
requirements (kVAR) of the total system load. If the output voltage of one generator is set slightly higher than the
other(s), it will supply lagging reactive current to the other generators in the group. This current will circulate
between the generators, possibly causing ampere overloading. One method of minimizing this effect is to cause
an individual generator output to sag, or "droop", in proportion to the lagging reactive current flow from it. As
reactive lagging generator output current increases, the DVR will cause the output voltage to droop (voltage will
decrease) proportionally. If the measured reactive output current is leading, the output voltage will rise (voltage
will increase) proportionally. In either case, this action will reduce the reactive current for better KVAR sharing
with other units. The droop percentage (parameter :30) determines how much the generator output voltage will
vary for a given amount of reactive current.

LOAD SHARING MODULE (LSM A4) INTERNAL OPERATION

The LSM consists of load power monitoring, load comparator, sync dynamics summer, speed trim summer, pulse
width modulation (PWM) output, A4K1 relay, circuits and a power supply for internal circuitry.

Load Power Monitoring

The output of current transformers CT-7, CT-8, and CT-9 is input to the load power monitoring circuit. Each current
is multiplied by the voltage monitored at pins 1, 2, and 3 of the LSM to generate voltages proportional to the
power in each phase of the output. These voltages are summed and input to a variable gain amplifier. The
amplifier can be calibrated, using the load gain potentiometer, to compensate for variations in components. The
output of the amplifier is input to the load comparator circuit.

Load Comparator Circuit

The Load Signal connection to the load comparator circuit on pins 22 and 23 is used for setup only. The load
sharing lines input (pins 10 and 11) to the load contactor circuit are connected to the paralleling connectors J32
and J33 in this generator set. Therefore, this point is connected to all other LSM A4 in other generators. This
connection is made through J32, J33, the paralleling relay PAR in the generator set, and A4K1 in this module.
Refer to DC circuits (FO-1, sheet 2 and sheet 3 ) for interconnections external to LSM. By connecting the load
sharing lines of this module to those in other generator sets (via the paralleling cables), the load signal voltage is
balanced with the other generator sets connected here. The load comparator circuit has a load gain potentiometer
to adjust each generator set load signal so that the load signal voltage of each is the same at full load. This
compensates for different CT ratios or different generator set sizes. In droop mode (A4K1 not energized), some of
the power signal from the variable gain amplifier is subtracted from the main power signal by the differential
amplifier in the load comparator circuit. The setting of the Droop potentiometer (only active in Droop) controls the
amount in the load comparator circuit. This reduces engine power according to the droop percentage set by this
potentiometer.

Sync Dynamics Summer

The sync input (pins 24 and 25) comes from the GSC and is a ±5 Vdc signal developed to control the speed of the
engine (and hence the generator). This signal is processed by the sync dynamics circuit and summed with the
output of the load comparator circuit.

0003-28
 TM 9-6115-730-24 0003

LOAD SHARING MODULE (LSM A4) INTERNAL OPERATION - Continued

Speed Trim Summer

The speed trim potentiometer is the FREQUENCY potentiometer on the EMCP and permits manual adjustment of
the load or frequency of the generator. This signal is summed with the output of the sync dynamics summer and
input to the PWM circuit. The potentiometer can trim the frequency of the generator output approximately 10%
above and below nominal in unit mode. In parallel mode, the potentiometer can change the load demand if in
droop mode also.

Pulse Width Modulation (PWM) Output

The PWM circuit takes the sum of all the inputs and converts the analog voltage level to a PWM signal for driving
ECM, setting the engine speed. The frequency is approximately 500 Hz. The duty cycle ranges from 10% for
lowest decrease in speed or load, to 90% for maximum increase in speed or load percentage. The duty cycle
varies according to the magnitude of difference between the desired load and the actual power generated.

Relay A4K1

Relay A4K1 is energized when the ISOCHRONOUS/DROOP switch is in ISOCHRONOUS and the load contactor
is energized. The contacts of A4K1 connect the load sharing input/output to the load comparator circuit. The 24
Vdc input from the batteries is converted to a plus and minus power source (+V and -V) and a plus and minus
reference supply (+VR and -VR) for the amplifiers in the module. In a non-paralleled condition, or when the
ISOCHRONOUS/DROOP switch is in DROOP, the load comparator circuit is not connected to the load sharing
lines. A4K1 is open in Droop mode and the external PAR relay disconnects this output from any other generators
in Unit mode. In this configuration, the power measured by the load power monitoring circuits are summed with the
sync input from the GSC and the speed trim potentiometer and the PWM output generated from that signal. In a
paralleled condition, you must be in isochronous mode in order to connect the load sharing lines to at least one
other (possibly more) LSM A4. In this mode, this average load signal of all sets in parallel is then summed with
the sync input and the speed trim potentiometer input to generate the PWM signal to the ECM. By doing this, the
speed loop is biased to divide the load equally between paralleled generator sets.

In a paralleled condition with Droop enabled, the frequency will vary with load. To minimize this, one generator
must be in isochronous mode. This generator set maintains the frequency of the system. On the paralleled
generator sets in droop mode, the droop percentage set into the LSM by the droop potentiometer and the speed
setting determine the load that is carried by the individual generator.

0003-29
 TM 9-6115-730-24 0003

GENERATOR

The generator (Figure 13) is a brushless, self-excited, externally voltage regulated, synchronous AC generator.
The generator consists of five major components: the main stator (armature); main rotor (field); exciter stator
(field); exciter rotor (armature); and rectifier assembly. The DVR controls generator output. The generator exciter
consists of a stationary field and a rotating armature. The DVR applies voltage to the stationary field (exciter
stator). The exciter armature generates an AC voltage that is rectified by the rotating rectifier assembly,
converting it to a pulsating DC signal. This DC is applied to the main rotor (field). As the generator shaft rotates,
the main rotor (field) induces a voltage into the main stator (armature). The main stator’s voltage output is
sampled and compared to the programmed desired value in the DVR The exciter field power is increased or
decreased in order to regulate the main stator output to the desired value. There are four poles on the generator.
There are two + poles and two - poles. During each revolution of the generator, two complete sine waves are
produced by the alternating +, -, +, - poles. For 60 Hz operation, the generator shaft will have to turn 60 ÷ 2
revolutions per second (rps) = 30 rps. Engine speed is in rpm, therefore 30 rps x 60 seconds per minute = 1800
rpm engine speed required for 60 Hz operation. 50 Hz operation is the same process (or 50 ÷ 60 x 1800 = 1500
rpm). Note that an excitation is required to get the process started. This excitation, also known as a Field Flash, is
described in the DC Power Distribution section. Since there is no permanent magnet structure in the
generator assembly, a voltage spike is applied to the exciter field (stator) to ensure that the regulation process
gets off to a good start. This generator is built with 2/3 pitch main stator windings and full Amortisseur (damper)
windings. These features make the generators suitable for parallel operation when used with the proper
voltage and load regulating devices.

Figure 13. Generator.

0003-30
 TM 9-6115-730-24 0003

WINTERIZATION KIT (FIGURE FO-1, SHEET 6)

There are two components of the winterization kit (Figure 14). One is the LCD display heaters and the other is the
fuel fired coolant water heater and pump. The LCD display heater consists of HTR1 and HTR2. These heaters
receive power from one of two directions. There is a thermostatic switch (TS) in the control panel that closes
when the temperature falls below -20°F ±10°F (-28.9°C ±5.6°C). This switch applies +24 Vdc power to HTR1 and
HTR2 in order to keep the liquid crystal displays (LCD) in the GSC and DVR from freezing. Note that this power is
only available when the ECS is NOT in OFF. There is also a connection to the winterization control box that will
apply power to these resistors any time the winterization system is turned on at the control panel.

The second component of the winterization kit is a fuel fired coolant water heater and pump. The heater burns
fuel from the main fuel tank in order to heat the coolant water. The water is then circulated through the engine in
order to prevent it from freezing up. When the fuel fired heater is turned on, an internal combustion blower starts,
the water pump starts circulating coolant, and the preheating phase of the glow plug is started.
After approximately 60 seconds, the heater fuel pump starts to add fuel to the combustion chamber. The fuel/air
mixture ignites. The speed of the air fan increases as well as the fuel pump speed through four stages. Low, Med,
High, and Power in order to bring the combustion chamber up to operating temperature.

The glow plug protection circuit has a flame detector, which will restart the heater if no flame is detected. If no
flame is detected twice, the heater is shut down and power must be cycled OFF and back ON to restart. The
heater continues to operate in the Power mode until either the temperature exceeds 162°F (72°C) or 2 hours has
elapsed (maximum time allowed in Power mode). The heater then switches between the four modes, as required
based on temperature of the coolant (which relates to heat necessary to raise the temperature of the coolant).

Figure 14. Winterization Kit.

0003-31
 TM 9-6115-730-24 0003

COMMON TOOLS AND TEST EQUIPMENT

For authorized common tools and equipment, refer to the Modified Table of Organization and Equipment (MTOE),
Common Table of Allowances (CTA) 50-970, Expendable/Durable Items (Except: Medical, Class V, Repair Parts,
and Heraldic Items), or Army Medical Department Expendable/Durable Items CTA 8-100, as applicable to your
unit.

SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT

Special Tools; Test, Measure, and Diagnostic Equipment (TMDE); and support equipment are needed for unit and
direct support maintenance. They are listed in the Repair Parts and Special Tools List (RPSTL), TM 9-6115-730-
24P, and in the Maintenance Allocation Chart (MAC) in WP 0123.

REPAIR PARTS

Repair parts are listed in the TM 9-6115-730-24P.

END OF WORK PACKAGE

0003-32
 TM 9-6115-730-24

CHAPTER 2

FIELD LEVEL
TROUBLESHOOTING PROCEDURES
 TM 9-6115-730-24

CHAPTER 2

FIELD LEVEL TROUBLESHOOTING PROCEDURES

WORK PACKAGE INDEX

Title WP Sequence No.

INTRODUCTION .................................................................................................................................... 0004

TROUBLESHOOTING INDEX................................................................................................................ 0005
GSC ALARM INDICATORS AND FAULT CODE TROUBLESHOOTING PROCEDURES ..................... 0006
SP FAULT CODE TROUBLESHOOTING PROCEDURES .................................................................... 0007
AL FAULT CODE TROUBLESHOOTING PROCEDURES..................................................................... 0008
GSC FAULT CODE TROUBLESHOOTING PROCEDURES.................................................................. 0009
DVR FAULT CODE TROUBLESHOOTING PROCEDURES.................................................................. 0010
FAILURES WITHOUT A FAULT CODE TROUBLESHOOTING PROCEDURES ................................... 0011
ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING SOFTWARE INSTALLATION.......................... 0012
ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING .......................................................................... 0013
 TM 9-6115-730-24 0004

FIELD LEVEL TROUBLESHOOTING

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
INTRODUCTION

MALFUNCTION/SYMPTOM INDEX

The Field level troubleshooting Malfunction/Symptom Index (WP 0005) lists common malfunctions found during
Field level maintenance of the 200 kW Tactical Quiet Generator (TQG). Identify the malfunction/ symptom that
best describes your problem and then turn to the Troubleshooting Procedures (WP 0006 thru WP 0013). Follow
each step in sequence through the corrective actions listed in the troubleshooting procedures table until a fault is
identified and resolved.

NOTE
Before you use troubleshooting procedures, be sure you have performed PMCS.

TROUBLESHOOTING PROCEDURES

The Troubleshooting Procedures (WP 0006 thru WP 0013) contain procedures that identify symptoms and
malfunctions, that are followed by corrective actions required to return the 200 kW TQG system to normal
operation. The troubleshooting procedures cannot list all possible symptoms or malfunctions or the tests and
inspections required for corrective action. If a malfunction is not listed or is not corrected by the listed corrective
actions, notify your supervisor. Before using troubleshooting be sure you have performed PMCS.

The work package INITIAL SETUP outlines what is needed for the task as well as certain conditions which must be
met before starting the task. Don’t start a task until the following conditions exist:

1. You understand the task.

2. You understand what you are to do.
3. You understand what is needed to do the work.
4. Ensure that you have the correct manual, all related manuals, and test equipment.

The work package troubleshooting procedures have three divisions: SYMPTOM, MALFUNCTION, and CORREC-
TIVE ACTION. Note that the SYMPTOMs are first listed in the Malfunction/Symptom Index (see WP 0005).

SYMPTOM: Symptoms are the indication that the generator set is not operating properly or at peak performance.
The symptom can be an electronically displayed fault code, an alarm or shutdown of the generator set, a visual
observation or a sound. Symptoms tell you that there is a problem.

MALFUNCTION: The malfunctions cause the symptom. In the troubleshooting procedures MALFUNCTIONs are
presented in order of the most likely cause for the SYMPTOM. MALFUNCTION troubleshooting procedures should
be performed in the order in which they appear.

CORRECTIVE ACTIONs are actions intended to correct the problem. The CORRECTIVE ACTION consists of
tests and inspections and any steps you take to isolate the malfunction. A test or inspection leads to a corrective
action. These are the “if” statements that tell you what to do when the malfunction is not fixed. For Army, corrective
action is accomplished by submitting a 5988E to the TAMMS clerk and the clerk processing a job order, with the
unit or direct support (Field Level) maintenance team. For Air Force, corrective action is accomplished by
submitting an AFR 66-1 maintenance reporting form.

Repairable LRUs shall be turned-in, in accordance with official supply procedures.

0004-1
 TM 9-6115-730-24 0004

TQG TROUBLESHOOTING

The 200 kW TQG set electronics has continuous self-testing capability. Most problems with the generator set will
generate a fault code that is displayed on the Generator Set Control (GSC) or the Digital Voltage Regulator (DVR).
The troubleshooting procedures for the 200 kW TQG are broken into six separate Work Packages (WP):

WP 0006 GSC Alarm Indicators and Fault Code Troubleshooting Procedures

WP 0007 SP Fault Code Troubleshooting Procedures
WP 0008 AL Fault Code Troubleshooting Procedures
WP 0009 GSC Fault Code Troubleshooting Procedures
WP 0010 DVR Fault Code Troubleshooting Procedures
WP 0011 Failures Without a Fault Code Troubleshooting Procedures
WP 0012 Electronic Technician (ET) Troubleshooting Software Installation
WP 0013 Electronic Technician (ET) Troubleshooting Procedures.

Before trying any fault isolation, make note and record all of the fault codes displayed on the GSC and DVR. Also,
note and record any fault lamps that are lit on the GSC and the alarm module.

The failure analysis here usually assumes a single fault code indication. Because of extensive self-testing
capability, a single failure will often generate multiple fault codes (e.g. a failure of a power supply will generate a
failure code for all of the sensors powered up by that power supply). It may be necessary to read through all of the
associated fault isolation procedures prior to starting in order to assess the fault location.

The voltages and currents in the 200 kW TQG are dangerous and capable of causing death instantaneously. The
engine and generator set are heavy and represent enormous mechanical power. Refer to the WARNING
SUMMARY before attempting to troubleshoot system. The following warnings, cautions, and notes should be read
and followed during all attempts at troubleshooting.

WARNING
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

High voltage is produced when this generator set is in operation. Make sure unit is completely
shut down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

Dangerously high voltage can exist across current transformer (CT) output with engine running.
CT could explode if disconnected from load with engine running. Do not disconnect CT with
generator rotating. Failure to comply can cause serious injury or death to personnel.

Slave receptacle (NATO connector) is electrically live at all times and is unfused. The Battery
Disconnect Switch does not remove power from the slave receptacle. NATO slave receptacle has
24 VDC even when Battery Disconnect Switch is set to OFF. This circuit is only dead when the
batteries are fully disconnected. Disconnect batteries before performing maintenance on the
slave receptacle. Failure to comply can cause injury or death to personnel.

0004-2
 TM 9-6115-730-24 0004

GSC ALARM INDICATORS AND FAULT CODE TROUBLESHOOTING

For troubleshooting using the fault identification displayed by the GSC you must first note the condition of the
various lamps and displayed information on the GSC displays.

Figure 1. Generator Set Control (GSC) Displays and Dedicated Alarm Indicators.

0004-3
 TM 9-6115-730-24 0004

GSC ALARM INDICATORS AND FAULT CODE TROUBLESHOOTING - Continued

Dedicated Shutdown Indicators Starts flashing when alarm condition is detected. Lights continuously after
shutdown.

Fault Shutdown Indicator Flashes to indicate system was shut down due to a fault.

Fault Alarm Indicator Flashes to indicate an alarm condition. Component Identifier (CID) and
Failure Mode Identifier (FMI) codes will be displayed on the upper display to
identify what is wrong. The CID identifies the component that has a problem,
the FMI describes the nature of the failure.

DIAG Indicator Flashes while there is an active Alarm condition. The diagnostic code should
be displayed.

Lights continuously when there is an inactive alarm condition or inactive

shutdown condition. The diagnostic code is inactive and the CID and FMI
were recorded in the Fault Log.

If not lit, there are no diagnostic codes available.

There are two basic types of faults: Active and Inactive. An active fault is one that is occurring now, an inactive fault
is a fault that has occurred previously.

GSC diagnostic codes are associated with failed components or circuits that provide information to the GSC or that
receive information from the GSC. Each diagnostic code consists of the following:

x A component identifier (CID) code

x A failure mode identifier (FMI) code
x The DIAG indicator lit

Two types of faults have diagnostic codes associated with them: alarm faults and shutdown faults. When a fault
occurs that has a diagnostic code associated with it, the DIAG indicator flashes, then the GSC flashes either the
fault alarm indicator, or the fault shutdown indicator. For a shutdown fault, the CID and FMI are shown on the upper
display immediately. For a fault alarm: the ALARM CODES key must be pressed; then the CID and FMI are shown
on the upper display. A flashing DIAG indicator means that the fault is presently active. When the DIAG indicator is
on continuously, the fault occurred previously.

DIAGNOSTIC EVENTS AND EVENT CODES

The GSC also displays codes for diagnostic events. These event codes are in the same format as the fault codes
and they can be active events and may be logged. The Symptom/Malfunction Index and troubleshooting tables
show these event codes in sequence with fault codes. Often event codes are related to fault codes and the
troubleshooting associated with them. Diagnostic events can be logged in the Engine Control Module (ECM) and
used to investigate engine malfunctions. Event codes indicate problems with the engine performance and are
symptoms to be investigated. They can also relate directly to required maintenance services or actions.

0004-4
 TM 9-6115-730-24 0004

GSC FAULT CODES

Component Identification (CID) Codes

CID codes are displayed on the GSC Upper Display during and after a fault is detected to identify the component
that caused the fault. These codes are stored in the GSC fault log. If an E is shown after the CID, the diagnostic
code is from the Engine Control Module (ECM).

Fault Mode Identification (FMI) Codes

FMI codes are used with the CID codes to describe the type of failure detected. FMI codes are in accordance with
SAE practice of J1587 diagnostics. These codes are stored in the GSC fault log.

FMI Code Description

0 Data is valid but data is above normal operating range

1 Data is valid but data is below normal operating range
2 Erratic, intermittent, or incorrect signal
3 Voltage above normal
4 Voltage below normal
5 Current is below normal or circuit is open
6 Current is above normal or circuit is grounded
7 Improper Mechanical Response
8 Abnormal frequency, pulse width, or period
9 Abnormal Update
10 Abnormal rate of change
11 Failure mode is not identifiable (Mechanical Failure)
12 Failed Component
13 Device is not calibrated

FAULT LOG

The GSC has a fault log to help with troubleshooting of diagnostic codes. Inactive fault codes are recorded in the
fault log for viewing later. Also, the number of occurrences is totaled and is shown on the upper display together
with the CID and FMI codes. An active alarm fault becomes inactive when the problem is no longer occurring. The
ENGINE CONTROL switch must be set to OFF/RESET to reset a shutdown fault.

0004-5
 TM 9-6115-730-24 0004

VIEWING FAULT LOG OP1

STEP 1. To view the fault log, set ENGINE CONTROL switch to COOL DOWN/STOP.

NOTE
In SERVICE MODE, the buttons on the GSC keypad perform new functions as follows:

POWER METER is Scroll Right

AC METER is Scroll Up
ENGINE METER is Scroll Down
LAMP TEST is Select
ALARM CODES is Enter

STEP 2. Press SERVICE MODE key on GSC keypad. SERV will be displayed on upper display. OP1 will be
displayed on lower display.

STEP 3. Press LAMP TEST key on keypad. If more than one diagnostic code is present, codes will scroll on
display. The number of occurrences is shown above the COUNT indicator. The lower display shows
value from the hour meter at the first occurrence and the last occurrence of each diagnostic code.

STEP 4. Press LAMP TEST key to stop scrolling.

STEP 5. Press POWER METER key. If more than one count of a diagnostic code is logged, the first
occurrence with a corresponding value from the hour meter shows on the lower display.

STEP 6. Press LAMP TEST key. Diagnostic codes continue scrolling.

STEP 7. Press EXIT key. OP1 shows on lower display.

STEP 8. Press EXIT to return display to normal mode.

FAULT LOG CLEARING OP4

OP4 is the option for clearing an inactive fault from the fault log. After a diagnostic fault is investigated and the fault
is corrected, the fault should be cleared from the fault log. Clearing the fault log prevents confusion if you are
investigating later faults.

NOTE
Service mode cannot be entered when the ENGINE CONTROL switch is set to AUTO. An active
shutdown indictor will be flashing. Active shutdown indicators must be deactivated in order to
access service mode.

STEP 1. Set Battery Disconnect Switch to ON.

STEP 2. Set DEAD CRANK SWITCH to NORMAL.

STEP 3. On EMCP, set ENGINE CONTROL switch to COOL DOWN/STOP.

0004-6
 TM 9-6115-730-24 0004

FAULT LOG CLEARING OP4 - Continued

NOTE
In SERVICE MODE, the buttons on the GSC keypad perform new functions as follows:

POWER METER is Scroll Right

AC METER is Scroll Up
ENGINE METER is Scroll Down
LAMP TEST is Select
ALARM CODES is Enter

STEP 4. Press SERVICE MODE key on GSC. SERV will be displayed on upper display. OP1 will be displayed
on lower display.

STEP 5. Press AC METER key five times. OP3 will be displayed.

STEP 6. Press the LAMP TEST key. P E _ _ _ _ _ _will be displayed. The left-most underline will be flashing.
If an error is made any time during the password entry, P E FAIL will be displayed. Password entry
can be restarted by pressing LAMP TEST key.

STEP 7. Press POWER METER key. P E 1 _ _ _ _ will be displayed. The left-most underline will be flashing.

STEP 8. Press ENGINE METER key. P E 1 3 _ _ _ will be displayed. The left-most underline will be flashing.

STEP 9. Press AC METER key. P E 1 3 2 _ _ will be displayed. The left-most underline will be flashing.

STEP 10. Press ENGINE METER key. P E 1 3 2 3 _ will be displayed. The underline will be flashing.

STEP 11. Press POWER METER key. P E 1 3 2 3 1 will be displayed.

STEP 12. Press ALARM CODES key. P E PASS will be displayed.

STEP 13. Press EXIT key. OP4 will be displayed.

STEP 14. Press LAMP TEST. A CID FMI fault code and the number of occurrences will be displayed. Lower
display shows hourmeter values of the first occurrence of the fault and the last occurrence of the fault.

STEP 15. Press LAMP TEST. The CID FMI fault code, hourmeter value, and fault count will flash.

STEP 16. Press and hold ALARM CODES for two seconds.

STEP 17. If there was only one CID FMI fault code, the CID FMI fault that was flashing will disappear and the
upper display will be blank except for flashing SERV indicator. OP1 is shown on lower display.
Proceed to step 20.

STEP 18. If there is more than one CID FMI fault code, the CID FMI that was flashing disappears. The upper
display shows the next CID FMI fault code, fault count, and the hourmeter value. Repeat steps 15
thru 17 until all faults are erased. The lower display then shows OP4. Proceed to step 20.

STEP 19. Press EXIT key. OP4 will show on lower display.

STEP 20. Press EXIT key. The display will be in normal mode.

0004-7
 TM 9-6115-730-24 0004

TRANSIENT CODES DURING TROUBLESHOOTING

During troubleshooting, certain work packages may disconnect the harness from the rear of the GSC. This action
will cause failure codes unrelated to the actual failure to appear. Clear these created diagnostic codes after the
particular fault is corrected and the diagnostic code is cleared. When the harness connector is removed from the
GSC, the following diagnostic codes are recorded in a properly operating system.

CID 100 FMI 02 Engine Oil Pressure Sensor

CID 110 FMI 02 Engine Coolant Temperature Sensor
CID 111 FMI 03 Engine Coolant Level Sensor
CID 175 FMI 03 Engine Oil Temperature Sensor
CID 190 FMI 03 Engine Speed Sensor
CID 336 FMI 02 Engine Control Switch

Clear diagnostic codes after the problem is investigated or the problem is corrected. This will avoid confusion
during investigation of a future problem. The DIAG indicator is off when all diagnostic codes are cleared from the
fault log and no active diagnostic codes exist.

0004-8
 TM 9-6115-730-24 0004

DVR FAULT CODE TROUBLESHOOTING

The DVR will annunciate four types of faults. These are described in detail below.

FAULT CLASSIFICATION DESCRIPTION

Alarm Fault Alarm Faults indicate a condition that will not inhibit the function of the DVR
and the generator set. Alarm Fault codes are in the 600’s range.

The generator set will continue to operate at a normal level.

Resetable Shutdown fault Resetable Shutdown Faults indicate a condition where either DVR or
generator set exhibits a degradation of performance.

Resetable Shutdown Fault codes are in the 700’s range.

The generator set continues to operate, but at a reduced level too low to
sustain load.

Resetting the fault returns the DVR to normal operation. The fault code
remains in parameter :92.
Non-resetable Shutdown fault Non-resetable Shutdown faults indicate a condition where the DVR cannot
be safely run.

Non-resetable Shutdown Fault codes are in the 800’s range.

The generator set continues to operate, but at a reduced level too low to
sustain load.

Setting the ENGINE CONTROL switch to OFF/RESET is required to reset

the fault.
Severe fault Severe faults may indicate the failure of the DVR.

Severe faults occur at power-up or when writing a new value to memory.

Severe faults cause the DVR to prohibit power generation. The keypad will
be disabled. Severe faults cannot be reset. The DVR will have to be
replaced.

Severe Fault codes are in the 900’s range.

0004-9
 TM 9-6115-730-24 0004

DVR FAULT CODE TROUBLESHOOTING - Continued

Fault codes are stored in Parameters. The following DVR parameters are associated with fault isolation:

Parameter :92 - Latest fault. Contains the code for the most recently declared, or current, fault that has
occurred after the last fault was reset. It may contain either alarm or shutdown faults.

Parameter :93 - Previous fault. Contains the fault code for the previous fault (both alarm and shutdown faults)
that were in parameter :92. This parameter may contain an active alarm if an active alarm was
present in parameter :92 and a shutdown fault occurred. The alarm code that was in parameter
:92 would be moved here and any code that was here is overwritten. When the code in
parameter :92 is cleared using the fault clear function (parameter :94), the code is moved here.

Parameter :94 - Fault Clear. This parameter acts like a switch to clear fault codes from latest fault parameter
:92. The code that was in parameter :92 is moved to parameter :93 (previous fault) overwriting
the code that was there and parameter :92 is returned to 0000.

Parameter :96 - Shutdown Fault Reset. Acts like a switch to reset an active shutdown fault. This will allow
the DVR to begin regulation again and stop the display from flashing the fault code.

When a fault condition occurs, the fault code will flash on the DVR display. Alarm faults must be cleared using
parameter :94 before another alarm fault can be declared. A shutdown fault will override an alarm fault, placing its
code in the latest fault parameter (:92), and will move the alarm fault code to the previous fault parameter (:93).
Parameter codes are retained during power down of the DVR.

To clear a fault, press and hold up arrow key or down key to select parameter :94 on the display and press
the function key . Each time the fault clear function is activated, the display will flash three times, the code that
was in parameter :92 (latest fault) is moved to parameter :93 (previous fault) overwriting the code that was there
and parameter :92 is returned to 0000. The display will return to parameter :01.

To reset a shutdown fault, press and hold up arrow key or down key to select parameter :96 on the display
and press the function key . Each time the fault clear function is activated, the display will flash three times,
the DVR will begin regulation again, the display will stop flashing, and the display will return to parameter :01.

TROUBLESHOOTING FAILURES WITHOUT A FAULT CODE

For troubleshooting failures without a fault code refer to the Malfunction/Symptom Index in WP 0005.

TROUBLESHOOTING USING MAINTENANCE SUPPORT DEVICE (MSD) AND ELECTRONIC TECHNICIAN

(ET) TOOL

The Field level troubleshooting Malfunction/Symptom Index (WP 0005) lists symptoms and malfunctions for
troubleshooting diagnostics to be performed for Field maintenance of the 200 kW Tactical Quiet Generator (TQG).
Identify the malfunction/symptom and diagnostic procedure that best describes your problem and then if directed,
turn to WP 0012 to set up the Electronic Technician (ET) tool and install necessary software. The ET tool allows
you to perform engine specific tests for additional diagnostics contained in WP 0013. Follow each step in
sequence through the diagnostic tests or inspections listed in the troubleshooting procedures table until a fault is
identified and corrected.

END OF WORK PACKAGE

0004-10
 TM 9-6115-730-24 0005

FIELD LEVEL TROUBLESHOOTING

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
TROUBLESHOOTING INDEX

Malfunction/Symptom Troubleshooting Procedure

GSC ALARM INDICATORS AND FAULT CODE

1. LOW OIL PRESSURE light ................................................................................................................ WP 0006

2. EMERGENCY STOP light .................................................................................................................. WP 0006
3 HIGH WATER TEMP light .................................................................................................................. WP 0006
4. ENGINE OVERSPEED light ............................................................................................................... WP 0006
5. OVERCRANK light.............................................................................................................................. WP 0006
6. FAULT SHUTDOWN light flashing red for shut down ........................................................................ WP 0006
7. FAULT ALARM light flashing yellow ................................................................................................... WP 0006
8. No indicator lit DIAG not on Fault codes displayed ......................................................................... WP 0006
9. No indicator lit DIAG not on No fault codes displayed..................................................................... WP 0006

SP FAULT CODE

1. SP 1 Low Fuel Level ........................................................................................................................... WP 0007

2. SP 2 (DVR Fault) ................................................................................................................................ WP 0007
3. SP 3 Bus Frequency Fault (Paralleling Only) ..................................................................................... WP 0007
4. SP 4 Bus Voltage Fault (Paralleling Only) .......................................................................................... WP 0007

AL FAULT CODE

1. AL 1 High Coolant Temperature ........................................................................................................ WP 0008

2. AL 2 Low Coolant Temperature.......................................................................................................... WP 0008
3. AL 3 Low Engine Oil Pressure............................................................................................................ WP 0008
4. AL 4 Fault Detected by Engine ECM .................................................................................................. WP 0008
5. AL 5 Low Engine Coolant Level.......................................................................................................... WP 0008
6. AL 7 Generator Over Voltage ............................................................................................................. WP 0008
7. AL 8 Generator Under Voltage ........................................................................................................... WP 0008
8. AL 9 Generator Over Frequency ........................................................................................................ WP 0008
9. AL 10 Generator Under Frequency .................................................................................................... WP 0008
10. AL 11 Generator Reverse Power........................................................................................................ WP 0008
11. AL 12 Phase Over Current ................................................................................................................. WP 0008
12. AL 13 Generator Total Over Current .................................................................................................. WP 0008
13. AL 14 Phase A No Voltage Input at GSC input (P7-10) ..................................................................... WP 0008
14. AL 15 GSC Configuration Error .......................................................................................................... WP 0008
15. AL 16 Incorrect Phase Sequence - Paralleling fault code .................................................................. WP 0008
16. AL 17 Improper Generator or Bus Voltage - Paralleling fault code .................................................... WP 0008
17. AL 18 Synchronizer Time-out - Paralleling fault code ........................................................................ WP 0008

0005-1
 TM 9-6115-730-24 0005

Malfunction/Symptom Troubleshooting Procedure

GSC FAULT CODE

1. CID 1 E FMI 11 Cylinder 1 Failure mode is not identifiable (Mechanical Failure) (Logged) .............. WP 0009
2. CID 2 E FMI 11 Cylinder 2 Failure mode is not identifiable (Mechanical Failure) (Logged) .............. WP 0009
3. CID 3 E FMI 11 Cylinder 3 Failure mode is not identifiable (Mechanical Failure) (Logged) .............. WP 0009
4. CID 4 E FMI 11 Cylinder 4 Failure mode is not identifiable (Mechanical Failure) (Logged) .............. WP 0009
5. CID 5 E FMI 11 Cylinder 5 Failure mode is not identifiable (Mechanical Failure) (Logged) .............. WP 0009
6. CID 6 E FMI 11 Cylinder 6 Failure mode is not identifiable (Mechanical Failure) (Logged) .............. WP 0009
7. CID 9 E FMI 02 High Altitude Derate (Active) Erratic, Intermittent, or Incorrect Signal ..................... WP 0009
8. CID 41 FMI 02 8 Volt Power Supply not Normal Erratic, Intermittent, or Incorrect
Signal (Logged)................................................................................................................................... WP 0009
CID 41 FMI 03 8 Volt Power Supply Above Normal Voltage Above Normal (Logged) ...................... WP 0009
CID 41 FMI 04 8 Volt Power Supply Below Normal Voltage Above Normal (Logged)....................... WP 0009
9. CID 85 E FMI 01 Shutdown Overridden Data is Valid but Data is Below Normal
Operating Range (Logged) ................................................................................................................. WP 0009
10. CID 91 FMI 08 Throttle Position Sensor Abnormal Frequency, Pulse Width, or Period
(Not Logged) ....................................................................................................................................... WP 0009
11. CID 94 FMI 01 Fuel Pressure Sensor Data is Valid but Data is Below Normal Operating
Range (Logged) .................................................................................................................................. WP 0009
CID 94 FMI 02 Fuel Pressure Sensor Erratic, Intermittent, or Incorrect Signal.................................. WP 0009
12. CID 94 E FMI 03 Fuel Pressure Sensor Voltage Above Normal (Logged) ........................................ WP 0009
CID 94 E FMI 04 Fuel Pressure Sensor Voltage Below Normal ........................................................ WP 0009
13. CID 96 E FMI 01 High Fuel Pressure Warning Data is Valid but Data is Below Normal
Operating Range (Active and Logged) ............................................................................................... WP 0009
14. CID 97 E FMI 01 Derate Overridden Data is Valid but Data is Below Normal Operating
Range (Logged) .................................................................................................................................. WP 0009
15. CID 100 E FMI 02 Oil Pressure Sensor Erratic, Intermittent, or Incorrect Signal (Logged) ............... WP 0009
16. CID 100 E FMI 03 Oil Pressure Sensor Voltage Above Normal (Logged) ......................................... WP 0009
CID 100 E FMI 04 Oil Pressure Sensor Voltage Below Normal......................................................... WP 0009
17. CID 110 E FMI 02 Engine Coolant Temperature Sensor Erratic, Intermittent, or Incorrect
Signal (Logged)................................................................................................................................... WP 0009
CID 110 FMI 03 Engine Coolant Temperature Sensor Voltage Above Normal (Logged).................. WP 0009
CID 110 E FMI 04 Engine Coolant Temperature Sensor Voltage Below Normal (Logged)............... WP 0009
18. CID 111 E FMI 03 Low Coolant Sensor Voltage Above Normal ........................................................ WP 0009
19. CID 168 E FMI 02 Electrical System Voltage Erratic, Intermittent, or Incorrect Signal ...................... WP 0009
CID 168 E FMI 03 Electrical System Voltage Above Normal ............................................................. WP 0009
CID 168 E FMI 04 Electrical System Voltage Below Normal.............................................................. WP 0009
20. CID 169 E FMI 01 Engine Oil Maintenance Required (Active)........................................................... WP 0009
21. CID 170 E FMI 01 Fuel Filter Change Required (Active) ................................................................... WP 0009
22. CID 172 E FMI 00 Intake Manifold Air Temperature Sensor Data is Valid but Data is Above Normal
Operating Range (Logged) ................................................................................................................. WP 0009
CID 172 E FMI 03 Intake Manifold Air Temperature Sensor Voltage Below Normal Voltage Open/
Short to Batt+. ..................................................................................................................................... WP 0009
CID 172 E FMI 04 Intake Manifold Air Temperature Sensor Voltage Below Normal Voltage Short to
Ground................................................................................................................................................ WP 0009
CID 172 E FMI 11 Intake Manifold Air Temperature Sensor Failure Mode is Not Identifiable
(Mechanical Failure) (Logged)............................................................................................................ WP 0009

0005-2
 TM 9-6115-730-24 0005

Malfunction/Symptom Troubleshooting Procedure

GSC FAULT CODE - Continued

23. CID 174 FMI 03 Fuel Temperature Sensor Voltage Above Normal ................................................... WP 0009
24. CID 190 FMI 02 Loss of Engine Speed Signal, Erratic, Intermittent, or Incorrect
Signal ........................................................................................................................................... WP 0009
CID 190 FMI 03 Magnetic Pickup Unit (Engine Speed Sensor) Voltage Above Normal.................... WP 0009
25. CID 190 E FMI 02 Loss of Engine Timing Signal, Erratic, Intermittent, or Incorrect
Signal............................................................................................................................................ WP 0009
CID 190 E FMI 11 Crankshaft (Bottom) Engine Timing Sensor Failure Mode is Not Identifiable
(Mechanical Failure) ........................................................................................................................... WP 0009
26. CID 248 FMI 09 CAT Data Link Abnormal update ............................................................................. WP 0009
27. CID 253 E FMI 02 Personality Module Mismatch Erratic, Intermittent, or Incorrect Signal................ WP 0009
28. CID 254 E FMI 12 ECM Self Test Failed Component ........................................................................ WP 0009
29. CID 261 E FMI 13 Engine Timing Calibration Device is Not Calibrated............................................. WP 0009
30. CID 262 E FMI 03 5 V Sensor Power Supply Voltage Above Normal................................................ WP 0009
CID 262 E FMI 04 5 V Sensor Power Supply Voltage Below Normal ................................................ WP 0009
31. CID 264 E FMI 03 E-Stop Shutdown Voltage Above Normal (Active) ............................................... WP 0009
32. CID 268 FMI 02 GSC Electronic Control Erratic, Intermittent, or Incorrect Signal ............................. WP 0009
33. CID 269 FMI 03 GSC 8V Sensor Power Supply Voltage Above Normal ........................................... WP 0009
CID 269 FMI 04 GSC 8V Sensor Power Supply Voltage Below Normal............................................ WP 0009
34. CID 273 FMI 03 Turbo Outlet Pressure Sensor Voltage Above Normal ............................................ WP 0009
CID 273 FMI 04 Turbo Outlet Pressure Sensor Voltage Below Normal............................................. WP 0009
35. CID 274 FMI 02 Atmospheric Pressure Sensor Erratic, Intermittent, or Incorrect Signal .................. WP 0009
36. CID 274 FMI 03 Atmospheric Pressure Sensor Voltage Above Normal ............................................ WP 0009
CID 274 FMI 04 Atmospheric Pressure Sensor Voltage Below Normal............................................. WP 0009
37. CID 334 FMI 02 Spare Output (P7-36) Erratic, Intermittent, or Incorrect Signal ................................ WP 0009
CID 334 FMI 03 Spare Output (P7-36) Voltage Above Normal.......................................................... WP 0009
CID 334 FMI 04 Spare Output (P7-36) Voltage Below Normal .......................................................... WP 0009
38. CID 336 E FMI 02 ENGINE CONTROL Switch (ECS) Erratic, Intermittent, or Incorrect Signal ........ WP 0009
39. CID 342 E FMI 02 Camshaft (Top) Engine Speed/Timing Sensor Erratic, Intermittent,
or Incorrect Signal (Logged) ............................................................................................................... WP 0009
CID 342 E FMI 11 Camshaft (Top) Engine Speed/Timing Sensor Failure mode is not
identifiable (Mechanical Failure) (Logged) ......................................................................................... WP 0009
40. CID 360 E FMI 01 Low Engine Oil Pressure Warning (Active & Logged) Data is Valid But
Data is Below Normal Operating Range............................................................................................. WP 0009
CID 360 E FMI 02 Low Engine Oil Pressure Derate (Active & Logged) Erratic, Intermittent,
or Incorrect Signal............................................................................................................................... WP 0009
CID 360 E FMI 03 Low Engine Oil Pressure Shutdown (Active & Logged)
Voltage Above Normal ........................................................................................................................ WP 0009
41. CID 361 E FMI 01 High Engine Coolant Temperature Warning (Active & Logged)
Data is Valid But Data is Below Normal Operating Range ................................................................. WP 0009
CID 361 E FMI 02 High Engine Coolant Temperature Derate (Active and Logged)
Erratic, Intermittent, or Incorrect Signal .............................................................................................. WP 0009
CID 361 E FMI 03 High Engine Coolant Temperature Shutdown (Active & Logged)
Voltage Above Normal ........................................................................................................................ WP 0009

0005-3
 TM 9-6115-730-24 0005

Malfunction/Symptom Troubleshooting Procedure

GSC FAULT CODE - Continued

42. CID 362 E FMI 01 Overspeed Warning (Active and Logged) Data is Valid But Data is Below
Normal Operating Range.................................................................................................................... WP 0009
CID 362 E FMI 03 Overspeed Shutdown (Active & Logged) Voltage Above Normal ........................ WP 0009
43. CID 368 E FMI 01 High Inlet Air Temperature Warning (Active and Logged) Data is Valid But
Data is Below Normal Operating Range............................................................................................. WP 0009
44. CID 390 E FMI 01 Fuel Filter Restriction Warning (Active and Logged) Data is Valid But
Data is Below Normal Operating Range............................................................................................. WP 0009
45. CID 391 E FMI 01 Inlet Air Restriction Warning (Active and Logged) Data is Valid But
Data is Below Normal Operating Range............................................................................................. WP 0009
46. CID 441 FMI 12 GSC Engine Governor Relay (EGR) Output Failed Component ............................. WP 0009
47. CID 442 FMI 12 GSC Generator Fault Relay (GFR) Output Failed Component................................ WP 0002
48. CID 443 FMI 12 GSC Crank Termination Relay (CTR) Output Failed Component.......................... WP 0009
49. CID 444 FMI 12 GSC Starter Motor Relay (SMR) Output Failed Component ................................... WP 0009
50. CID 445 FMI 12 GSC Run Relay (RR) Output Failed Component..................................................... WP 0009
51. CID 447 FMI 12 GSC Fuel Control Relay (FCR) Output Failed Component ..................................... WP 0009
52. CID 448 FMI 12 GSC Programmable Spare Relay (PSR) Output Failed Component....................... WP 0009
53. CID 500 FMI 12 GSC Failed Component ........................................................................................... WP 0009
54. CID 545 FMI 05 Ether Control Relay Current is Below Normal or Circuit is Open............................. WP 0009
CID 545 FMI 06 Ether Control Relay Current is Above Normal or Circuit is Grounded ..................... WP 0009
55. CID 566 FMI 07 Unexpected Shutdown Improper Mechanical Response ......................................... WP 0009
56. CID 590 FMI 09 Engine Electronic Control Module Abnormal Update............................................... WP 0009
57. CID 770 FMI 09 Customer Communication Module (CCM) Data Link Abnormal Update.................. WP 0009
58. CID 858 FMI 02 Close Breaker Output Erratic, Intermittent, or Incorrect Signal................................ WP 0009
CID 858 FMI 03 Close Breaker Output Voltage Above Normal.......................................................... WP 0009
CID 858 FMI 04 Close Breaker Output Voltage Below Normal.......................................................... WP 0009
59. CID 1038 FMI 02 Speed Adjust 1 Output P7-27 (+) and P7-28 (-) Erratic,
Intermittent, or Incorrect Signal........................................................................................................... WP 0009
CID 1038 FMI 03 Speed Adjust 1 Output P7-27 (+) and P7-28 (-) Voltage Above Normal ............... WP 0009
CID 1038 FMI 04 Speed Adjust 1 Output P7-27 (+) and P7-28 (-) Voltage Below Normal................ WP 0009
60. CID 1167 FMI 04 K1 Sense Input (P7-25) Voltage Below Normal..................................................... WP 0009
61. CID 1168 FMI 03 Dead Bus Sense Input (P7-29) Voltage Above Normal ......................................... WP 0009
62. CID 1169 FMI 02 AC Transformer Box (ATB) Sensor Erratic, Intermittent, or Incorrect Signal......... WP 0009
63. CID 1170 FMI 02 Bus Transformer Box (BTB) Sensor Erratic, Intermittent, or Incorrect Signal ....... WP 0009
CID 1170 FMI 04 Bus Transformer Box (BTB) Sensor Voltage Below Normal.................................. WP 0009
CID 1170 FMI 08 Bus Transformer Box (BTB) Sensor Abnormal frequency, pulse width,
or period.............................................................................................................................................. WP 0009
64. CID 1589 E FMI 02 Turbo Air Inlet Pressure Sensor Erratic, Intermittent,
or Incorrect Signal............................................................................................................................... WP 0009
65. CID 1589 E FMI 03 Turbo Air Inlet Pressure Sensor Voltage Above Normal .................................... WP 0009
CID 1589 E FMI 04 Turbo Air Inlet Pressure Sensor Voltage Below Normal..................................... WP 0009

0005-4
 TM 9-6115-730-24 0005

Malfunction/Symptom Troubleshooting Procedure

DVR FAULT CODE

1. 0000 No Fault Present................................................................................................................... WP 0010

2. 601 Internal Memory Failure .......................................................................................................... WP 0010
3. 602 Internal Watchdog Failure....................................................................................................... WP 0010
4. 603 Rotating Diode Malfunction ..................................................................................................... WP 0010
5. 604 Reverse VAR.......................................................................................................................... WP 0010
6. 701 Undervoltage .......................................................................................................................... WP 0010
7. 702 Overvoltage ............................................................................................................................ WP 0010
8. 703 Overexcitation ........................................................................................................................ WP 0010
9. 704 Reverse VAR.......................................................................................................................... WP 0010
10. 801 Instantaneous Trip.................................................................................................................. WP 0010
11. 802 Loss of Sensing ...................................................................................................................... WP 0010
12. 803 Loss of Frequency .................................................................................................................. WP 0010
13. 901 DVR Memory Failure .............................................................................................................. WP 0010

FAILURES WITHOUT A FAULT CODE

1. Starting Motor Remains Engaged .................................................................................................. WP 0011

2. Engine Does Not Shut Down When A Shutdown Fault Occurs or Engine Shuts Down with No
GSC Fault Codes .......................................................................................................................... WP 0011
3. GSC Operation Is Erratic ............................................................................................................... WP 0011
4. Display Of Voltage on GSC is Zero For One or More Phases......................................................... WP 0011
5. Display of Current on GSC is Zero For One or More Phases.......................................................... WP 0011
6. Display of Voltage on GSC is Inaccurate ....................................................................................... WP 0011
7. Display of Current on GSC is Inaccurate........................................................................................ WP 0011
8. Display of Power on GSC is Inaccurate ......................................................................................... WP 0011
9. Generator Produces No Voltage .................................................................................................... WP 0011
10. Generator Produces Low Voltage Under No Load Condition .......................................................... WP 0011
11. Generator Produces Low Voltage When Load is Applied ............................................................... WP 0011
12. Generator Produces Fluctuating Voltage ....................................................................................... WP 0011
13. Generator Produces High Voltage ................................................................................................. WP 0011
14. Generator is Overheating .............................................................................................................. WP 0011
15. Equipment Runs Normally on Other Source Of Power (Utility or Other Generator Set), But
Will Not Run on This Generator Set.............................................................................................. WP 0011
16. Undesirable Speed Decrease With Load Increase........................................................................ WP 0011
17. Load Sharing Module A4 Erratic Operation................................................................................... WP 0011
18. Engine Not Properly Sharing Load With Other Generator Sets (Parallel Operation) .................... WP 0011
19. Engine Will Not Crank (Starter Pinion Engages and Engine Does Not Turn Over) ...................... WP 0011
20. Engine Cranks But Will Not Start .................................................................................................. WP 0011
21. Engine Misfires, Runs Rough, or is Unstable................................................................................ WP 0011
22. Low Power/Poor or No Response to Throttle................................................................................ WP 0011
23. Intermittent Engine Shut Downs.................................................................................................... WP 0011
24. Excessive Black Smoke................................................................................................................ WP 0011
25. Excessive White Smoke ............................................................................................................... WP 0011
26. Can Not Reach Operating Engine RPM........................................................................................ WP 0011
27. Poor Acceleration or Response .................................................................................................... WP 0011
28. Poor Fuel Consumption ................................................................................................................ WP 0011
29. Engine Stalls at Low RPM ............................................................................................................ WP 0011
30. Auxiliary Fuel Pump Does Not Operate ........................................................................................ WP 0011

0005-5
 TM 9-6115-730-24 0005

Malfunction/Symptom Troubleshooting Procedure

FAILURES WITHOUT A FAULT CODE - Continued

31. Engine Runs Out of Fuel With No LOW FUEL LEVEL Alarm........................................................ WP 0011
32. Alternator Does Not Charge Batteries............................................................................................ WP 0011
33. Coolant in Engine Oil..................................................................................................................... WP 0011
34. Coolant Temperature Too High...................................................................................................... WP 0011
35. ECM Will Not Communicate With Other Systems or Display Modules ............................................ WP 0011
36. Engine Oil in Coolant..................................................................................................................... WP 0011
37. Engine Oil in Exhaust System........................................................................................................ WP 0011
38. Engine Oil Temperature Too High ................................................................................................. WP 0011
39. Engine Vibration ............................................................................................................................ WP 0011
40. Excessive Engine Oil Consumption ............................................................................................... WP 0011
41. Excessive Valve Lash.................................................................................................................... WP 0011
42. Exhaust Temperature is Too High ................................................................................................. WP 0011
43. Fuel in Engine Oil .......................................................................................................................... WP 0011
44. Intermittent Low Power or Power Cutout........................................................................................ WP 0011
45. Low Engine Oil Pressure ............................................................................................................... WP 0011
46. Mechanical Noise (Knock) in Engine.............................................................................................. WP 0011
47. Noise Coming From Cylinder......................................................................................................... WP 0011

ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING

1. Electrical Connectors Wiggle Test...................................................................................................... WP 0013

2 Electrical Power Supply Circuit Test................................................................................................... WP 0013
3. Engine Timing Sensor Circuit Test ..................................................................................................... WP 0013
4. Ether Injection System Test................................................................................................................ WP 0013
5. Injector Solenoid Circuit Test ........................................................................................................ WP 0013
6. Speed Control Test ....................................................................................................................... WP 0013
7. Electronic Service Tool (Cat ET) will not communicate with ECM................................................... WP 0013
8. Engine Timing Sensor Calibrate .................................................................................................... WP 0013
9. Flash Programming ....................................................................................................................... WP 0013
10. Engine Fuel Pressure Reading ...................................................................................................... WP 0013
11. Engine Status................................................................................................................................ WP 0013
12. Load Injector Code ........................................................................................................................ WP 0013
13. Copy Configuration/ECM Replacement............................................................................................. WP 0013

END OF WORK PACKAGE

0005-6
 TM 9-6115-730-24 0006

FIELD LEVEL TROUBLESHOOTING

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
GSC ALARM INDICATORS AND FAULT CODE TROUBLESHOOTING PROCEDURES

INITIAL SETUP:

Personnel Required References

One TM 9-6115-730-10

TROUBLESHOOTING USING DEDICATED SHUTDOWN INDICATORS

The dedicated shutdown indicators identify the system that is responsible for an engine shutdown. The Generator
Set Control (GSC) activates the appropriate dedicated shut down fault lamp when the particular fault condition is
sensed. The lamp will flash until the GSC shuts the engine down, then the lamp will light continuously. Dedicated
shutdowns are not recorded in the GSC fault log.

The GSC dedicated shutdown indicators and their sensors are described in WP 0009.

WARNING
Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool
before performing checks, services, and maintenance. Failure to comply can cause injury or
death to personnel.

CAUTION
The dipstick is marked so that the crankcase oil can be checked while engine is stopped or
running. Always make sure dipstick is checked. Remove oil filler cap when checking oil with
engine running.

SYMPTOM
1. LOW OIL PRESSURE light

MALFUNCTION
LOW OIL PRESSURE detected by engine. The signal is routed through Engine Control Module
(ECM) to GSC.

CORRECTIVE ACTION
STEP 1. Check oil level and perform service per TM 9-6115-730-10.
STEP 2. If fault codes displayed on upper display, troubleshoot per WP 0009.

0006-1
 TM 9-6115-730-24 0006

TROUBLESHOOTING USING DEDICATED SHUTDOWN INDICATORS - Continued

SYMPTOM
2. EMERGENCY STOP light

MALFUNCTION
Detected when PUSH TO STOP EMERGENCY STOP pushbutton on Electronic Modular Control
Panel (EMCP) is pressed. Pressing EMERGENCY STOP disables the control input to the ECM,
stopping the engine immediately. EMERGENCY STOP disables the starter circuit so that the GSC can
not restart the engine (DEAD CRANK SWITCH can still crank the engine). An input from the
EMERGENCY STOP notifies the GSC that the button is pressed.

CORRECTIVE ACTION
STEP 1. Correct emergency situation that caused operator to press EMERGENCY STOP.
STEP 2. If fault codes present on upper display, troubleshoot per WP 0009.
STEP 3. When Tactical Quiet Generator (TQG) is returned to service, continue
operations.

SYMPTOM
3. HIGH WATER TEMP light

MALFUNCTION
HIGH WATER TEMP is detected by engine sensor. The signal is routed through ECM to GSC.

CORRECTIVE ACTION
STEP 1. Check coolant level and perform service per TM 9-6115-730-10.
STEP 2. If fault codes displayed on upper display, troubleshoot per WP 0009.

SYMPTOM
4. ENGINE OVERSPEED light

MALFUNCTION
Engine RPM is monitored directly by the GSC using a magnetic pickup unit (MPU) on the engine
flywheel. ENGINE OVERSPEED RPM is set by OP5-0, P010.

CORRECTIVE ACTION
STEP 1. If fault codes displayed on upper display, troubleshoot per WP 0009.
STEP 2. If necessary, verify OP5-0, P010 setpoint EMCP programming (WP 0083
Table 4).

0006-2
 TM 9-6115-730-24 0006

TROUBLESHOOTING USING DEDICATED SHUTDOWN INDICATORS - Continued

SYMPTOM
5. OVERCRANK light

MALFUNCTION
If engine does not start within 90 seconds after setting ENGINE CONTROL switch to MANUAL
START (or the remote start contacts are closed with the ENGINE CONTROL switch in AUTO
START), GSC declares overcrank condition starting is disabled.

CORRECTIVE ACTION
Correct any displayed faults per WP 0009 or troubleshoot per WP 0011.

SYMPTOM
6. FAULT SHUTDOWN light flashing red for shut down.

MALFUNCTION
CID and FMI fault codes displayed.

CORRECTIVE ACTION
Troubleshoot displayed CID and FMI codes (WP 0009).

MALFUNCTION
SP1, SP2, SP3, or SP4 displayed. DIAG not on.

CORRECTIVE ACTION
Troubleshoot displayed SP (Spare Input) code (WP 0007).

MALFUNCTION
AL1 thru AL8 fault code displayed. DIAG not on.

CORRECTIVE ACTION
Troubleshoot displayed AL code (WP 0008).

0006-3
 TM 9-6115-730-24 0006

TROUBLESHOOTING USING DEDICATED SHUTDOWN INDICATORS - Continued

SYMPTOM
7. FAULT ALARM light flashing yellow.

MALFUNCTION
CID and FMI fault codes display. Evaluate with dedicated shutdown indicators.

CORRECTIVE ACTION
Troubleshoot CID and FMI codes (WP 0009).

MALFUNCTION
SP1, SP2, SP3, or SP4 displayed. DIAG not on.

CORRECTIVE ACTION
Troubleshoot displayed SP code (WP 0007).

MALFUNCTION
AL1 thru AL8 fault code displayed. DIAG not on.

CORRECTIVE ACTION
Troubleshoot displayed AL code (WP 0008).

SYMPTOM
8. No indicator lit. DIAG not on. Fault codes displayed.

MALFUNCTION
CID and FMI codes displayed.

CORRECTIVE ACTION
Troubleshoot displayed CID and FMI codes (WP 0009).

MALFUNCTION
SP1, SP2, SP3, or SP4 displayed.

CORRECTIVE ACTION
Troubleshoot displayed SP code (WP 0007).

MALFUNCTION
AL1 thru AL8 fault code displayed.

CORRECTIVE ACTION
Troubleshoot displayed AL code (WP 0008).

0006-4
 TM 9-6115-730-24 0006

TROUBLESHOOTING USING DEDICATED SHUTDOWN INDICATORS - Continued

SYMPTOM
9. No indicator lit. DIAG not on. No fault codes displayed.

MALFUNCTION
Undiagnosed shutdown.

CORRECTIVE ACTION
Troubleshoot fault without code (WP 0011).

END OF WORK PACKAGE

0006-5/6 blank
 TM 9-6115-730-24 0007

FIELD LEVEL TROUBLESHOOTING

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
SP FAULT CODE TROUBLESHOOTING PROCEDURES

INITIAL SETUP:

Personnel Required References

One WP 0083
TM 9-6115-730-10

TROUBLESHOOTING USING SP FAULT CODES

SP (Spare Input) Fault Codes are associated with four inputs that are considered spare inputs. Spare fault code
programming is contained in OP6-0, Protective Relay Programming (see WP 0083, Table 7 for details). These
codes are not stored in the GSC fault log. When a spare input fault is detected, the FAULT SHUTDOWN lamp
flashes and the corresponding code (SP1, SP2, etc.) is displayed on the upper GSC display. Fault condition on SP
1 and 4 is programmed to shut down the engine immediately.

WARNING
Fuels used in the generator set are flammable. When filling the fuel tank, maintain metal-to-metal
contact between filler nozzle and fuel tank opening to eliminate static electrical discharge. Failure
to comply can result in flames and possible explosion and cause injury or death to personnel and
damage to the generator set.

Fuels used with the generator set are flammable. Do not smoke or use open flames when
performing maintenance. Failure to comply can result in flames and possible explosion and can
cause injury or death to personnel and damage to the generator set.

NOTE
SP1 thru SP4 must be evaluated using dedicated shutdown lights, alarm conditions, and
available fault codes.

0007-1
 TM 9-6115-730-24 0007

TROUBLESHOOTING USING SP FAULT CODES - Continued

SYMPTOM
1. SP1

MALFUNCTION
Low Fuel Level.

CORRECTIVE ACTION
STEP 1. Verify if LOW FUEL LEVEL indicator on Alarm Module is lit.
STEP 2. Verify fuel level on fuel level gage.
STEP 3. If using internal fuel source, perform fuel service and refill TQG per TM 9-6115-
730-10.
STEP 4. If using external (auxiliary) source, verify that auxiliary fuel line is connected per
TM 9-6115-730-10 and that AUX FUEL pump switch is set to ON.
STEP 5. Verify that external (auxiliary) fuel is present and clean.
STEP 6. If external (auxiliary) fuel is present and clean, troubleshoot auxiliary fuel pump
(WP 0011, SYMPTOM 30).
STEP 7. Verify the problem has been resolved.

SYMPTOM
2. SP2

MALFUNCTION
DVR fault.

CORRECTIVE ACTION
STEP 1. Troubleshoot DVR fault per WP 0010.
STEP 2. Verify the problem has been resolved.

0007-2
 TM 9-6115-730-24 0007

TROUBLESHOOTING USING SP FAULT CODES - Continued

NOTE
SP3 and SP4 active during paralleling only.

SYMPTOM
3. SP3

MALFUNCTION
Bus Frequency Fault (Paralleling Only)
When main contactor relay K1 is energized and one or both of the following is true for more than 2
seconds an SP2 fault is announced: The difference in frequency between the generator and the bus
is greater than 0.2 Hz. The difference in phase between the generator and the bus is greater than 10
degrees. The GSC will stop synchronization process until the fault is cleared and corrected.

CORRECTIVE ACTION
STEP 1. Verify that no fault codes are listed on upper display.
STEP 2. Verify equipment setup is correct per TM 9-6115-730-10.
STEP 3. Verify equipment setup and parameters for synchronization (WP 0083, Table 6).
STEP 4. Restart generator sets.
STEP 5. Adjust and evaluate operation using synchronization lights per TM 9-6115-730-
10.
STEP 6. Operate per TM 9-6115-730-10.
STEP 7. Verify the problem has been resolved.

SYMPTOM
4. SP4

MALFUNCTION
Bus Voltage Fault (Paralleling Only)
Input is active when 208 or 416 VAC is detected on the load bus by dead bus relay low sensor (DBLO)
or dead bus relay high sensor (DBHI). This input is compared to the reading of the bus. If the voltage
of phase A is less than 20% of the rated voltage, it is considered to be dead. If the condition of these
measurements is different with regards to presence or absence of bus voltage, a fault is announced.

CORRECTIVE ACTION
STEP 1. Verify that no fault codes are listed on upper display.
STEP 2. Verify equipment setup is correct TM 9-6115-730-10.
STEP 3. Verify equipment setup and parameters for synchronization (WP 0083, Table 6).
STEP 4. Restart generator sets.
STEP 5. Adjust and evaluate operation using synchronization lights per TM 9-6115-730-
10.

0007-3
 TM 9-6115-730-24 0007

TROUBLESHOOTING USING SP FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 6. Operate per TM 9-6115-730-10.
STEP 7. Verify the problem has been resolved.

END OF WORK PACKAGE

0007-4
 TM 9-6115-730-24 0008

FIELD LEVEL TROUBLESHOOTING

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
AL FAULT CODE TROUBLESHOOTING PROCEDURES

INITIAL SETUP:

Personnel Required References

One WP 0083
TM 9-6115-730-10

TROUBLESHOOTING USING AL FAULT CODES

Alarm Fault Codes are shown on the upper display and consist of specific engine fault codes, protective relay
function codes, and paralleling fault codes. Alarm Fault Codes rely upon programmed setpoints.

Engine fault code programming is contained in OP5-0, Engine/Generator Programming (see WP 0083 for details).
Protective relay function code programming is contained in OP5-1, Protective Relay Programming (see WP 0083).
Paralleling fault code programming is contained in OP5-3, Synchronization Programming (see WP 0083).

Alarm Fault codes are not stored in the GSC fault log.

WARNING
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

High voltage is produced when this generator set is in operation. Make sure unit is completely
shut down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

Dangerously high voltage can exist across current transformer (CT) output with engine running.
CT could explode if disconnected from load with engine running. Do not disconnect CT with
generator rotating. Failure to comply can cause serious injury or death to personnel.

Slave receptacle (NATO connector) is electrically live at all times and is unfused. The Battery
Disconnect Switch does not remove power from the NATO connector. Use caution when
connecting or disconnecting cable(s) to the NATO connector to prevent damage to equipment.
Use caution when troubleshooting this circuit. This circuit is only dead when the batteries are fully
disconnected. Failure to comply can cause serious injury or death to personnel.

0008-1
 TM 9-6115-730-24 0008

TROUBLESHOOTING USING AL FAULT CODES - Continued

WARNING
Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool
before performing checks, services, and maintenance. Failure to comply can cause injury or
death to personnel.

SYMPTOM
1. AL 1

MALFUNCTION
High Coolant Temperature

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to MANUAL START.
STEP 2. On GSC keypad, press ALARM CODES.
STEP 3. Verify AL1 appears on upper display. Check setpoints per WP 0083.
Verify GSC OP5-0 setpoint P015 (WP 0083, Table 4).
STEP 4. Verify if any fault codes or engine fault codes are displayed on upper display and
record. If fault codes displayed, troubleshoot per WP 0009.
STEP 5. On EMCP set ENGINE CONTROL switch to OFF/RESET. Battery Disconnect
switch is OFF; DEAD CRANK SWITCH is OFF.
STEP 6. Open right side engine access door and check coolant level in coolant recovery
(overflow) bottle. If required, replace coolant per TM 9-6115-730-10, WP 0015.
STEP 7. Inspect coolant system lines for leaks per PMCS (WP 0016).
STEP 8. Inspect alternator and water pump belts. Check water pump belt tension.
a. If required, tighten water pump belt.
b. If required, replace alternator or water pump belts (WP 0075).
STEP 9. Inspect engine for damaged fan.
If fan damaged, repair per WP 0066.
STEP 10. Inspect radiator for obstructions or blockage. Remove obstructions or blockage if
present.
STEP 11. Inspect radiator for damage. If radiator damaged, repair or replace (WP 0068).
STEP 12. Verify the problem has been resolved.

0008-2
 TM 9-6115-730-24 0008

TROUBLESHOOTING USING AL FAULT CODES - Continued

SYMPTOM
2. AL 2

MALFUNCTION
Low Coolant Temperature

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to MANUAL START.
STEP 2. On GSC keypad, press ALARM CODES.
STEP 3. Verify AL2 appears on upper display.

NOTE
This fault will be displayed if the coolant temperature is below 70° F (programmable by setpoint
P016), and may occur for a short time after start up.
STEP 4. Verify if any fault codes or engine fault codes are displayed on upper display and
record.
a. If fault codes displayed, troubleshoot per fault code (WP 0009).
b. Verify setpoint P016 (WP 0083, Table 4).
STEP 5. Verify the problem has been resolved.

CAUTION
The dipstick is marked so that the crankcase oil can be checked while engine is running or
stopped. Always make sure dipstick is checked. Remove oil filler cap when checking oil with
engine running.

SYMPTOM
3. AL 3

MALFUNCTION
Low Engine Oil Pressure
Low engine operating speed can cause this alarm code. Note and record engine speed for reference.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to MANUAL START.
STEP 2. On GSC keypad, press ALARM CODES.
STEP 3. Verify AL3 appears on upper display.
STEP 4. Verify if any fault codes or engine fault codes are displayed on upper display and
record.

0008-3
 TM 9-6115-730-24 0008

TROUBLESHOOTING USING AL FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 5. Check engine oil level and service engine if oil is low per TM 9-6115-730-10.
STEP 6. If fault codes displayed, troubleshoot per fault code (WP 0009).
STEP 7. Verify setpoints P013 or P014 (WP 0083, Table 4).
STEP 8. Verify the problem has been resolved.

SYMPTOM
4. AL 4

MALFUNCTION
Fault Detected by Engine ECM

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. On GSC keypad, press ALARM CODES.
STEP 3. Verify AL4 appears on upper display.
STEP 4. Verify if any fault codes or engine fault codes are displayed on upper display and
record. Troubleshoot per displayed fault codes (WP 0009).
STEP 5. Verify the problem has been resolved.

WARNING
Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool
before performing checks, services, and maintenance. Failure to comply can cause injury or
death to personnel.

SYMPTOM
5. AL 5

MALFUNCTION
Low Engine Coolant Level

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. On GSC keypad, press ALARM CODES.
STEP 3. Verify AL5 appears on upper display.
STEP 4. Verify if any fault codes or engine fault codes are displayed on upper display and
record.

0008-4
 TM 9-6115-730-24 0008

TROUBLESHOOTING USING AL FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 5. Inspect coolant system lines for leaks.
STEP 6. Inspect engine coolant system per PMCS (WP 0016).
STEP 7. Open right engine access door and check engine coolant level in coolant
recovery (overflow) bottle. Check if coolant is low and service surge tank
WP 0065.
STEP 8. Troubleshoot per displayed fault codes and WP 0009.
STEP 9. Verify the problem has been resolved.

SYMPTOM
6. AL 7

MALFUNCTION
Generator Over Voltage

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to MANUAL START.
STEP 2. On GSC keypad, press ALARM CODES.
STEP 3. Verify AL7 appears on upper display.
STEP 4. Verify if any faults are displayed on DVR. Check set points per WP 0083.
STEP 5. If overvoltage 702 present, go to WP 0010, SYMPTOM 7 and troubleshoot.
STEP 6. Verify that the problem has been resolved.
STEP 7. Troubleshoot per WP 0009, CID 1169 FMI 02, SYMPTOM 62.
STEP 8. Verify if any fault codes displayed and record.
STEP 9. If problem has not been resolved, troubleshoot per WP 0009.
STEP 10. Verify that the problem has been resolved.

SYMPTOM
7. AL 8

MALFUNCTION
Generator Under Voltage

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to MANUAL START.
STEP 2. On GSC keypad, press ALARM CODES.
STEP 3. Verify AL8 appears on upper display.

0008-5
 TM 9-6115-730-24 0008

TROUBLESHOOTING USING AL FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 4. Verify if any faults are displayed on DVR. Check set points per WP 0083.
a. If no DVR fault codes are displayed, check ATB fuses (FO-1, Sheet 5).
b. If DVR fault code 701 is present, go to WP 0010, SYMPTOM 6 and
troubleshoot.
STEP 5. Verify that the problem has been resolved.
STEP 6. Troubleshoot per WP 0009, CID 1169 FMI 02, SYMPTOM 62.
STEP 7. Verify if any fault codes displayed and record.
STEP 8. If problem has not been resolved, troubleshoot per WP 0009.
STEP 9. Verify that the problem has been resolved.

SYMPTOM
8. AL 9

MALFUNCTION
Generator Over Frequency

CORRECTIVE ACTION
STEP 1. On keypad, press ALARM CODES.
STEP 2. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to MANUAL START.
STEP 3. On GSC keypad, press ALARM CODES.
STEP 4. Verify AL9 appears on upper display.
STEP 5. Verify if any fault codes or engine fault codes are displayed on upper display and
record.
a. Troubleshoot fault code and WP 0009, CID 362 E FMI 01 (SYMPTOM 42).
b. Verify OP5-0 engine/generator setpoints (WP 0083, Table 4).
STEP 6. Verify the problem has been resolved.

SYMPTOM
9. AL 10

MALFUNCTION
Generator Under Frequency

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to MANUAL START.
STEP 2. On GSC keypad, press ALARM CODES.

0008-6
 TM 9-6115-730-24 0008

TROUBLESHOOTING USING AL FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 3. Verify AL10 appears on upper display.
STEP 4. Verify if any fault codes or engine fault codes are displayed on upper display and
record.
STEP 5. Troubleshoot per WP 0011, Engine Cannot Reach Operating RPM
(SYMPTOM 26).
STEP 6. Verify the problem has been resolved.

NOTE
This alarm code should occur only when the generator sets are operated in parallel mode.

SYMPTOM
10. AL 11

MALFUNCTION
Generator Reverse Power

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Battery Disconnect
switch is OFF; DEAD CRANK SWITCH is OFF.
STEP 2. Verify that paralleling cables are securely connected between generator sets to
be paralleled.
STEP 3. Verify that load cables are connected properly by observing proper phase
polarity.
STEP 4. Verify that generator sets are set for same output voltage.
STEP 5. Parallel generator sets in accordance with TM 9-6115-730-10.
a. Verify the problem has been resolved.
b. If problem remains, visually inspect for damage, and check continuity
between pins on paralleling cables.
c. If problem remains, verify if any fault codes or engine fault codes are
displayed on GSC upper display and record.
STEP 6. Troubleshoot per displayed fault codes and WP 0009.
STEP 7. Verify protective relay function code disabled by setpoint P125 (WP 0083).
STEP 8. Enable protective relay function code setpoint P125 (WP 0083, Table 5).
STEP 9. Verify the problem has been resolved.

0008-7
 TM 9-6115-730-24 0008

TROUBLESHOOTING USING AL FAULT CODES - Continued

SYMPTOM
11. AL 12

MALFUNCTION
Phase Over Current

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to MANUAL START.
STEP 2. Verify that generator set load is properly balanced between each of the three
phases and that the generator set is not overloaded.
STEP 3. Verify that problem is resolved. If not, continue to the next step.
STEP 4. On GSC keypad, press ALARM CODES.
STEP 5. Verify AL12 appears on upper display.
STEP 6. Verify OP5-1 setpoints P128 thru P137 (WP 0083, Table 5).
a. If setpoints are changed, verify that the problem has been resolved.
b. If setpoints are not changed, verify if any fault codes or engine fault codes
are displayed on GSC upper display and record.
STEP 7. Troubleshoot per displayed fault codes and WP 0009.
STEP 8. Verify the problem has been resolved.
STEP 9. If not, replace Overload/Short Circuit Module (WP 0042)

SYMPTOM
12. AL 13

MALFUNCTION
Generator Total Over Current

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to MANUAL START.
STEP 2. Verify that generator set load is properly balanced between each of the three
phases and that the generator set is not overloaded.
STEP 3. Verify that problem is resolved. If not, continue to the next step.
STEP 4. On GSC keypad, press ALARM CODES.
STEP 5. Verify AL13 appears on upper display.
STEP 6. Verify OP5-1 setpoints P128 thru P137 (WP 0083, Table 5).
a. If setpoints are changed, verify that the problem has been resolved.
b. If setpoints are not changed, verify if any fault codes or engine fault codes
are displayed on GSC upper display and record.

0008-8
 TM 9-6115-730-24 0008

TROUBLESHOOTING USING AL FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 7. Troubleshoot per displayed fault codes and WP 0009.
STEP 8. Verify the problem has been resolved.
STEP 9. If not, replace Overload/Short Circuit Module (WP 0042).

SYMPTOM
13. AL 14

MALFUNCTION
Phase A No Voltage Input at GSC input (P7-10)

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to MANUAL START.
STEP 2. Verify that generator set load is properly balanced between each of the three
phases and that the generator set is not overloaded.
STEP 3. Verify that problem is resolved. If not, continue to the next step.
STEP 4. On GSC keypad, press ALARM CODES.
STEP 5. Verify AL14 appears on upper display. Check setpoints per WP 0083.
STEP 6. Troubleshoot A5F1 on AC transformer box (ATB) A5 per WP 0011,
SYMPTOM 4.
STEP 7. If indicated, replace A5F1 on back of ATB A5 (WP 0042).
a. Verify the problem has been resolved.
b. If not, replace ATB A5 (WP 0042).
STEP 8. Verify that problem has been resolved.

SYMPTOM
14. AL 15

MALFUNCTION
GSC Configuration Error

STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. On GSC keypad, press ALARM CODES.
STEP 3. Verify AL15 appears on upper display. Check setpoints per WP 0083, Table 1,
Table 3, and Table 5.
STEP 4. Verify if any fault codes or engine fault codes are displayed on upper display and
record.
a. Troubleshoot per displayed fault codes and WP 0009.
b. Turn ENGINE CONTROL switch to MANUAL START.

0008-9
 TM 9-6115-730-24 0008

TROUBLESHOOTING USING AL FAULT CODES - Continued

CORRECTIVE ACTION - Continued

c. Verify that engine speed rpm is for correct output frequency by pressing
ENGINE METER key on GSC.
1800 rpm for 60 Hz
1500 rpm for 50 Hz
STEP 5. Verify the problem has been resolved.

NOTE
This alarm code should occur only when the generator sets are operated in parallel mode.

SYMPTOM
15. AL 16

MALFUNCTION
Incorrect Phase Sequence - Paralleling fault code

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
Turn the ENGINE CONTROL switch to OFF/RESET.
STEP 2. Verify that paralleling cables are securely connected between generator sets to
be paralleled.
STEP 3. Verify that generator sets are set for same output voltage.
STEP 4. Parallel generator sets per TM 9-6115-730-10.
a. Verify the problem has been resolved.
b. If problem remains, verify if any fault codes or engine fault codes are
displayed on GSC upper display and record.
STEP 5. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to MANUAL START.
STEP 6. Verify that load cables are connected properly by observing proper phase
polarity.
STEP 7. On GSC keypad, press ALARM CODES.
STEP 8. Verify AL16 appears on upper display. Check setpoints per WP 0083.
STEP 9. Verify if any fault codes or engine fault codes are displayed on upper display and
record.
a. On EMCP set SYNC MODE switch to OFF.
b. Troubleshoot per displayed fault codes and WP 0009.
STEP 10. Verify the problem has been resolved.

0008-10
 TM 9-6115-730-24 0008

TROUBLESHOOTING USING AL FAULT CODES - Continued

NOTE
This alarm code should occur only when the generator sets are operated in parallel mode.

SYMPTOM
16. AL 17

MALFUNCTION
Improper Generator or Bus Voltage - Paralleling fault code

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to MANUAL START.
STEP 2. On generator set GSC displays, check the voltages on for both generator sets
and record output voltages for all phases. All phases should be the same for
both generator sets.
STEP 3. On EMCP of both generator sets, set ENGINE CONTROL switch to
OFF/RESET. Battery Disconnect switch to OFF; DEAD CRANK SWITCH to
OFF.
STEP 4. Check both generator sets and verify that all cables are connected properly and
all load terminal connections are tight per TM 9-6115-730-10.
STEP 5. Parallel generator sets per TM 9-6115-730-10.
STEP 6. Verify the problem has been resolved.
STEP 7. If problem remains, set AC CIRCUIT INTERRUPTER switch on GSC to OPEN.
a. On generator set #1, set AC CIRCUIT INTERRUPTER switch on GSC to
CLOSED.
b. Measure voltage at output load terminal lugs and record.
c. On generator set #1, set AC CIRCUIT INTERRUPTER switch on GSC to
OPEN.
d. On generator set #2, set AC CIRCUIT INTERRUPTER switch on GSC to
CLOSED.
e. Measure voltage at output load terminal lugs and record.
f. On generator set #2, set AC CIRCUIT INTERRUPTER switch on GSC to
OPEN.
STEP 8. If voltages at output load terminal lugs are different, adjust generator set voltages
equal to each other.
STEP 9. Parallel generator sets per TM 9-6115-730-10.
STEP 10. Verify the problem has been resolved.
STEP 11. If not resolved, check wiring at LSM A4.
STEP 12. If wiring at LSM A4 is good, replace LSM A4 (WP 0042).

0008-11
 TM 9-6115-730-24 0008

TROUBLESHOOTING USING AL FAULT CODES - Continued

NOTE
This alarm code should occur only when the generator sets are operated in parallel mode.

SYMPTOM
17. AL 18

MALFUNCTION
Synchronizer Time-out - Paralleling fault code

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to MANUAL START.
STEP 2. On keypad, press ALARM CODES.
STEP 3. Verify AL18 appears on upper display. Check setpoints per WP 0083.
STEP 4. Verify if any fault codes or engine fault codes are displayed on upper display and
record.
STEP 5. Troubleshoot per displayed fault codes and WP 0009.
STEP 6. On EMCP set SYNC MODE switch to OFF.
STEP 7. Check all paralleling connections to load per TM 9-6115-730-10.
STEP 8. Verify the problem has been resolved.

END OF WORK PACKAGE

0008-12
 TM 9-6115-730-24 0009

FIELD LEVEL TROUBLESHOOTING

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
GSC FAULT CODE TROUBLESHOOTING PROCEDURES

INITIAL SETUP:

Tools and Special Tools References

Multimeter WP 0083
FO-1
Personnel Required FO-2
FO-3
One FO-4
TM 9-6115-730-10

TROUBLESHOOTING USING GSC FAULT CODES

WARNING
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

High voltage is produced when this generator set is in operation. Make sure unit is completely
shut down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET. Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF.)

0009-1
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
CID 1 thru CID 6 are for the unit fuel injectors in cylinders 1 through 6 respectively. The ECM is
capable of detecting the following conditions:

Open circuit in injector wiring

Open circuit in the internal wiring of the injector
Short to ground
Injector internal short circuit
Short to B+

SYMPTOM
1. CID 1 E FMI 06
CID 1 E FMI 11

MALFUNCTION
Cylinder 1.
FMI 06 – Injector Current Fault.
FMI 11 - Failure Mode is Not Identifiable (Mechanical Failure).

CORRECTIVE ACTION
STEP 1. On EMCP, turn ENGINE CONTROL switch to OFF/RESET. Battery Disconnect
switch is OFF, DEAD CRANK SWITCH is OFF.
STEP 2. Inspect connectors ENG-P2 and ENG-P1 on engine harness (FO-2, sheet 1).
STEP 3. Conduct an appropriate pull test on wires in the ENG-P2 and ENG-P1 connectors
to ensure wires are tight and secure.
STEP 4. Check the wires on the engine harness (ENG-P2 connector to ENG-P1
connector) and the fuel injector harness (ENG-J300 connector to fuel injectors)
for abrasion and pinch points (WP 0088).
Repair the connectors or wiring and/or replace the connectors or wiring, if
necessary (WP 0088).
STEP 5. Perform Injector Solenoid Test (WP 0013, SYMPTOM 5).
STEP 6. Verify the problem is resolved.

0009-2
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

SYMPTOM
2. CID 1 E FMI 06
CID 2 E FMI 11

MALFUNCTION
Cylinder 2.
FMI 06 – Injector Current Fault.
FMI 11 - Failure mode is not identifiable (Mechanical Failure).

CORRECTIVE ACTION
Perform steps in SYMPTOM 1.

SYMPTOM
3. CID 1 E FMI 06
CID 3 E FMI 11

MALFUNCTION
Cylinder 3.
FMI 06 – Injector Current Fault.
FMI 11 - Failure mode is not identifiable (Mechanical Failure).

CORRECTIVE ACTION
Perform steps in SYMPTOM 1.

SYMPTOM
4. CID 1 E FMI 06
CID 4 E FMI 11

MALFUNCTION
Cylinder 4.
FMI 06 – Injector Current Fault.
FMI 11 - Failure mode is not identifiable (Mechanical Failure).

CORRECTIVE ACTION
Perform steps in SYMPTOM 1.

0009-3
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

SYMPTOM
5. CID 1 E FMI 06
CID 5 E FMI 11

MALFUNCTION
Cylinder 5.
FMI 06 – Injector Current Fault.
FMI 11 - Failure mode is not identifiable (Mechanical Failure).

CORRECTIVE ACTION
Perform steps in SYMPTOM 1.

SYMPTOM
6. CID 1 E FMI 06
CID 6 E FMI 11

MALFUNCTION
Cylinder 6.
FMI 06 – Injector Current Fault.
FMI 11 - Failure mode is not identifiable (Mechanical Failure).

CORRECTIVE ACTION
Perform steps in SYMPTOM 1.

SYMPTOM
7. CID 9 E FMI 02

MALFUNCTION
High Altitude Degradation.
FMI 02 - Erratic, Intermittent, or Incorrect Signal.
Event Code. Engine power lowered because of altitude. Higher the altitude, the lower the air density.
Clean dense air is needed for efficient combustion.

CORRECTIVE ACTION
Check for related alarm codes or fault codes and troubleshoot (WP 0008 and/or WP 0009).

0009-4
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
Pins 4 (+) and 5 (-) of ECM connector J2 is an 8 Vdc supply. This is supplied by the ECM for an
accelerator pedal control when this engine is used in a truck. This supply is not used on the
generator set.

SYMPTOM (Not Applicable)

8. CID 41 FMI 02
CID 41 FMI 03
CID 41 FMI 04

MALFUNCTION
8 Volt Power Supply not Normal.
FMI 02 - Erratic, intermittent, or incorrect signal.
FMI 03 - Voltage above normal.
FMI 04 - Voltage below normal.

CORRECTIVE ACTION
STEP 1. Inspect wiring at ECM connector J2.
a. Repair or replace wiring, as required (WP 0088).
b. If wiring is not defective, replace ECM (WP 0082).
STEP 2. Verify the problem is resolved.

SYMPTOM
9. CID 85 E FMI 01

MALFUNCTION
Shutdown Overridden. Data is Valid but Data is Below Normal Operating Range.
Event Code. Red FAULT ALARM indicator flashes on GSC has detected a shutdown fault which was
overridden (Battle Short).

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. Verify the Battle Short Switch is set to OFF.
STEP 3. Press ALARM CODES on GSC keypad.
STEP 4. Verify associated alarm code and fault code and troubleshoot (WP 0008 and/or
WP 0009).

0009-5
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

SYMPTOM
10. CID 91 FMI 08

MALFUNCTION
Throttle Position Signal.
FMI 08 - Abnormal Frequency, Pulse Width, or Period.

CORRECTIVE ACTION
STEP 1. On EMCP, turn ENGINE CONTROL switch to OFF/RESET. Battery Disconnect
Switch is OFF; DEAD CRANK SWITCH is OFF.
STEP 2. Inspect connector ENG-P1 on ECM to EMCP harness (FO-2, Sheet 2). Inspect
connector ENG-P300 on ECM to ENG-P300 harness (FO-2, Sheet 1).
STEP 3. Conduct an appropriate pull test on wires to ensure wires are tight and secure.
STEP 4. Check the wires on the ECM to EMCP harness for abrasion and pinch points
(WP 0090).
Repair and/or replace the connectors and/or wiring (WP 0088), as necessary.
STEP 5. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 6. Measure 24 +/- 3 Vdc between terminal 15 (+) and terminal 16 (-) on LSM A4
(FO-4, sheet 2).
If 24 +/- 3 Vdc is not measured between terminal 15 (+) and terminal 16 (-) on the
LSM A4, perform Speed Control Test (WP 0013, SYMPTOM 6, STEP 6).
STEP 7. Verify the problem is resolved.
STEP 8. If 24 +/- 3 Vdc is measured between terminal 15 (+) and terminal 16 (-) on LSM
A4 (FO-4, Sheet 2), refer to WP 0013, SYMPTOM 6, STEP 3.
a. On EMCP, turn ENGINE CONTROL switch to MANUAL START.
b. Measure DC voltage between LSM A4 terminals 19 (+) and 20 (-).
Measurement should be 3.1 Vdc @ 60 Hz under no load. If not, adjust
speed trim potentiometer to bring signal to 3.1 Vdc and generator frequency
to 60 Hz.
c. If PWM output of LSM A4 is low and/or cannot be adjusted to 3.1 Vdc, check
speed trim potentiometer connections and test speed trim potentiometer
resistance. If speed trim potentiometer is ok, replace LSM A4 (WP 0042).
STEP 9. Verify the problem has been resolved.

0009-6
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

SYMPTOM
11. CID 94 FMI 01
CID 94 FMI 02

MALFUNCTION
Fuel Pressure Sensor.
FMI 01 - Data is Valid But Data is Below Normal Operating Range.
FMI 02 - Erratic, Intermittent, or Incorrect Signal.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. Disconnect engine harness connector ENG-J202 from fuel pressure sensor
(WP 0088, Figure 1, sheet 1 and FO-2, sheet 1).
STEP 3. Measure voltage between ENG-J202-A (+) and ENG-J202-B (-) of harness
connector (WP 0088, Figure 2, sheet 1).
a. If voltage is not present, repair or replace harness (WP 0088). Verify the
problem has been resolved.
b. If repairing wiring does not resolve fault, replace the fuel pressure sensor
(WP 0098). Verify the problem has been resolved.
c. If voltage is not present between ENG-J202-A (+) and ENG-J202-B (-)
proceed to STEP 3d.
d. Remove ENG-P2 from ECM and verify continuity between ENG-J202-C and
ENG-P2-16 per FO-2, sheet 1.
(1) If continuity is not present, repair or replace harness (WP 0088). Verify
the problem has been resolved.
(2) If the problem is not resolved, replace ECM (WP 0082).
STEP 4. Verify the problem is resolved.

0009-7
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
This procedure is used for FMI codes 03 and 04 for all pressure sensors.

SYMPTOM
12. CID 94 E FMI 03
CID 94 E FMI 04

MALFUNCTION
Fuel Pressure Sensor.
FMI 03 - Voltage Above Normal.
FMI 04 - Voltage Below Normal.

CORRECTIVE ACTION
STEP 1. On EMCP, turn ENGINE CONTROL switch to OFF/RESET. Battery Disconnect
Switch is OFF; DEAD CRANK SWITCH is OFF.
STEP 2. Inspect connectors ENG-P2 on the engine harness (FO-2, sheet 1) and ENG-P1
on the ECM to EMCP Harness (FO-2, sheet 2).
STEP 3. Conduct an appropriate pull test on wires in the ENG-P2 and ENG-P1 connectors
to ensure wires are tight and secure.
STEP 4. Check the wires on both harnesses for abrasion and pinch points (WP 0088).
Repair and/or replace the connectors and/or wiring (WP 0088).
STEP 5. If necessary, disconnect the harness connectors, for the fuel pressure sensor, oil
pressure sensor, turbo outlet pressure sensor, atmospheric pressure sensor, and
turbo inlet pressure sensor.
STEP 6. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 7. Measure 5.0 +/- 0.2 Vdc between terminals A (supply) and B (return) at each
sensor connector.
a. If 5.0 +/- 0.2 Vdc is not measured on all sensor connectors, remove ENG-P2
from ECM J2. Check for 5.0 +/- 0.2 Vdc on the pins for the bad sensor
reading (WP 0088 and FO-2 Sheet 1). Verify continuity of the signal wire
(pin C) for the suspect sensor connector.
b. On EMCP, turn ENGINE CONTROL switch to OFF/RESET. Battery
Disconnect Switch is OFF; DEAD CRANK SWITCH is set to OFF.
(1) If the voltage was present, repair/replace the ECM J2 engine harness
(WP 0088).
(2) If the voltage was not present, replace the ECM (WP 0082).
c. Reconnect all of the sensor connectors.
d. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to
NORMAL. On EMCP turn the ENGINE CONTROL switch to COOL
DOWN/STOP. Retest the system.

0009-8
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

CORRECTIVE ACTION - Continued

e. If the problem is not resolved, proceed to STEP 8.
STEP 8. On EMCP, turn ENGINE CONTROL switch to OFF/RESET. Battery Disconnect
Switch is OFF. DEAD CRANK SWITCH is set to OFF.
STEP 9. Disconnect the connector from the defective sensor.
a. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to
NORMAL. On EMCP turn the ENGINE CONTROL switch to COOL
DOWN/STOP.
b. Check for a 03 diagnostic code.
c. On EMCP, turn ENGINE CONTROL switch to OFF/RESET. Battery
Disconnect Switch is OFF. DEAD CRANK SWITCH is set to OFF.
d. Connect a jumper wire and connect to pins B and C of the bad sensor
connector.
e. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to
NORMAL. On EMCP turn the ENGINE CONTROL switch to COOL
DOWN/STOP.
f. Check for a 04 diagnostic code. If the correct code is present, the ECM is
working OK. Replace the defective sensor (WP 0098).
g. If the diagnostic code remains 03, proceed to STEP 10.
STEP 10. On EMCP, turn ENGINE CONTROL switch to OFF/RESET. Battery Disconnect
Switch is OFF. DEAD CRANK SWITCH is set to OFF. Remove the jumper wire.
STEP 11. Replace the ECM (WP 0082) and retest the system. Verify the problem is
resolved.

SYMPTOM
13. CID 96 E FMI 01

MALFUNCTION
High Fuel Pressure Warning.
FMI 01 - Data is Valid but Data is Below Normal Operating Range.
Event Code. Indicates that sensor detects a fuel system backup to cause high pressure warning.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. Press ALARM CODES on GSC keypad.
STEP 3. Check for associated alarm code and fault code and troubleshoot (WP 0008
and/or WP 0009).
STEP 4. If no fault code, inspect fuel filter and fuel/water separator per PMCS (WP 0016)
and perform service as required.

0009-9
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

SYMPTOM
14. CID 97 E FMI 01

MALFUNCTION
Derate Overridden.
FMI 01 - Data is Valid but Data is Below Normal Operating Range.
Event Code. Engine derate overridden. Verify presence of fault.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. Press ALARM CODES on GSC keypad.
STEP 3. Check for logged fault code, troubleshoot, and correct (WP 0008 and/or
WP 0009).
STEP 4. Verify the problem is resolved.

NOTE
The following failure indicates that GSC is unable to receive valid data about oil pressure from
ECM.

SYMPTOM
15. CID 100 E FMI 02

MALFUNCTION
Oil Pressure Sensor.
FMI 02 - Erratic, Intermittent, or Incorrect Signal.

CORRECTIVE ACTION
STEP 1. On EMCP, turn ENGINE CONTROL switch to OFF/RESET. Battery Disconnect
switch is OFF, DEAD CRANK SWITCH is OFF.
STEP 2. Inspect connectors ENG-P2 on the engine harness (FO-2, sheet 1) and P1 on
the ECM to EMCP Harness (FO-2, sheet 2).
STEP 3. Conduct an appropriate pull test on wires in the ENG-P2 and ENG-P1 connectors
to ensure wires are tight and secure.
STEP 4. Disconnect ENG-P2 from ECM J2, ENG-P201 from the oil pressure sensor, and
ENG-P202 from the fuel pressure sensor. Verify continuity from ENG-P201-A to
ENG-P202-A and ENG-P2-2. Verify continuity from ENG-P201-B to ENG-P202-
B and ENG-P2-3. Verify continuity from ENG-P201-C to ENG-P2-24.
STEP 5. Check the wires on both ENG-P1 and ENG-P2 harnesses for abrasion and pinch
points (WP 0088).
STEP 6. If necessary, repair and/or replace the connectors and/or wiring (WP 0088).

0009-10
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 7. Disconnect the harness connectors, for the fuel pressure sensor, oil pressure
sensor, injection actuation sensor, turbo outlet pressure sensor, atmospheric
pressure sensor, and turbo inlet pressure sensor.
STEP 8. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 9. Measure 5.0 +/- 0.2 Vdc between terminals A (supply) and B (return) at each
sensor connector.
If 5.0 +/- 0.2 Vdc is not measured on all sensor connectors, perform Electrical
Connectors Wiggle Test (WP 0013, SYMPTOM 1).
STEP 10. If the problem is not resolved, replace the oil pressure sensor (WP 0098).
STEP 11. Retest the system. Verify that the problem has been cleared.
STEP 12 If the problem has not been resolved, replace ECM (WP 0082).
STEP 13. Retest the system and verify the problem has been resolved.

NOTE
The following failure is usually a broken wire, or a frayed wire shorting to an adjacent wire or to
ground.

SYMPTOM
16. CID 100 E FMI 03
CID 100 E FMI 04

MALFUNCTION
Oil Pressure Sensor.
FMI 03 - Voltage Above Normal.
FMI 04 - Voltage Below Normal.

CORRECTIVE ACTION
Troubleshoot oil pressure sensor using steps in SYMPTOM 12.

0009-11
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
This failure indicates that GSC is unable to receive any valid data about the coolant temperature
from the ECM.

SYMPTOM
17. CID 110 E FMI 02
CID 110 E FMI 03
CID 110 E FMI 04

MALFUNCTION
Coolant Temperature Sensor.
FMI 02 - Erratic, Intermittent, or Incorrect Signal.
FMI 03 - Voltage Above Normal.
FMI 04 - Voltage Below Normal.

CORRECTIVE ACTION
STEP 1. On EMCP, turn ENGINE CONTROL switch to OFF/RESET. Battery Disconnect
switch is OFF, DEAD CRANK SWITCH is OFF.
STEP 2. Inspect connectors ENG-P2 on the engine harness (FO-2, sheet 1) and ENG-P1
on the ECM to EMCP Harness (FO-2, sheet 2).
STEP 3. Conduct an appropriate pull test on wires in the ENG-P2 and ENG-P1 connectors
to ensure wires are tight and secure.
STEP 4. Check the wires on both harnesses for abrasion and pinch points (WP 0088).
Repair and/or replace the connectors and/or wiring (WP 0088).
STEP 5. Disconnect engine harness connector ENG-P100 from coolant temperature
sensor (WP 0088, Figure 1, sheet 1, and FO-2, sheet 1).
STEP 6. Connect a new sensor to engine harness connector ENG-P100, but do not install
the sensor into the engine.
STEP 7. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 8. On GSC keypad, press GSC ALARM CODES button.
a. If the fault has cleared, replace coolant temperature sensor
(WP 0098). Verify the problem has been resolved.
b. If the fault has not cleared, continue with STEP 9.
STEP 9. Turn ENGINE CONTROL switch to OFF/RESET. Battery Disconnect switch is
OFF, DEAD CRANK SWITCH is OFF.

0009-12
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 10. Remove engine harness connector ENG-P100 from the new sensor. Leave
ENG-P100 disconnected.
a. Use a jumper wire long enough to reach from engine harness connector
ENG-P100-1 to the engine ground stud.
b. Install jumper wire onto ENG-P100-1.
STEP 11. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 12. On GSC keypad, press GSC ALARM CODES button.
a. Verify a diagnostic code 03 appears.
b. Short the jumper wire (ENG-P100-1) to the engine ground.
c. Verify a diagnostic code 04 appears. This verifies the ECM is working
properly.
STEP 13. Turn ENGINE CONTROL switch to OFF/RESET. Battery Disconnect switch is
OFF, DEAD CRANK SWITCH is OFF.
STEP 14. Remove the jumper wire and connect all wires and connectors.
If a diagnostic code 03 and/or a diagnostic code 04 did not appear in STEP 13,
repair or replace the engine harness. Verify the problem has been resolved.
STEP 15. If the problem is not resolved, replace ECM (WP 0082).
STEP 16. Verify the problem is resolved.

NOTE
The low coolant sensor is powered by 8 Vdc from the GSC. When coolant is present at the
sensor, a logic low (near zero volts) is sent to the GSC. When coolant is not present at the
sensor, a logic high is sent to the GSC.

SYMPTOM
18. CID 111 E FMI 03
CID 111 E FMI 04

MALFUNCTION
Low Coolant Sensor.
FMI 03 - Voltage Above Normal.
FMI 04 - Voltage Below Normal.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. Disconnect ECM to EMCP harness connector ENG-P16 from low coolant sensor
(WP 0088, Figure 1 sheet 2, and FO-2, sheet 2).

0009-13
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 3. Measure the voltage on the ECM to EMCP harness connector between ENG-
P16-A (+) and ENG-P16-B (-). Also measure the voltage between ENG-P16-C
(+) and ENG-P16-B (-).
If the voltage between ENG-P16-A (+) and ENG-P16-B (-) is not 7.5 to 8.5 Vdc or
voltage between ENG-P16-C (+) and ENG-P16-B (-) is not 2.0 to 3.0 Vdc, repair
or replace ECM to EMCP harness (WP 0088).
STEP 4. If repairing or replacing the ECM to EMCP harness does not correct the problem,
replace the low coolant sensor (WP 0098).
STEP 5. If replacing the low coolant sensor does not correct the problem, proceed to
STEP 6.
STEP 6. Turn ENGINE CONTROL switch to OFF/RESET. Battery Disconnect Switch is
OFF; DEAD CRANK SWITCH is OFF.
STEP 7. Disconnect the defective sensor connector.
a. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to
NORMAL. On EMCP turn the ENGINE CONTROL switch to COOL
DOWN/STOP.
b. Check for a 03 diagnostic code.
c. On EMCP, turn ENGINE CONTROL switch to OFF/RESET. Battery
Disconnect Switch is OFF. DEAD CRANK SWITCH is set to OFF.
d. Connect a jumper wire and connect to pins B and C of the bad sensor
connector.
e. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to
NORMAL. On EMCP turn the ENGINE CONTROL switch to COOL
DOWN/STOP.
f. Check for a 04 diagnostic code. If the correct code is present, the ECM is
working OK. Replace the defective sensor (WP 0098).
g. If the diagnostic code remains 03, proceed to STEP 8.
STEP 8. On EMCP, turn ENGINE CONTROL switch to OFF/RESET. Battery Disconnect
Switch is OFF. DEAD CRANK SWITCH is set to OFF. Remove the jumper wire.
STEP 9. Replace the ECM (WP 0082) and retest the system. Verify the problem is
resolved.
STEP 10. Verify the problem has been resolved.

0009-14
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

SYMPTOM
19. CID 168 E FMI 02
CID 168 E FMI 03
CID 168 E FMI 04

MALFUNCTION
Electrical System Voltage.
FMI 02 - Erratic, Intermittent, or Incorrect Signal.
FMI 03 - Voltage Above Normal.
FMI 04 - Voltage Below Normal.

CORRECTIVE ACTION
STEP 1. On EMCP, turn ENGINE CONTROL switch to OFF/RESET. Battery Disconnect
switch is OFF, DEAD CRANK SWITCH is OFF.
STEP 2. Inspect connector ENG-P2 on the Engine Harness (FO-2, sheet 1) and connector
ENG-P1 on the ECM to EMCP Harness (FO-2, sheet 2).
STEP 3. Conduct an appropriate pull test on wires in the ENG-P2 and ENG-P1 connectors
to ensure wires are tight and secure.
STEP 4. Check the wires on both harnesses for abrasion and pinch points (WP 0088).
Repair and/or replace the connectors and/or wiring (WP 0088).
STEP 5. Perform Electrical Power Supply Test (WP 0013, SYMPTOM 2).
STEP 6. Verify the problem has been resolved.

0009-15
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

SYMPTOM
20. CID 169 E FMI 01

MALFUNCTION
Engine Oil Maintenance Required.
FMI 01 - Data is valid but data is below normal operating range.
Event Code. Engine oil change is required.

CORRECTIVE ACTION
STEP 1. Perform engine oil and filter change (WP 0079).
STEP 2. Set Battery Disconnect Switch to ON; Set DEAD CRANK SWITCH to NORMAL.
On EMCP, turn ENGINE CONTROL switch to COOL DOWN/ STOP.
STEP 3. Reset CATSW2 after oil filter and oil are changed.
STEP 4. Record engine oil maintenance.
STEP 5. Verify the fault code has cleared.

SYMPTOM
21. CID 170 E FMI 01

MALFUNCTION
Fuel Filter Change Required.
FMI 01 - Data is valid but data is below normal operating range.
Event Code. Inspect fuel filter for leaks, proper mounting, cracks, damage, or missing parts and
change fuel filter.

CORRECTIVE ACTION
STEP 1. Perform fuel filter change (WP 0080).
STEP 2. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP, turn ENGINE CONTROL switch to COOL DOWN/ STOP.
STEP 3. Reset CATSW1 after fuel filter change.
STEP 4. Record fuel filter maintenance.
STEP 5. Verify the fault code has cleared.

0009-16
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
The following codes are generated when the intake air manifold temperature sensor sees
a temperature greater than 194º F (90º C) for two seconds or longer (FMI 00); or greater than
228º F (109º C) (FMI 11) for two seconds or longer. This problem is often caused by one of the
following:

Incorrect fuel injection timing

Low air inlet system pressure
Restriction in air inlet

SYMPTOM
22. CID 172 E FMI 00
CID 172 E FMI 03
CID 172 E FMI 04
CID 172 E FMI 11

MALFUNCTION
Intake manifold air temperature sensor.
FMI 00 - Data is Valid but Data is Above Normal Operating Range.
FMI 03 - Voltage above normal.
FMI 04 - Voltage below normal.
FMI 11 - Failure mode is not identifiable (Mechanical Failure)

CORRECTIVE ACTION
STEP 1. Inspect and service air cleaner per TM 9-6115-730-10.
STEP 2. If air cleaner required service, verify the fault code has cleared. If not continue to
the next step.
STEP 3. On EMCP, turn ENGINE CONTROL switch to OFF/RESET. Battery Disconnect
switch is OFF, DEAD CRANK SWITCH is OFF.
STEP 4. Inspect connectors ENG-P2 on the engine harness (FO-2, sheet 1) and ENG-P1
on the ECM to EMCP Harness (FO-2, sheet 2).
STEP 5. Conduct an appropriate pull test on wires in the ENG-P2 and ENG-P1 connectors
to ensure wires are tight and secure.
STEP 6. Check the wires on both harnesses for abrasion and pinch points (WP 0088).
Repair and/or replace the connectors and/or wiring (WP 0088).

0009-17
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TROUBLESHOOTING USING GSC FAULT CODES - Continued

CORRECTIVE ACTION – Continued

STEP 7. Disconnect engine harness connector ENG-P103 from intake manifold air
temperature sensor (WP 0088, Figure 1, sheet 1, and FO-2, sheet 1).
a. Use a jumper wire long enough to reach from engine harness connector
P103-1 to the engine ground stud.
b. Install jumper wire onto P103-1.
STEP 8. Set Battery Disconnect Switch to ON, Set DEAD CRANK SWITCH to NORMAL.
Turn ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 9. On GSC keypad, press GSC ALARM CODES button.
a. Verify a diagnostic code 03 appears.
b. Short the jumper wire (ENG-P103-1) to the engine ground.
c. Verify a diagnostic code 04 appears. This verifies the ECM is working
properly.
STEP 10. Turn ENGINE CONTROL switch to OFF/RESET. Battery Disconnect Switch is
OFF; DEAD CRANK SWITCH is OFF.
STEP 11. Remove the jumper wire and connect all wires and connectors.
If a diagnostic code 03 and/or a diagnostic code 04 did not appear in STEP 9,
check continuity between ENG-P103-1 to ENG-P2-35 and between ENG-P103-2
to ENG-P2-18, P100-2, and P105-2. Repair or replace the engine harness (WP
0088) as necessary.
STEP 12. If the problem is not resolved, replace intake manifold air temperature sensor
(WP 0098).
STEP 13. Verify the problem is resolved. If not, replace ECM (WP 0082).
STEP 14. Verify the fault code has cleared.

0009-18
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

SYMPTOM
23. CID 174 FMI 03
CID 174 FMI 04

MALFUNCTION
Fuel Temperature Sensor.
FMI 03 - Voltage Above Normal.
FMI 04 - Voltage Below Normal.

CORRECTIVE ACTION
STEP 1. On EMCP, turn ENGINE CONTROL switch to OFF/RESET. Battery Disconnect
switch is OFF, DEAD CRANK SWITCH is OFF.
STEP 2. Inspect connectors ENG-P2 on the engine harness (FO-2, sheet 1) and ENG-P1
on the ECM to EMCP Harness (FO-2, sheet 2).
STEP 3. Conduct an appropriate pull test on wires in the ENG-P2 and ENG-P1 connectors
to ensure wires are tight and secure.
STEP 4. Check the wires on both harnesses for abrasion and pinch points (WP 0088).
Repair and/or replace the connectors and/or wiring (WP 0088).
STEP 5. Disconnect engine harness connector ENG-P105 from fuel temperature sensor
(WP 0088, Figure 1, sheet 1, and FO-2, sheet 1).
a. Use a jumper wire long enough to reach from engine harness connector
P105-1 to the engine ground stud.
b. Install jumper wire onto P105-1.
STEP 6. Set Battery Disconnect Switch to ON, Set DEAD CRANK SWITCH to NORMAL.
Turn ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 7. On GSC keypad, press GSC ALARM CODES button.
a. Verify a diagnostic code 03 appears.
b. Short the jumper wire (ENG-P105-1) to the engine ground.
c. Verify a diagnostic code 04 appears. This verifies the ECM is working
properly.
STEP 8. Turn ENGINE CONTROL switch to OFF/RESET. Battery Disconnect Switch is
OFF; DEAD CRANK SWITCH is OFF.
STEP 9. Remove the jumper wire and connect all wires and connectors.
If a diagnostic code 03 and/or a diagnostic code 04 did not appear in STEP 7,
check continuity between ENG-P105-1 to ENG-P2-33 and between ENG-P105-2
to ENG-P2-18, P100-2, and P105-2. Repair or replace the engine harness (WP
0088) as necessary.
STEP 10. If the problem is not resolved, replace fuel temperature sensor (WP 0098).
STEP 11. Verify the problem is resolved. If not, replace ECM (WP 0082).
STEP 12. Verify the fault code has cleared.

0009-19
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
The magnetic pickup unit (MPU) on this engine is located at the rear of the engine on the flywheel
housing.

SYMPTOM
24. CID 190 FMI 02
CID 190 FMI 03

MALFUNCTION
Loss of Engine Speed Signal.
Magnetic pickup unit (engine speed sensor).
FMI 02 - Erratic, intermittent, or incorrect signal.
FMI 03 - Voltage above normal.

CORRECTIVE ACTION
STEP 1. Turn the ENGINE CONTROL switch to OFF/RESET.
STEP 2. Disconnect ENG-P14 from the magnetic pickup unit (MPU) (WP 0088, Figure 2,
Sheet 2, and FO-2, Sheet 2).
STEP 3. Measure MPU resistance.
a. If resistance is not 100 to 350 ohms, replace the MPU (WP 0098).
b. If resistance is correct, set DVM to AC volts. Turn DEAD CRANK SWITCH
to CRANK. Measure 2 to 3 Vac from ground to ENG P14-1 and ENG P14-2
(MPU pigtail connector).
(1) If voltage measurement is not OK, adjust the MPU (WP 0098). Verify the
problem is resolved. If not, the MPU is damaged or it is not functioning.
Replace the magnetic pickup unit (WP 0098). Verify the problem is
resolved.
(2) If the voltage measurement is OK, the MPU is functioning OK. Replace
LSM A4 (WP 0041). Verify the problem is resolved.
STEP 4. Reconnect ENG-P14 to the MPU ).(WP 0088, Figure 2, sheet 2, andFO-2, sheet
2). Disconnect ENG-P37 from the back of the GSC. Measure resistance
between ENG-P37-1 and ENG-P37-2. Resistance should be 100 to 350 ohms.
a. If resistance is not 100 to 350 ohms, troubleshoot wiring harness between
ENG-P37 and ENG-P14 (WP 0088). Repair as necessary (WP 0088).
Verify the problem has been resolved.
b. If the problem has not been resolved, troubleshoot wiring between EMCP
J37-1 to GSC P7-1 and EMCP J37-2 to GSC P7-2. Repair as necessary
(WP 0090). Verify the problem has been resolved.
c. If the problem has not been resolved, check all GSC fuses (FO-4, Sheets 3
and 5).
d. If GSC fuses are ok, replace GSC (WP 0041).
STEP 5. Verify the problem has been resolved.

0009-20
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

SYMPTOM
25. CID 190 E FMI 02
CID 190 E FMI 11

MALFUNCTION
Loss of Engine Speed Signal.
Crankshaft (bottom) engine timing sensor.
FMI 02 - Erratic, intermittent, or incorrect signal.
FMI 11 - Failure mode is not identifiable (Mechanical Failure).

CORRECTIVE ACTION
STEP 1. Turn the ENGINE CONTROL switch to OFF/RESET. Battery Disconnect switch
is OFF, DEAD CRANK SWITCH is OFF.
STEP 2. Disconnect connector ENG-P401 from the crankshaft engine timing sensor (FO-
2, sheet 1). The sensor connector has a wire clip that must be removed in order
to disconnect the connector from the sensor.
STEP 3. Measure engine timing sensor resistance.
a. If resistance is not 75 to 230 ohms, replace crankshaft engine timing sensor
(WP 0098).
b. If resistance is correct, inspect and adjust engine timing (WP 0013,
SYMPTOM 3).
c. Verify the problem has been resolved. If not, continue to the next step.
STEP 4. If the problem is not resolved, remove and inspect sensor
(WP 0013, SYMPTOM 3, steps 6-a thru 6-f)
a. If sensor is damaged, replace and adjust sensor (WP 0098,
WP 0013, SYMPTOM 3). Verify the problem is resolved.
b. If the sensor does not appear to be damaged, reinstall sensor.
STEP 5. Disconnect ENG-P2 from the ECM J2 (WP 0088, Figure 2, sheet 3 and
FO-2, sheet 1).
STEP 6. Inspect engine harness and verify continuity between ENG-P401-A and
ENG-P2-49 and between ENG-P401-B and ENG-P2-48 (FO-2, sheet 1).
a. If open or shorted, repair or replace engine harness (WP 0088), as
necessary
b. Verify the problem has been resolved. If not, replace ECM (WP 0082).
STEP 7. Verify the problem has been resolved.

0009-21
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

SYMPTOM
26. CID 248 FMI 09

MALFUNCTION
CAT Data Link.
FMI 09 - Abnormal update.

CORRECTIVE ACTION
STEP 1. Turn the ENGINE CONTROL switch to OFF/RESET. Battery Disconnect Switch
is OFF; DEAD CRANK SWITCH is OFF.
STEP 2. Disconnect ENG-P1 from ECM.
STEP 3. Verify continuity between CDC P7-E and ENG P1-9 and between CDC P7-D and
ENG P1-8 per FO-4, sheet 1, FO-2, sheet 2 and WP 0088, Figure 2, sheet 3.
a. Repair or replace harness, as required (WP 0088). Verify the problem has
been resolved.
b. If the problem is not resolved, continue to STEP 4.
STEP 4. Perform Electronic Service Tool (Cat ET) will not communicate with ECM
(WP 0013, SYMPTOM 7).
STEP 5. Verify the problem has been resolved.

NOTE
This code indicates that a customer or system parameter has not been programmed, or the code
in the personality module in the ECM does not match the code for the ECM. The engine may be
limited in horsepower or speed.

SYMPTOM
27. CID 253 E FMI 02

MALFUNCTION
Personality Module Mismatch.
FMI 02 - Erratic, Intermittent, or Incorrect Signal.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON, Set DEAD CRANK SWITCH to NORMAL.
Turn ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. Verify the flash file in the ECM (WP 0013, SYMPTOM 9).
If flash file is incorrect, load correct flash file into the ECM (WP 0013,
SYMPTOM 9). Verify the problem has been resolved.
STEP 3. If the problem is not resolved, replace ECM (WP 0082).
Load correct flash file into ECM (WP 0013, SYMPTOM 9).
STEP 4. Verify the problem is resolved.

0009-22
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
This fault code indicates that the ECM has detected an internal power supply or memory problem
that can not be repaired.

SYMPTOM
28. CID 254 E FMI 12

MALFUNCTION
ECM Self Test.
FMI 12 - Failed Component.

CORRECTIVE ACTION
STEP 1. If the ECM fails Self Test, replace ECM (WP 0082).
STEP 2. Load correct flash file into ECM (WP 0013, SYMPTOM 9).
STEP 3. Verify the ECM passes Self Test.

SYMPTOM
29. CID 261 E FMI 13

MALFUNCTION
Engine Timing Calibration.
FMI 13 - Device is Not Calibrated.

CORRECTIVE ACTION
Perform Engine Timing Calibration (WP 0013, SYMPTOM 8).

0009-23
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
These failures are caused by either a failed sensor or a problem with the wiring.

SYMPTOM
30. CID 262 E FMI 03
CID 262 E FMI 04

MALFUNCTION
5 V Sensor Power Supply.
FMI 03 - Voltage Above Normal.
FMI 04 - Voltage Below Normal.

CORRECTIVE ACTION
STEP 1. On EMCP, turn ENGINE CONTROL switch to OFF/RESET. Battery Disconnect
switch is OFF, DEAD CRANK SWITCH is OFF.
STEP 2. Inspect connectors ENG-P2 on the engine harness (FO-2, sheet 1) and ENG-P1
on the ECM to EMCP Harness (FO-2, sheet 2).
STEP 3. Conduct an appropriate pull test on wires (WP 0088) in the ENG-P2 and ENG-P1
connectors to ensure wires are tight and secure.
STEP 4. Check the wires on both harnesses for abrasion and pinch points (WP 0088).
Repair and/or replace the connectors and/or wiring (WP 0088).
STEP 5. Set Battery Disconnect Switch to ON, Set DEAD CRANK SWITCH to NORMAL.
On EMCP, turn ENGINE CONTROL switch to COOL DOWN/STOP
STEP 6. Check for FMI 03 and/or FMI 04 failure modes with associated fault codes CID 94
and CID 100 simultaneously or CID 273, and CID 274 simultaneously..
a. If found, go to STEP 7 and troubleshoot engine wiring harness. Check for
opens or shorts in the sensors common wires.
b. If not found, proceed to STEP 8.
STEP 7. Troubleshoot engine wiring harness per WP 0088, Figure FO-2, Sheets 1 and 2.
a. Disconnect engine wiring harness connectors ENG-P1 and ENG-P2 and the
connectors to sensors listed in STEP 8.
b. Check continuity between ENG-P1 and ENG-P2 and all sensors identified in
STEP 8.
c. If wires all have continuity, reconnect all sensor connectors, ENG-P1 and
ENG-P2. Proceed to STEP 8.
d. If continuity is not found, repair or replace wiring harness as necessary per
WP 0088.
e. Reconnect all sensors, ENG-P1 and ENG-P2 and verify is the problem still
exists. If so, proceed to STEP 8.

0009-24
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 8. Set Battery Disconnect Switch to ON, Set DEAD CRANK SWITCH to NORMAL.
Turn ENGINE CONTROL switch to COOL DOWN/STOP. Disconnect the
following sensors one at a time, while observing the GSC (WP 0088, Figure 1).
a. Oil pressure sensor.
b. Turbo outlet pressure sensor.
c. Fuel pressure sensor.
d. Atmospheric pressure sensor.
e. Turbo inlet pressure sensor.
STEP 9. On EMCP, turn ENGINE CONTROL switch to OFF/RESET, Battery Disconnect
Switch to OFF; and DEAD CRANK SWITCH to OFF.
STEP 10. If the diagnostic code deactivated after a particular sensor was disconnected,
replace the sensor causing the fault (WP 0098).
STEP 11. Set Battery Disconnect Switch to ON, Set DEAD CRANK SWITCH to NORMAL.
Turn ENGINE CONTROL switch to COOL DOWN/STOP. Verify if problem still
exists. If all sensors have been disconnected and fault remains active, go to
STEP 12.
STEP 12. Turn the ENGINE CONTROL switch to OFF/RESET. Battery Disconnect Switch
is OFF; DEAD CRANK SWITCH is OFF.
STEP 13. If not performed earlier, troubleshoot wiring harness in STEP 7 (a), (b), (d) and
(e).
STEP 13. Set Battery Disconnect Switch to ON, Set DEAD CRANK SWITCH to NORMAL.
Turn ENGINE CONTROL switch to COOL DOWN/STOP. Check for fault code.

STEP 14. If fault still exist, replace ECM (WP 0082) Verify fault code has cleared.

0009-25
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

SYMPTOM
31. CID 264 E FMI 03

MALFUNCTION
E-Stop Shutdown.
FMI 03 - Voltage Above Normal.
Event Code. Red EMERGENCY STOP indicator on GSC flashes when PUSH TO STOP
EMERGENCY STOP pushbutton is pressed on control panel. Engine shuts down and does not start
until pushbutton is pulled out and ENGINE CONTROL switch is set to OFF/RESET and back to
MANUAL START.

CORRECTIVE ACTION
STEP 1. Determine reason for Emergency Stop situation.
a. Correct emergency stop condition.
b. Reset emergency stop switch to the OFF position.
c. Verify the fault has cleared. If not proceed to the next step.

STEP 2 . Turn the ENGINE CONTROL switch to OFF/RESET. Battery Disconnect Switch
is OFF; DEAD CRANK SWITCH is OFF.
STEP 3. Check for an open circuit between the following test points (FO-1, sheet 2; FO-2,
sheet 1):
a. GSC A1-13 to PB3-14
b. Terminal 1A on the Emergency Stop switch and Terminal 2A on the
Emergency Stop switch.
c. Terminal TB3-14 and Terminal 1A on the Emergency Stop switch.
d. Terminal 2A on the Emergency Stop switch and the Battery Disconnect
Switch.
e. Terminal 27 of the ENG-P37 harness connector and Terminal TB3-14.
f. ECM connector ENG-P1-23 and Terminal 27 of the engine harness
connector.
STEP 4. If an open circuit is detected between any of the test points, repair the wiring
and/or replace damaged components.
STEP 5. Check each connection for corrosion.
STEP 6. Ensure all wires are properly crimped and/or tightened (WP 0088).
STEP 7. Verify the problem has been resolved.

0009-26
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
The GSC displays a CID 268 FMI 02 when the setpoint data is invalid or the setpoint data is out
of range. After displaying this code, the GSC sets the affected setpoint(s) to the default value(s).

SYMPTOM
32. CID 268 FMI 02

MALFUNCTION
GSC Electronic Control.
FMI 02 - Erratic, Intermittent, or Incorrect Signal.

CORRECTIVE ACTION
STEP 1. Turn the ENGINE CONTROL switch to OFF/RESET. Battery Disconnect Switch
is OFF; DEAD CRANK SWITCH is OFF (to reset the GSC).
STEP 2. Set Battery Disconnect Switch to ON, Set DEAD CRANK SWITCH to NORMAL.
Turn ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 3. Verify the problem has been resolved. If not, check for other fault codes.
Troubleshoot and resolve as required.
STEP 4. Verify all programmable setpoints in the GSC (WP 0083).
STEP 5. If the problem is not resolved, reprogram the GSC setpoints (WP 0083).
STEP 6. If reprogramming the GSC does not resolve the fault, replace the GSC
(WP 0041).
STEP 7. Verify the problem has been resolved.

0009-27
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
If the sensor power supply is detected to be greater than 8.5 Vdc or less than 7.5 Vdc, this fault
code will appear.

SYMPTOM
33. CID 269 FMI 03
CID 269 FMI 04

MALFUNCTION
GSC 8V Sensor Power Supply.
FMI 03 - Voltage Above Normal.
FMI 04 - Voltage Below Normal.

CORRECTIVE ACTION
STEP 1. Turn the ENGINE CONTROL switch to OFF/RESET. Battery Disconnect switch
is OFF, DEAD CRANK SWITCH is OFF (to reset GSC).
STEP 2. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 3. Observe fault codes on GSC.
a. Disconnect low coolant sensor connector ENG-P16. Using DVM, measure
voltage between ENG-P16-A and ENG-P16-B. If voltage is between 7.5 and
8.5 Vdc go to STEP 3 d. If voltage is above 8.5 Vdc or below 7.5 Vdc go to
STEP 3 b.
b. Verify wiring on ECM to EMCP harness between GSC P37 and low coolant
sensor connector ENG-P16 (WP 0088). Repair as necessary (WP 0088).
c. If wiring harness was repaired, verify the problem has been resolved.
d. Verify all programmable setpoints in the GSC (WP 0083).
e. If fault still appears on GSC, replace the GSC (WP 0041).
STEP 4. Verify the problem has been resolved.

0009-28
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES – Continued

SYMPTOM
34. CID 273 FMI 03
CID 273 FMI 04

MALFUNCTION
Turbo Outlet Pressure Sensor.
FMI 03 - Voltage Above Normal.
FMI 04 - Voltage Below Normal.

CORRECTIVE ACTION
Troubleshoot turbo outlet pressure sensor using steps in SYMPTOM 12.

SYMPTOM
35. CID 274 FMI 02

MALFUNCTION
Atmospheric Pressure Sensor.
FMI 02 - Erratic, Intermittent, or Incorrect Signal.

CORRECTIVE ACTION
STEP 1. On EMCP, turn ENGINE CONTROL switch to OFF/RESET. Battery Disconnect
switch is OFF, DEAD CRANK SWITCH is OFF.
STEP 2. Perform Wiggle Test (WP0013, SYMPTOM 1) and verify continuity between
ENG-P2 and atmospheric pressure sensor connector ENG-P203 (per FO-2,
sheet 1) Repair or replace engine harness wiring (WP 0088), as necessary.
STEP 3. On EMCP, turn ENGINE CONTROL switch to COOL DOWN/STOP. Battery
Disconnect switch is ON, DEAD CRANK SWITCH is NORMAL.
STEP 4. Check for an active 02 diagnostic code. If the fault has not been resolved,
replace atmospheric pressure sensor (WP 0098).
STEP 5. If replacing sensor does not resolve fault, replace ECM (WP 0082).
STEP 6. Verify the problem has been resolved.

0009-29
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

SYMPTOM
36. CID 274 FMI 03
CID 274 FMI 04

MALFUNCTION
Atmospheric Pressure Sensor.
FMI 03 - Voltage Above Normal.
FMI 04 - Voltage Below Normal.

CORRECTIVE ACTION
Troubleshoot atmospheric pressure sensor using steps in SYMPTOM 12.

0009-30
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

SYMPTOM
37. CID 334 FMI 02
CID 334 FMI 03
CID 334 FMI 04

MALFUNCTION
Cool Down circuit (P7-36).
FMI 02 - Erratic, Intermittent, or Incorrect Signal.
FMI 03 - Voltage Above Normal.
FMI 04 - Voltage Below Normal.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON, Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. Measure voltage between cool down relay (CDR) pin 13 (+) and TB3-1 (-) per
FO-4, sheets 2 and 4.
a. If voltage is not approximately 24 Vdc (battery voltage), repair or replace
control box harness (WP 0044). Verify the problem has been resolved.
b. If harness is good, replace relay CDR (WP 0042). Verify the problem has
been resolved.
c. If harness repair does not resolve fault and CDR is good, check all GSC
fuses (FO-4, Sheets 3 and 5). If GSC fuses are ok,.continue to STEP 3.
STEP 3. Turn the ENGINE CONTROL switch to MANUAL START and allow engine to
accelerate to operating speed. After 3 minutes, turn ENGINE CONTROL switch
to COOL DOWN/STOP..
STEP 4. Measure voltage between cool down relay (CDR) pin 13 (+) and GSC P7-36 (-)
for less than 1.0 Vdc, per FO-4, sheets 1, 2, and 4.
STEP 5. If fault still exist, replace GSC (WP 0041). Verify the problem has been resolved.

0009-31
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
A fault code is generated if none of the GSC inputs from the ENGINE CONTROL switch are
connected to ground, or if more than one input is grounded.

SYMPTOM
38. CID 336 E FMI 02

MALFUNCTION
ENGINE CONTROL switch.
FMI 02 - Erratic, Intermittent, or Incorrect Signal.

CORRECTIVE ACTION
STEP 1. Turn the ENGINE CONTROL switch to OFF/RESET. Battery Disconnect switch
is OFF, DEAD CRANK SWITCH is OFF.
STEP 2. Inspect the harness between ENGINE CONTROL switch and the GSC per FO-4,
sheets 1, 4, and 5. Look for broken and shorted wires. Repair or replace control
box harness, as required (WP 0044 and WP 0088).
STEP 3. Verify continuity of ENGINE CONTROL switch in accordance with FO-1, sheet 2.
a. If ENGINE CONTROL switch is defective, replace ENGINE CONTROL
switch (WP 0041).
b. If ENGINE CONTROL switch is good, check all GSC fuses (FO-4, Sheets 3
and 5).
c. If GSC fuses are OK, replace GSC (WP 0041).
STEP 4. Verify the problem has been resolved.

0009-32
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
The camshaft (top) engine timing sensor functions as the backup timing sensor in the event the
crankshaft (bottom) engine timing sensor fails.

SYMPTOM
39. CID 342 E FMI 02
CID 342 E FMI 11

MALFUNCTION
Camshaft (Top) Engine Timing Sensor.
FMI 02 - Erratic, Intermittent, or Incorrect Signal.
FMI 11 - Failure mode is not identifiable (Mechanical Failure).

CORRECTIVE ACTION
STEP 1. Turn the ENGINE CONTROL switch to OFF/RESET. Battery Disconnect switch
is OFF, DEAD CRANK SWITCH is OFF.
STEP 2. Disconnect engine harness connector ENG-P402 from the camshaft (top) engine
timing sensor (WP 0088, Figure 2, sheet 1, and FO-2, sheet 1). The sensor
connector has a wire clip that must be removed in order to disconnect the
connector from the sensor.
a. Measure engine timing sensor resistance.
b. If resistance is not 600 to 1800 ohms, replace camshaft (top) engine timing
sensor (WP 0098).
c. If resistance is correct, inspect and adjust engine timing (WP 0013,
SYMPTOM 3.
d. If sensor damaged, replace and/or adjust sensor (WP 0098, WP 0013,
SYMPTOM 3).
STEP 3. Disconnect engine harness connector ENG-P2 from ECM J2 (WP 0088, Figure 2,
Sheet 3, and FO-2, Sheet 1). Connect ENG-P402 to the camshaft (top) engine
timing sensor (WP 0088, Figure 2, sheet 1, and FO-2, sheet 1)
STEP 4. Inspect engine harness and measure continuity between ENG-P2-58 and ENG-
P2-59 (WP 0088, Figure 2, sheet 3). Measurement should be approximately the
same as in STEP 2 b. If open or shorted, repair or replace engine harness
(WP 0088), as necessary.
STEP 5. Verify the problem has been resolved.

0009-33
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TROUBLESHOOTING USING GSC FAULT CODES - Continued

SYMPTOM
40. CID 360 E FMI 01
CID 360 E FMI 02
CID 360 E FMI 03

MALFUNCTION
Low Engine Oil Pressure Warning (Active & Logged).
FMI 01 - Data Is Valid But Data is Below Normal Operating Range.
FMI 02 - Erratic, Intermittent, or Incorrect Signal.
FMI 03 - Voltage Above Normal.
Event Code. Red LOW OIL PRESSURE indicator flashes when oil pressure drops below the
programmed low oil pressure setpoints. Engine shuts down and does not start until fault is corrected.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON, Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. Press ALARM CODES on GSC keypad.
STEP 3. Check oil level and perform service per TM 9-6115-730-10.
STEP 4. Verify the fault code has been cleared.
STEP 5. Verify all alarm and fault codes.
a. If CID 100 is active, troubleshoot engine oil pressure sensor per SYMPTOM
15 and SYMPTOM 16.
b. Troubleshoot other alarm and fault codes, as necessary.
STEP 6. Verify all programmable setpoints (WP 0083).
STEP 7. Verify the fault code has been cleared.

0009-34
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TROUBLESHOOTING USING GSC FAULT CODES - Continued

SYMPTOM
41. CID 361 E FMI 01
CID 361 E FMI 02
CID 361 E FMI 03

MALFUNCTION
High engine coolant temperature warning (Active & Logged).
FMI 01 - Data Is Valid But Data is Below Normal Operating Range.
FMI 02 - Erratic, Intermittent, or Incorrect Signal.
FMI 03 - Voltage Above Normal.
Event Code. Red HIGH WATER TEMP indicator on GSC flashes when coolant temperature rises
above programmed setpoints.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON, Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. Press ALARM CODES on GSC keypad.
STEP 3. Verify associated alarm and fault code and troubleshoot (WP 0008 and/or
WP 0009).
a. If CID 110 is active, troubleshoot per SYMPTOM 17.
b. Troubleshoot all other alarm and fault codes per WP 0008 and WP 0009.
STEP 4. Verify all programmable setpoints (WP 0083).
STEP 5 Open right side engine access door and check coolant level in coolant recovery
(overflow) bottle.
STEP 6. If required service coolant per TM 9-6115-730-10.
STEP 7. Inspect coolant system lines and radiator for leaks per PMCS (WP 0016).
STEP 8. Inspect fan and alternator and water pump belt per PMCS (WP 0016 and
WP 0075). Check water pump belt tension. Correct if necessary.
STEP 9. If required, replace water pump belt (WP 0075).
STEP 10. Verify the problem has been resolved.

0009-35
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TROUBLESHOOTING USING GSC FAULT CODES - Continued

SYMPTOM
42. CID 362 E FMI 01
CID 362 E FMI 03

MALFUNCTION
Overspeed Warning (Active and Logged).
FMI 01 - Data is Valid But Data is Below Normal Operating Range.
FMI 03 - Voltage Above Normal.
Red ENGINE OVERSPEED indicator flashes when engine speed rises above programmed setpoint
for engine overspeed.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON, Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. Press ALARM CODES on GSC keypad.
STEP 3. Check for associated alarm code and fault code and troubleshoot (WP 0008
and/or WP 0009).
a. If CID 190 is active, troubleshoot per SYMPTOM 24.
b. Troubleshoot all alarm and fault codes per WP 0008 and WP 0009.
c. Check programmable setpoint P010 (WP 0085, Table 4).
STEP 4. Correct faults and resume normal generator operations.

SYMPTOM
43. CID 368 E FMI 01

MALFUNCTION
High Inlet Air Temperature Warning (Active and Logged).
FMI 01 - Data is Valid But Data is Below Normal Operating Range.
Event Code. Intake manifold air temperature sensor detected temperature outside of normal
operating range. This input affects ignition timing.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON, Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. Press ALARM CODES on GSC keypad.
STEP 3. Check for associated alarm code and fault code and troubleshoot (WP 0008
and/or WP 0009).
a. If CID 172 is active, troubleshoot per SYMPTOM 22.
b. Troubleshoot all alarm and fault codes per WP 0008 and WP 0009.
STEP 4. Correct faults and resume normal generator operations.

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TROUBLESHOOTING USING GSC FAULT CODES - Continued

SYMPTOM
44. CID 390 E FMI 01

MALFUNCTION
Fuel Filter Restriction Warning (Active and Logged).
FMI 01 - Data is Valid But Data is Below Normal Operating Range.
Event Code. Indicates that sensor detects a fuel system restriction.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON, Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. Press ALARM CODES on GSC keypad.
STEP 3. Check for associated alarm code and fault code and troubleshoot (WP 0008
and/or WP 0009).
a. If CID 94 is active, troubleshoot per SYMPTOMS 11.
b. Troubleshoot all alarm and fault codes per WP 0008 and WP 0009.
STEP 4. If no fault code, inspect fuel filter and fuel water/separator per PMCS (WP 0016,
WP 0061 and WP 0080) and perform service as directed.

SYMPTOM
45. CID 391 E FMI 01

MALFUNCTION
Inlet Air Restriction Warning (Active and Logged).
FMI 01 - Data is Valid But Data is Below Normal Operating Range.
Event Code. Indicates that sensor detects inlet air restriction.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON, Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. Press ALARM CODES on GSC keypad.
STEP 3. Check for associated alarm code and fault code and troubleshoot (WP 0008
and/or WP 0009).
a. If CID 1589 is active, troubleshoot per SYMPTOMS 64 and 65.
b. Troubleshoot all alarm and fault codes per WP 0008 and WP 0009.
STEP 4. If no fault code, inspect air inlets (WP 0071 and WP 0072).
STEP 5. Remove debris or obstructions and perform service as directed.
STEP 6. Verify the problem has been resolved.

0009-37
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
When the GSC activates the EGR, K1 is displayed on the GSC lower display.

SYMPTOM
46. CID 441 FMI 12

MALFUNCTION
GSC Engine Governor Relay (EGR) Output.
FMI 12 - Failed Component.

CORRECTIVE ACTION
STEP 1. Turn the ENGINE CONTROL switch to OFF/RESET. Battery Disconnect switch
is OFF, DEAD CRANK SWITCH is OFF.
STEP 2. Verify that GSC relay module A1-13 is connected to ground A1-28 when the
PUSH TO STOP EMERGENCY STOP pushbutton (ESPB) is pulled out per
FO-4, sheet 5.
a. Repair or replace control box harness between ESPB and GSC (WP 0044)
and (WP 0088), as necessary.
b. If harness is good, replace ESPB (WP 0041).
STEP 3. Verify continuity of wiring between GSC pins A1-13 and A1-14 (RM-13 and
RM-14) and the ECM per FO-4, sheets 1 and 5, FO-1, sheet 2.
a. Repair or replace harness between GSC and ECM (WP 0088).
b. Verify harness is good. If so, check all GSC fuses (FO-4, Sheets 3 and 5). If
GSC fuses are OK, replace GSC (WP 0041). Verify the problem has been
resolved. If not, proceed to the next step.
c. Verify harness is good and GSC is good. If so, replace ECM (WP 0082).
STEP 4. Verify the problem has been resolved.

0009-38
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

SYMPTOM
47. CID 442 FMI 12

MALFUNCTION
GSC Generator Fault Relay (GFR) Output.
FMI 12 - Failed Component.

CORRECTIVE ACTION
STEP 1. Turn the ENGINE CONTROL switch to OFF/RESET. Battery Disconnect switch
is OFF, DEAD CRANK SWITCH is OFF.
STEP 2. Remove fuse A1F5 from rear of GSC.
STEP 3. Check fuse A1F5.

STEP 4 If fuse is good, reinstall fuse and disconnect RM 22.

STEP 5. Measure resistance between A1-7 and A1-22 on GSC relay module
(checking K2 relay).

a. If resistance is not less than 5 ohms, replace K2 relay.

b. If resistance is greater than 5 ohms measured in

STEP 5, check all GSC fuses (FO-4, Sheets 3 and 5).

c. If K2 relay and fuses are good, repair or replace

wiring harness (WP 0088), as necessary. Verify problem is
resolved.

STEP 7. Set Battery Disconnect Switch to ON, Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 8. Push in PUSH TO STOP EMERGENCY STOP pushbutton.

STEP 9. Reconnect wire(s) to GSC A1-22. If problem is not resolved, replace GSC
(WP 0041). Verify the problem has been resolved.

0009-39
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
An internal set of CTR contacts short between pins A1-1 and A1-2 on the GSC to maintain power
at pin A1-2 if ENGINE CONTROL switch were to be placed in COOL DOWN/STOP position with
the engine running. When active GSC CTR output will display K3 on GSC lower display.

SYMPTOM
48. CID 443 FMI 12

MALFUNCTION
GSC Crank Termination Relay (CTR) Output.
FMI 12 - Failed Component.

CORRECTIVE ACTION
STEP 1. Check fuse A1F10 on GSC. Replace if necessary.
STEP 2. Verify the problem has been resolved. If not, proceed to the next step.
STEP 3. Check all GSC fuses (FO-4, Sheets 3 and 5). If GSC fuses are ok, replace GSC
(WP 0041).
STEP 4. Verify the problem is resolved.

NOTE
When active GSC SMR output displays K4 GSC lower display.

SYMPTOM
49. CID 444 FMI 12

MALFUNCTION
GSC Starter Motor Relay (SMR) Output.
FMI 12 - Failed Component.

CORRECTIVE ACTION
STEP 1. Turn the ENGINE CONTROL switch to OFF/RESET. Battery Disconnect switch
is OFF, DEAD CRANK SWITCH is OFF.
STEP 2. Remove fuse A1F4 from rear of GSC.
STEP 3. Check fuse A1F4.
a. If fuse is bad, replace fuse A1F4. Verify the problem has been resolved.
b. If fuse is good, repair or replace wiring harness (WP 0088, Table 1 and Table
2, and WP 0044), as necessary.
c. If wiring is good, proceed to the next step.
STEP 4. Disconnect wire(s) from GSC relay module A1-18 (per FO-4, sheet 5).
STEP 5. On relay module, measure resistance between A1-6 and A1-18. Record
measured resistance.

0009-40
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 6. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn ENGINE CONTROL switch to MANUAL START.

NOTE
Measurement must be made before the total cycle crank time of 90 seconds (setpoint P017
WP 0083) is exceeded.
STEP 7. Quickly measure resistance between A1-6 and A1-18. If resistance not less than
5 ohms or if resistance not greater than 5,000 ohms, measured in STEP 5, check
all GSC fuses (FO-4, Sheets 3 and 5). If GSC fuses are ok, replace GSC
(WP 0041).
STEP 8. Turn the ENGINE CONTROL switch to OFF/RESET. Battery Disconnect Switch
is OFF; DEAD CRANK SWITCH is OFF.
STEP 9. Reinstall fuse A1F4 and reconnect wire(s) to GSC A1-18.
STEP 10. Verify the problem has been resolved.

0009-41
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
When active GSC RR output displays K5 on GSC lower display.

SYMPTOM
50. CID 445 FMI 12

MALFUNCTION
GSC Run Relay (RR) Output.
FMI 12 - Failed Component.

CORRECTIVE ACTION
STEP 1. Turn the ENGINE CONTROL switch to OFF/RESET. Battery Disconnect switch
is OFF, DEAD CRANK SWITCH is OFF.
STEP 2. Remove fuse A1F6 from rear of GSC.
STEP 3. Check fuse A1F6.
a. If fuse is bad, replace A1F6. Verify the problem has been resolved.
b. If fuse is not bad, repair or replace wiring harness (WP 0088 Table 1 and
Table 2 and WP 0044).
c. If wiring is good proceed to the next step.
STEP 4. Disconnect wire(s) from GSC relay module A1-24 per FO-4, sheet 5.
STEP 5. Measure the resistance between relay module A1-8 and A1-24. Resistance
should be greater than 5,000 ohms. Record resistance measurement.
STEP 6. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn ENGINE CONTROL switch to MANUAL START.
STEP 7. Measure the resistance between A1-8 and A1-24. If resistance not less than 5
ohms or the resistance was not greater than 5,000 ohms, measured in STEP 5,
check all GSC fuses (FO-4, Sheets 3 and 5). If GSC fuses are ok, replace GSC
(WP 0041).
STEP 8. Turn the ENGINE CONTROL switch to OFF/RESET. Battery Disconnect Switch
is OFF; DEAD CRANK SWITCH is OFF.
STEP 9. Reinstall fuse A1F6 and reconnect wire(s) to GSC A1-24.
STEP 10. Verify the problem has been resolved.

0009-42
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
When the GSC activates the FCR, K7 is displayed on GSC lower display. An internal set of FCR
contacts short between Relay Module pins A1-1 and A1-2 on the GSC to maintain power at A1-2
if the ECS is placed in COOL DOWN/STOP position with the engine running.

SYMPTOM
51. CID 447 FMI 12

MALFUNCTION
GSC Fuel Control Relay (FCR) Output.
FMI 12 - Failed Component.

CORRECTIVE ACTION
STEP 1. Check fuse A1F10 on GSC. Replace fuse if bad.
STEP 2. Verify the problem has been resolved. If not, proceed to the next step.
STEP 3. Check all GSC fuses (FO-4, Sheets 3 and 5). If GSC fuses are ok, replace GSC
(WP 0041).
STEP 4. Verify the problem has been resolved.

NOTE
The programmable spare relays (PSR1 and PSR2) are used for activating customer equipment.
PSR1 is normally closed while PSR2 is normally open.

SYMPTOM
52. CID 448 FMI 12

MALFUNCTION
GSC programmable spare relays (PSR1 and PSR2) output.
FMI 12 - Failed Component.

CORRECTIVE ACTION
STEP 1. Turn the ENGINE CONTROL switch to OFF/RESET. Battery Disconnect Switch
is OFF; DEAD CRANK SWITCH is OFF.
STEP 2. Remove fuse A1F8 and A1F9 from rear of GSC.
STEP 3. Check fuse A1F8 and A1F9.
a. If fuse is bad, replace A1F8 and/or A1F9. Verify the problem has been
resolved.
b. If fuse is not bad, repair or replace wiring harness (WP 0088 Table 1 and
Table 2 and WP 0044). Verify the problem has been resolved.
c. If wiring is good, proceed to the next step.
STEP 4. Disconnect wire(s) from GSC relay module (RM) A1-26 per FO-4, sheet 5.

0009-43
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TROUBLESHOOTING USING GSC FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 5. On the GSC relay module, measure resistance between RM-25 and RM-11.
Resistance should be greater than 5000 ohms. Measure resistance between
RM-26 and RM-10. Resistance should be less than 5 ohms.
STEP 6. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn ENGINE CONTROL switch to MANUAL START.
STEP 7. Measure resistance between RM-25 and RM-11. Resistance should be less than
5 ohms. Measure resistance between RM-26 and RM-10. Resistance should be
greater than 5000 ohms.
STEP 8. Turn the ENGINE CONTROL switch to OFF/RESET. Battery Disconnect Switch
is OFF; DEAD CRANK SWITCH is OFF.
STEP 9. If any of the measurements fail, replace the GSC (WP 0041).
STEP 10. Reinstall fuse A1F8 and A1F9 and reconnect wire(s) to GSC A1-26.
STEP 11. Verify the problem has been resolved.

0009-44
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
The following fault code means the GSC is unable to measure the AC voltage and AC current.
The engine remains able to start and run. This diagnostic code will be shown even when ENGINE
CONTROL switch is set to OFF/RESET.

SYMPTOM
53. CID 500 FMI 12

MALFUNCTION
GSC.
FMI 12 - Failed Component.

CORRECTIVE ACTION
STEP 1. Check fuses A5F1, A5F2, and A5F3. Replace if bad.
STEP 2. Verify the problem has been resolved.
STEP 3. Verify the wiring on the A5 module (WP 0088).
STEP 4. Verify the problem has been resolved.
STEP 5. Verify connector A5-P1 is not loose or damaged (WP 0088).
STEP 6. Verify the problem has been resolved.
STEP 7. Verify setpoints (WP 0083, Table 8).
STEP 8. Verify the problem has been resolved.
STEP 9. Check all GSC fuses (FO-4, Sheets 3 and 5). If GSC fuses are ok, replace GSC
(WP 0041).
STEP 10. Verify the problem has been resolved.

0009-45
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
This fault code means the GSC did not control the engine shutdown. The GSC detected that
engine speed dropped from rated speed to 0 RPM when the GSC has not called for a shutdown.
The GSC has determined that there is no engine speed sensor fault that would explain the engine
shutdown. The engine is disabled from running or starting.

SYMPTOM
54. CID 545 FMI 05
CID 545 FMI 06

MALFUNCTION
Ether Control Relay.
FMI 05 - Current is Below Normal or Circuit is Open.
FMI 06 - Current is Above Normal or Circuit is Grounded.
STEP 1. Turn the ENGINE CONTROL switch to OFF/RESET. Battery Disconnect switch
is OFF, DEAD CRANK SWITCH is OFF.
STEP 2. Inspect/repair engine harness wiring between ether injection assembly connector
ENG-P101 and ECM connector J2 per FO-2, sheet 1, as necessary.
STEP 3. If wiring repair does not resolve fault, replace ether injector assembly (WP 0073).
STEP 4. If replacing ether injector assembly does not resolve fault, replace ECM
(WP 0082).
STEP 5. Verify the problem has been resolved.

SYMPTOM
55. CID 566 FMI 07

MALFUNCTION
Unexpected Shutdown.
FMI 07 - Improper Mechanical Response.

CORRECTIVE ACTION
STEP 1. Turn the ENGINE CONTROL switch to OFF/RESET. Battery Disconnect switch
is OFF, DEAD CRANK SWITCH is OFF.
STEP 2. Check fuel level and quality.
a. If fuel tank is empty, fill tank per TM 9-6115-730-10.
b. If fuel quality is suspect, drain and replace fuel.

0009-46
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 3. Inspect fuel filter. If fuel filter is clogged, replace fuel filter (WP 0080).
STEP 4. Inspect air filter. If air filter is clogged, replace air filter (WP 0071).
STEP 5. Check fuses A1F2 and A1F10 (per FO-4, sheet 5). If fuse is bad, replace fuse.
STEP 6. Refer to engine troubleshooting if there is an obvious engine problem.
Troubleshooting without Fault Codes (WP 0011).
STEP 7. Verify the problem has been resolved.

NOTE
This fault code means the ECM has stopped responding to the periodic requests for information
from the GSC.

SYMPTOM
56. CID 590 FMI 09

MALFUNCTION
Engine Electronic Control Module.
FMI 09 - Abnormal Update.

CORRECTIVE ACTION
STEP 1. Turn the ENGINE CONTROL switch to OFF/RESET. Battery Disconnect switch
is OFF, DEAD CRANK SWITCH is OFF.
STEP 2. Verify continuity between GSC P7-19 and ECM ENG-P1-8 and between GSC
P7-20 and ECM ENG-P1-9 per FO-4, sheet 1 and FO-2, sheet 2.
a. Repair or replace harness, as required (WP 0088).
b. If harness is good, check all GSC fuses (FO-4, Sheets 3 and 5).
c. If GSC fuses are OK, replace GSC (WP 0041).
d. If replacing GSC does not correct fault, replace ECM (WP 0082).
STEP 3. Verify the problem has been resolved.

0009-47
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
This fault code means the GSC detected a short to B+ or B- on one of the lines (P7-21 and
P7-22) of the CCM data link. The CCM output is not used.

SYMPTOM
57. CID 770 FMI 09

MALFUNCTION
Customer Communication Module (CCM) Data Link.
FMI 09 - Abnormal Update.

CORRECTIVE ACTION
STEP 1. Troubleshoot data link per WP 0013, SYMPTOM 7.
STEP 2. If the problem is not resolved, replace ECM (WP 0082).
STEP 3. Verify the problem has been resolved.

0009-48
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
If the Close Breaker output (P7-37) voltage is detected to be above or below normal, this fault
code will appear. This fault occurs only in AUTO PARALLEL mode.

SYMPTOM
58. CID 858 FMI 02
CID 858 FMI 03
CID 858 FMI 04

MALFUNCTION
Close Breaker Output.
FMI 02 - Erratic, Intermittent, or Incorrect Signal.
FMI 03 - Voltage Above Normal.
FMI 04 - Voltage Below Normal.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON, Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. In control box, locate wire between SYNC MODE switch (SMS) pin 11 and P7-37
per FO-4 sheet 1 and FO-1 sheet 3.
STEP 3. Disconnect wire from SMS pin 11 and measure voltage at end of wire.
a. If voltage is not 5.2 ±1.0 Vdc, repair or replace control box harness (WP 0044
and WP 0088), as necessary. Verify the problem has been resolved.
b. If the problem has not been resolved, check all GSC fuses (FO-4,
Sheets 3 and 5).
c. If GSC fuses are ok, replace GSC (WP 0041).
STEP 4. Verify the problem has been resolved.

0009-49
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
This output varies from +5 Vdc to -5 Vdc and is sent to Load Sharing Module A4 to generate the
signal sent to the engine controller to set and control the speed of the engine. If the
synchronization is disabled, the output will be approximately 0 Vdc.

NOTE
Set two generators in parallel mode per TM 9-6115-730-10. Generator set A will be the test unit
(with the fault) and generator set B will be the load unit.

SYMPTOM
59. CID 1038 FMI 02
CID 1038 FMI 03
CID 1038 FMI 04

MALFUNCTION
Speed Adjust 1 Output (P7-27 (+) and P7-28 (-).
FMI 02 - Erratic, Intermittent, or Incorrect Signal.
FMI 03 - Voltage Above Normal.
FMI 04 - Voltage Below Normal.

CORRECTIVE ACTION
STEP 1. Turn the ENGINE CONTROL switch to OFF/RESET. Set Battery Disconnect
Switch to OFF. Set DEAD CRANK SWITCH to OFF on generator set A. Set
SYNC MODE switch to OFF.
STEP 2. Disconnect wire from LSM A4-24 per FO-4, sheet 2, on generator set A.
STEP 3. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP, on generator set A.
STEP 4. Measure the voltage on the end of the wire (A4-24+) with respect to A4-25.
a. If voltage not 0 ± 1 Vdc, repair or replace harness (WP 0044 and WP 0088),
as necessary.
b. If harness is good continue to the next step.
STEP 5. On both generator sets, set Battery Disconnect Switch to ON. Set DEAD CRANK
SWITCH to NORMAL. Turn the ENGINE CONTROL switch to MANUAL START.
Set SYNCH switch to SEMI-AUTOMATIC. Close load contactor on generator set
B.
STEP 6. Adjust the engine speed so the frequency, on generator set A is 1 Hz higher than
what is on the load bus (generator set B).
STEP 7. Allow the voltage to stabilize.

0009-50
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TROUBLESHOOTING USING GSC FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 8. Measure the voltage on the end of the wire (A4-24+) with respect to A4-25.
a. If voltage not -4 Vdc to -6 Vdc, repair or replace harness (WP 0044 and WP
0088), as necessary.
b. If harness is good continue to the next step.
STEP 9. Adjust the engine speed so the frequency is 1 Hz lower than what is on the load
bus.
STEP 10. Allow voltage to stabilize.
STEP 11. Measure voltage on the end of the wire (A4-24+) with respect to A4-25.
a. If voltage is not 4 Vdc to 6 Vdc, repair or replace harness (WP 0044).
b. If voltages are good, replace LSM A4 (WP 0042).
c. If harness is good and voltages are bad, check all GSC fuses (FO-4,
Sheets 3 and 5).
d. If GSC fuses are ok, replace GSC (WP 0041).
STEP 12. Verify the problem has been resolved.

0009-51
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
This failure is displayed when Main Contactor K1 is closed (input is grounded) and one or both of
the following are true:

The difference in frequency between the generator and the bus is greater than 0.2 Hz.
The difference in phase between the generator and the bus is greater than 10 degrees.

When the above conditions are true for more than two seconds, the fault will occur. The GSC will
then stop the synchronization process until the fault is cleared and corrected.

SYMPTOM
60. CID 1167 FMI 04

MALFUNCTION
K1 Sense Input (P7-25).
FMI 04 - Voltage Below Normal.

CORRECTIVE ACTION
STEP 1. Turn the ENGINE CONTROL switch to OFF/RESET. Battery Disconnect switch
is OFF, DEAD CRANK SWITCH is OFF.
STEP 2. Disconnect wire at TB3-12 leading to P7-25 per FO-4, sheet 4.
STEP 3. Set Battery Disconnect Switch to ON, Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 4. Measure voltage on end of wire (TB3-12 +) with respect to TB3-1 (-). Record
measured voltage
STEP 5. Check A6 BTB fuses (FO-1, Sheet 5). Replace if necessary. Verify wiring for A6
BTB (FO-1, Sheet 5). Repair if necessary (WP 0088).
STEP 6. Turn the ENGINE CONTROL switch to MANUAL START.
STEP 7. Adjust engine speed so the generator frequency is more than 0.2 Hz different
(high or low) than what is on the load bus.
STEP 8. Perform the Permissive Paralleling Procedure. TM 9-6115-730-10.
STEP 9. Ensure the Synchroscope is present on the GSC display.
STEP 10. Touch the loose end of the disconnected wire to TB3-1 (Ground).
a. If fault CID 1167 FMI 04 is displayed on the GSC, repair or replace harness
(WP 0044 and WP 0088).
b. If fault is not displayed or if voltage measured in STEP 4 was not 9.5 to 11.5
Vdc, check all GSC fuses (FO-4, Sheets 3 and 5).
c. If GSC fuses are ok, replace GSC (WP 0041).
STEP 11. Verify the problem has been resolved.

0009-52
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TROUBLESHOOTING USING GSC FAULT CODES - Continued

NOTE
This input is high when the bus is live. Input status is compared to reading of bus voltage at
P7-17 and P7-18. If the status of the voltage measurements is different than the dead bus
sense input with regards to presence or absence of bus voltage a fault is announced.

SYMPTOM
61. CID 1168 FMI 03

MALFUNCTION
Dead Bus Sense Input (P7-29).
FMI 03 - Voltage Above Normal.

CORRECTIVE ACTION
STEP 1. On EMCP, set the ENGINE CONTROL switch to OFF/RESET. Battery
Disconnect switch is OFF, DEAD CRANK SWITCH is OFF.
STEP 2. Disconnect wire from relay DBHI pin 2 per FO-4, sheet 2.
STEP 3. Set Battery Disconnect Switch to ON, Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 4. Measure the voltage on end of the wire (DBHI-2 +) with respect to relay DBLO
pin 4 (-).
a. If voltage is not 9.5 to 11.5 Vdc, repair or replace wiring between GSC and
DBHI (WP 0044 and WP 0088).
b. If wiring is good, check all GSC fuses (FO-4, Sheets 3 and 5).
c. If GSC fuses are ok, replace GSC (WP 0041).
STEP 5. On EMCP, set the ENGINE CONTROL switch to OFF/RESET. Battery
Disconnect switch is OFF, DEAD CRANK SWITCH is OFF.
STEP 6. Reconnect wire to relay DBHI-2.
STEP 7. Ensure that load bus is dead.
STEP 8. Disconnect the wire from relay DBHI-10.
STEP 9. Set Battery Disconnect Switch to ON, Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 10. Measure the voltage on relay DBHI-10 (+) with respect to relay DBLO-4 (-).
a. If voltage is not 9.5 to 11.5 Vdc, replace relay DBHI (WP 0042).
b. If DBHI is good, repair or replace harness, as required (WP 0044 and
WP 0088).
c. If harness is good, replace relay DBLO (WP 0042).
STEP 11. Verify the problem has been resolved.

0009-53
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

SYMPTOM
62. CID 1169 FMI 02

MALFUNCTION
AC Transformer Box (ATB) Sensor.
FMI 02 - Erratic, Intermittent, or Incorrect Signal.

CORRECTIVE ACTION
STEP 1. Turn the ENGINE CONTROL switch to OFF/RESET. Battery Disconnect Switch
is OFF; DEAD CRANK SWITCH is OFF.
STEP 2. Set Battery Disconnect Switch to ON, Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to MANUAL START.
STEP 3. Using the GSC, observe the values of voltages by phase and record.
a. Turn the ENGINE CONTROL switch to OFF/RESET. Battery Disconnect
Switch is OFF; DEAD CRANK SWITCH is OFF.
b. Check fuses A5F1 thru A5F3 on ATB A5 and replace, as required
(WP 0042). Verify the problem is resolved. If fuses are good, continue to the
next step.
c. If voltages were not within 5% of the desired values and within 5% of each
other, repair or replace generator harness between GSC and ATB A5 per
FO-4, sheet 3 (WP 0088). Verify the problem is resolved. If not proceed to
the next step
d. If voltages were not within 5% of the desired values and within 5% of each
other, repair or replace generator harness between generator output and
ATB A5 per FO-4, sheet 3 and FO-3, sheet 2 (WP 0088). Verify the problem
is resolved. If not proceed to the next step.
e. If ATB A5 is good, continue to next step.
STEP 4. Set Battery Disconnect Switch to ON, Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to MANUAL START.
STEP 5. Read Line to N voltages for all three phases on GSC and record
STEP 6. Measure the voltages at TB1 between terminal 10 and terminals 1, 2 & 3, and
record.
STEP 7. Measure the voltages between TB1, terminal 10 and A5F1, A5F2, and A5F3.
Record voltages.
STEP 8. If voltages do not match, troubleshoot wiring harness (WP 0088) between TB1
and A5. Repair or replace wiring harness as necessary.

0009-54
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 9. Compare voltages between GSC control panel reading and A5. If they match,
troubleshoot wiring harness between TB1 and GSC for loose connection,
corrosions, and broken wires. Repair and replace, as necessary (WP 0088).
STEP 10. If GSC voltage and A5 voltage do not match, check continuity of wires between
A5P1 and GSCP7 (FO-1, sheet 5).
STEP 11. If continuity is present, replace A5 module (WP 0042).
STEP 12. Verify that problem is resolved. If problem still exists, check all GSC fuses
(FO-4, Sheets 3 and 5). If GSC fuses are ok, replace GSC (WP 0041).
STEP 13. Verify the problem is resolved.

NOTE
The Bus Transformer Box isolates and reduces the Load Bus voltages for use by the GSC. The
GSC uses the reduced value of L1 (Phase A) to determine the voltage level on the load bus. The
GSC uses the reduced value of L3 (Phase C) to measure the frequency of the voltage on the load
bus.

SYMPTOM
63. CID 1170 FMI 02
CID 1170 FMI 04
CID 1170 FMI 08

MALFUNCTION
Bus Transformer Box (BTB) Sensor.
FMI 02 - Erratic, Intermittent, or Incorrect Signal.
FMI 04 - Voltage Above Normal.
FMI 08 - Voltage Below Normal.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect switch to OFF.
STEP 2. Check BTB A6 fuses A6F1 and A6F2 per FO-4, sheet 3. Replace BTB A6 fuses,
as required (WP 0041).
STEP 3. Remove BTB A6 fuses A6F1 and A6F2. Measure resistance between wires B11
and B12 connected to A6 fuse block. Resistance should be 2140 + / - 400 ohms.
Record resistance measurement.
STEP 4. If A6 is replaced, verify that problem is resolved.
STEP 5. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to MANUAL START. Set the GSC to
display L to L voltage. Adjust voltage to 208 voltage.
STEP 6. Measure and record voltage between A6B21 and A6F1 and between A6B21 and
A6F2.

0009-55
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 7. Measure voltage at Load output terminal board, TB2, between terminals L0 (N)
and L1 and between L0 (N) and L3. Record voltages.
STEP 8. If voltage is not same as generator output, repair or replace harness between
BTB A6 and generator output per FO-4 sheet 3 and FO-3 sheet 2 (WP 0088).
STEP 9. Measure voltage between A6J1-A and A6J1-B per FO-4 sheet 5. Value should
be the same as the value in step 4 divided by 15: (208 Vac = 14 Vac) (416 Vac =
28 Vac).
a. If voltage is zero, or resistance measured in STEP 2 was incorrect, replace
A6 (WP 0042)
b. If voltage is correct, check continuity between A6P1-A and P7-17 and
between A6P1-B to P7-18 (WP 0042).
c. If continuity is not present, repair or replace wiring harness as necessary
(WP 0088). Verify that problem has been resolved.
d. If problem is not resolved, check all GSC fuses (FO-4, Sheets 3 and 5).
e. If GSC fuses are ok, replace GSC (WP 0041).
STEP 10. Verify the problem is resolved.

SYMPTOM
64. CID 1589 E FMI 02

MALFUNCTION
Turbo Air Inlet Pressure Sensor.
FMI 02 - Erratic, Intermittent, or Incorrect Signal.

CORRECTIVE ACTION
STEP 1. On EMCP, turn ENGINE CONTROL switch to OFF/RESET. Battery Disconnect
switch is OFF, DEAD CRANK SWITCH is OFF.
STEP 2. Inspect wiring and verify continuity between engine harness ENG-P2 and turbo
air inlet pressure sensor connector ENG-P15 per FO-2, sheet 1. Repair or
replace engine harness wiring (WP 0088).
STEP 3. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 4. Check for an active 02 diagnostic code. If the fault has not been resolved,
replace turbo air inlet pressure sensor (WP 0098).
STEP 5. If replacing sensor does not resolve fault, replace ECM (WP 0082).
STEP 6. Verify the problem has been resolved.

0009-56
 TM 9-6115-730-24 0009

TROUBLESHOOTING USING GSC FAULT CODES - Continued

SYMPTOM
65. CID 1589 E FMI 03
CID 1589 E FMI 04

MALFUNCTION
Turbo air inlet pressure sensor.
FMI 03 - Voltage Above Normal.
FMI 04 - Voltage Below Normal.

CORRECTIVE ACTION
Troubleshoot turbo air inlet pressure sensor using steps in SYMPTOM 12.

END OF WORK PACKAGE

0009-57/58 blank
 TM 9-6115-730-24 0010

FIELD LEVEL TROUBLESHOOTING

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
DVR FAULT CODE TROUBLESHOOTING PROCEDURES

INITIAL SETUP:

Personnel Required References

One WP 0083
TM 9-6115-730-10
FO-1
FO-3
FO-4

TROUBLESHOOTING USING DVR FAULT CODES

WARNING
Metal jewelry can conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

High voltage is produced when this generator set is in operation. Make sure unit is completely
shut down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

Ensure that the engine cannot be started while maintenance is being performed. (ENGINE
CONTROL switch set to OFF/RESET. Battery Disconnect Switch is OFF; DEAD CRANK
SWITCH is OFF.)

0010-1
 TM 9-6115-730-24 0010

TROUBLESHOOTING USING DVR FAULT CODES - Continued

SYMPTOM
1. Code 0000 No Fault Present

MALFUNCTION
None

CORRECTIVE ACTION
None

SYMPTOM
2. Code 601

MALFUNCTION
Internal Memory Failure

CORRECTIVE ACTION
STEP 1. Set the ENGINE CONTROL switch to OFF/RESET to reset the fault (WP 0006).
STEP 2. Set Battery Disconnect switch to ON. Set DEAD CRANK SWITCH to ON. Set
the ENGINE CONTROL Switch to COOL DOWN/STOP.
STEP 3. Check all parameters between :01 and :38 (WP 0083). Verify the problem has
been resolved.
a. If fault reoccurs periodically, may be indication of failing battery. Check for
related failures and correct. Check for battery error codes on GSC. Codes
displaying FMI 04 indicate low voltage. Check batteries (WP 0050).
b. If the problem has not been resolved, check for additional DVR fault codes.
Correct any faults. Verify the problem has been resolved.
c. If the problem has not been resolved, memory is failing in Digital Voltage
Regulator (DVR). Replace DVR (WP 0042).
STEP 4. Verify the problem is resolved.

0010-2
 TM 9-6115-730-24 0010

TROUBLESHOOTING USING DVR FAULT CODES - Continued

NOTE
The watchdog is a circuit that monitors the computer to be sure it can not go off line. This failure
indicates that the computer went off line and was reset by the watchdog circuit. This failure can
occur during engine cranking if battery voltage dips too low.

SYMPTOM
3. Code 602

MALFUNCTION
Internal Watchdog Failure

CORRECTIVE ACTION
STEP 1. Measure voltage at B+ and B- terminals on front of DVR while starting generator
set.
a. If voltage is less than 18 Vdc, go to STEP 2.
b. If voltage is greater than 18 Vdc, proceed to STEP 8.
STEP 2. Inspect battery connections for corrosion or loose connections per FO-4, sheet 3.
Clean and tighten connections.
STEP 3. Inspect battery connections on TB3, terminals 1-10 and TB4, terminals 17-20 for
corrosion or loose connections. Clean and tighten connections.
STEP 4. Inspect battery connections B+ and B- on rear of Generator Set Control (GSC)
for corrosion or loose connections. Clean and tighten connections.
STEP 5. Inspect battery connections B+ and B- on front of DVR for corrosion and loose
connections. Clean and tighten connections.
STEP 6. Measure voltage drop across resistor assembly A7 CB1 per FO-4, sheet 4. If
voltage drop is not less than 0.1 Vdc, replace CB1 (WP 0042).
STEP 7. Troubleshoot charging system per alternator does not charge batteries system
troubleshooting procedure (WP 0011, SYMPTOM 23).
STEP 8. If the problem is not resolved, replace DVR (WP 0042).
STEP 9. Verify the problem is resolved.

0010-3
 TM 9-6115-730-24 0010

TROUBLESHOOTING USING DVR FAULT CODES - Continued

NOTE
The variation (ripple) of exciter field current exceeds the diode monitor trip point (parameter: 19)
for a period of five seconds.

SYMPTOM
4. Code 603

MALFUNCTION
Rotating Diode Defective.

CORRECTIVE ACTION
STEP 1. Check DVR parameter 19 in accordance with WP 0083.
STEP 2. Disconnect wire from DVR A3F1 and check continuity between A3F1 and TB5-2.
If continuity does not exist, repair or replace wiring harness as necessary
(WP 0088).
STEP 3. Verify that G1F1 is connected to TB5 terminal 2 and G1F2 is connected to TB5
terminal 1.
STEP 4. Disconnect wire from DVR A3 terminal F2. Check continuity between A3F2 and
TB1-5 terminal 1. If continuity does not exist, repair or replace wiring harness as
necessary (WP 0088).
STEP 5. If continuity exists, replace rotating diodes (WP 0094).
STEP 6. If replacing rotating diodes does not resolve the problem, repair main generator
(G1) (WP 0094).
STEP 7. If the problem is not resolved, replace the generator (WP 0095).

0010-4
 TM 9-6115-730-24 0010

TROUBLESHOOTING USING DVR FAULT CODES - Continued

WARNING
Dangerously high voltage can exist across current transformer (CT) output with engine running.
CT could explode if disconnected from load with engine running. Do not disconnect CT with
generator rotating. Failure to comply can cause serious injury or death to personnel.

NOTE
The DVR detected a 0.4 per unit or greater leading reactive power for a time greater than the
value entered in reverse VAR trip time (parameter :20). This fault shuts down the DVR and
removes excitation from the field. This function is only active if parameter :21 is set to 2. This
function is inactive if parameter :22 is set to 1.

SYMPTOM
5. Code 604

MALFUNCTION
Reverse VAR (Alarm Fault)

CORRECTIVE ACTION
STEP 1. Two connections reversed could cause this fault. Verify current transformer
CCCT and voltage inputs from PT2, PT3, and DVR terminals 20, 22, and 24 are
connected per FO-3 and FO-4.
STEP 2. Retrieve and verify all DVR parameters (WP 0083). Record :04 (generator rated
current) and :05 (current transformer output at rated output current) values.
STEP 3. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to ON. Turn
ENGINE CONTROL switch to MANUAL START.
STEP 4. Connect load at 25% to 50% of rated load. Use 0.8 power factor inductive load, if
possible.
STEP 5. On GSC measure current in phase B. Record value.
STEP 6. Measure AC voltage between terminals A3-5 and A3-6 of DVR per FO-4,
sheet 3. Record value.
a. The voltage measured, divided by the value in parameter :05 should be
roughly equal to the measured current divided by parameter :04.
b. If not approximately the same, replace DVR (WP 0042).
STEP 7. Fault code could have been caused by a fault of the load.
a. If problem recurs and fault can not be traced to load, replace DVR
(WP 0042).
b. If the problem is not resolved, refer to generator repair (WP 0094) or
generator replacement (WP 0095).
STEP 8. Verify the problem is resolved.

0010-5
 TM 9-6115-730-24 0010

TROUBLESHOOTING USING DVR FAULT CODES - Continued

NOTE
The DVR detected that the generator voltage has been less than the undervoltage trip point
(parameter :13) for more than the amount of time specified by the undervoltage trip time
(parameter :14). This alarm is disabled during the start-up profile.

SYMPTOM
6. Code 701

MALFUNCTION
Undervoltage.

CORRECTIVE ACTION
STEP 1. Adjust VOLTAGE Adjust Potentiometer on control panel clockwise to increase
voltage.
STEP 2. If paralleled to other generator sets, check VOLTAGE adjust setting on each set.
STEP 3. Start generator set and verify that problem has been resolved.
STEP 4. If problem is not resolved, perform Voltage Adjust Potentiometer test (WP 0041).
STEP 5. Measure battery voltage at B+ and B- terminals on DVR per FO-4, sheet 3.
Voltage should be 18 to 32 Vdc.
STEP 6. Verify that correct DVR parameters are entered (WP 0083) and that parameters
match the reconnection board position (WP 0014). Enter proper parameters
(WP 0083). Verify parameters after entry.
STEP 7. With generator set running, measure AC voltage between pins A3-26 and A3-28,
A3-28 and A3-30, and A3-26 and A3-30 per FO-4, sheet 3.
STEP 8. If voltages are not between 95 to 120 Vac at all three locations, shut down
generator set.
STEP 9. Check fuses F1-10A, F2-10A, F3-10A and replace defective fuses.
a. Open fuse holder F1, F2, and F3.
b. Check resistance, F1-1 to F2-1, F2-1 to F3-1, and F3-1 to F1-1. Resistance
should be less than 1 ohm. If open or above 1 ohm, troubleshoot wires
between F12, F2, and F3 to TB1 and alternator.
c. Check resistance, F1-2 to F2-2, F2-2 to F3-2, and F3-2 to F1-1. Resistance
should be between 0.2 to 0.4 ohms. If open or above 0.4 ohms, troubleshoot
wires between F12, F2, and F3 and transformer PT2 and PT3, and
transformer primary winding, PT2, PT3 before removing wires from A3-26,
A3-28, and A3-30.
STEP 10. Check resistance, A3-26 to a3-28; A3-28 to A3-30, and A3-30 to A3-26.
Resistance should be between 0.2 and 2.0 ohms. If open or above 2 ohms,
troubleshoot secondary winding of PT2 and PT3 and wires between A3-26, A3-
28 and A3-30 to PT2 and PT3.
STEP 11. Measure AC voltage between pins A3-20 and A3-22, A3-22 and A3-24, and
A3-20 and A3-24.

0010-6
 TM 9-6115-730-24 0010

TROUBLESHOOTING USING DVR FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 12. Voltages should be the same and at the proper ratio to the output voltage in
accordance with parameter :02.
STEP 13. If the problem is not resolved, replace DVR (WP 0042).
STEP 14. Verify the problem is resolved.
STEP 15. If the problem is not resolved, repair or replace generator (WP 0094 or
WP 0095).

0010-7
 TM 9-6115-730-24 0010

TROUBLESHOOTING USING DVR FAULT CODES - Continued

NOTE
The DVR detected that the generator voltage has been more than the overvoltage trip point
(parameter :11) for more than the amount of time specified by the overvoltage trip time
(parameter :12).

SYMPTOM
7. Code 702

MALFUNCTION
Overvoltage.

CORRECTIVE ACTION
STEP 1. Adjust VOLTAGE adjust potentiometer on control panel counterclockwise to
reduce voltage.
STEP 2. If paralleled to other generator sets, check voltage setting on other sets.
STEP 3. Start generator set and verify that problem has been resolved.
STEP 4. If problem not resolved, perform VOLTAGE Adjust Potentiometer test (WP 0041).
STEP 5. Verify that correct parameters are entered in DVR and that parameters match the
reconnection board position (WP 0083).
STEP 6. Enter proper parameters (WP 0083). Verify parameters after entry.
STEP 7. With generator set running, measure AC voltage between pins A3-26 and A3-28,
A3-28 and A3-30, and A3-26 and A3-30 per FO-4, sheet 3.
STEP 8. If voltages not 95 to 120 Vac at all three locations, shut down generator set.
STEP 9. Check fuses F1-10A, F2-10A, F3-10A and replace defective fuses.
a. Open fuse holder F1, F2, and F3.
b. Check resistance, F1-1 to F2-1, F2-1 to F3-1, and F3-1 to F1-1. Resistance
should be less than 1 ohm. If open or above 1 ohm, troubleshoot wires
between F12, F2, and F3 to TB1 and alternator.
c. Check resistance, F1-2 to F2-2, F2-2 to F3-2, and F3-2 to F1-1. Resistance
should be between 0.2 to 0.4 ohms. If open or above 0.4 ohms, troubleshoot
wires between F12, F2, and F3 and transformer PT2 and PT3, and
transformer primary winding, PT2, PT3 before removing wires from A3-26,
A3-28, and A3-30.
STEP 10. Check resistance, A3-26 to a3-28; A3-28 to A3-30, and A3-30 to A3-26. Resis-
tance should be between 0.2 and 2.0 ohms. If open or above 2 ohms, trouble-
shoot secondary winding of PT2 and PT3 and wires between A3-26, A3-28 and
A3-30 to PT2 and PT3.
STEP 11. Measure AC voltage between pins A3-20 and A3-22, A3-22 and A3-24, and
A3-20 and A3-24.
STEP 12. Voltages should be the same and at the proper ratio to the output voltage in
accordance with parameter :02.
STEP 13. If the problem is not resolved, replace DVR (WP 0042).
STEP 14. If the problem is not resolved, repair or replace generator (WP 0094 or
WP 0095).

0010-8
 TM 9-6115-730-24 0010

TROUBLESHOOTING USING DVR FAULT CODES - Continued

SYMPTOM
8. Code 703

MALFUNCTION
Overexcitation

CORRECTIVE ACTION
STEP 1. If operating in parallel, re-parallel the generator sets in accordance with
TM 9-6115-730-10.
STEP 2. Start generator set and verify that problem has been resolved with no load.
STEP 3. If the problem does not exist with no load, verify that generator set is not
overloaded. Reduce load below rated generator set load.
STEP 4. Inspect wiring between TB1 and terminals A3-20, A3-22, and A3-24 of DVR per
FO-3 and FO-4.
STEP 5. Repair or replace wiring (WP 0088).
STEP 6. Check DVR A3 parameters (WP 0083).
STEP 7. If the problem exists with no load, replace DVR (WP 0042).
STEP 8. Repair or replace as required (WP 0094 or WP 0095).
STEP 9. Verify the problem is resolved.

0010-9
 TM 9-6115-730-24 0010

TROUBLESHOOTING USING DVR FAULT CODES - Continued

WARNING
Dangerously high voltage can exist across current transformer (CT) output with engine running.
CT could explode if disconnected from load with engine running. Do not disconnect CT with
generator rotating. Failure to comply can cause serious injury or death to personnel.

NOTE
The DVR detected a 0.4 per unit or greater leading reactive power for a time greater than the
value entered in reverse VAR trip time (parameter :20). This fault shuts down the DVR and
removes excitation from the field. This function is only active if parameter :21 is set to 2. This
function is inactive if parameter :22 is set to 1.

SYMPTOM
9. Code 704

MALFUNCTION
Reverse VAR (Shutdown Fault)

CORRECTIVE ACTION
STEP 1. Verify current transformer CCCT and voltage inputs from PT2, PT3, and DVR
terminals 20, 22, and 24 are connected per FO-3 and FO-4.
STEP 2. Two connections reversed could cause this fault. Connect per schematic and
wiring diagram FO-4.
STEP 3. Retrieve and verify all DVR parameters (WP 0083). Record :04 (generator rated
current) and :05 (current transformer output at rated output current) values.
STEP 4. On EMCP set ENGINE CONTROL switch to MANUAL START.
STEP 5. Connect load at 25% to 50% of rated load. Use 0.8 power factor inductive load, if
possible.
STEP 6. On GSC measure current in phase B. Record value.
STEP 7. Measure AC voltage between terminals A3-5 and A3-6 of DVR per FO-4,
sheet 3. Record value.
a. The voltage measured, divided by the value in parameter :05 should be
roughly equal to the measured current divided by parameter :04.
b. If not approximately the same, proceed to next step.
STEP 8. Fault code could have been caused by a fault of the load.
a. If problem recurs and fault can not be traced to load, replace DVR
(WP 0042).
b. If the problem is not resolved, refer to generator repair (WP 0094) or
replacement (WP 0095).
STEP 9. Verify the problem is resolved.

0010-10
 TM 9-6115-730-24 0010

TROUBLESHOOTING USING DVR FAULT CODES - Continued

NOTE
The DVR detected that the exciter field current was greater than approximately 28 Amps. The
DVR shut off the exciter field current.

SYMPTOM
10. Code 801

MALFUNCTION
Instantaneous Trip

CORRECTIVE ACTION
STEP 1. On keypad, press ALARM CODES and check GSC related codes. Resolve as
required.
STEP 2. Disconnect wire from DVR, A3, and Terminal F2. Measure resistance between
disconnected wire and F1.
a. If resistance is less than 4 ohms, troubleshoot exciter circuit between F1, F2,
and exciter windings (WP 0088). Repair or replace wiring harness as
necessary.
b. Repair or replace Generator G1 as necessary (WP 0094 or WP 0095).
c. If resistance is 4 ohms or greater, replace DVR (WP 0042).
STEP 3. Verify the problem is resolved.

NOTE
The DVR detects that one of the sense inputs is open or shorted to another input.

SYMPTOM
11. Code 802

MALFUNCTION
Loss of Sensing

CORRECTIVE ACTION
STEP 1. Inspect wiring and verify continuity between TB1 and terminals
A3-20, A3-22, and A3-24 of DVR per FO-3 and FO-4.
a. Repair or replace wiring (WP 0044 and WP 0088) as necessary.
b. If the problem is not resolved, replace the DVR (WP 0042).
STEP 2. Verify the problem is resolved.

0010-11
 TM 9-6115-730-24 0010

TROUBLESHOOTING USING FAULT CODES - Continued

NOTE
The DVR detects that there is no AC frequency present for 200 ms while the measured voltage is
greater than 50% of nominal.

SYMPTOM
12. Code 803

MALFUNCTION
Loss of Frequency

CORRECTIVE ACTION
STEP 1. Check fuses F1, F2, or F3 per FO-1, sheet 4 and FO-3, sheet 1.
STEP 2. Replace fuses F1, F2, or F3, as required (WP 0055).
STEP 3. Troubleshoot wiring harness.
a. Check and repair wiring between PT2, PT3 and DVR, as required
(WP 0088).
b. Check and repair wiring between PT2, PT3, and fuses F1, F2, and F3, as
required (WP 0088).
c. Check and repair wiring between fuses (F1, F2, and F3) and generator, as
required (WP 0088).
d. Remove fuses F1, F2, and F3. Measure resistance between F1 terminal 2
and F2 terminal 2. If not 0.3 +/- 0.1 ohms, replace transformer PT2
(WP 0053).
e. Measure resistance between F2 terminal 2 and F3 terminal 2. If not 0.3
+/- 0.1 ohms, replace transformer PT3 (WP 0053).
f. Measure resistance between F3 terminal 2 and F1 terminal 2. If not 0.6
+/- 0.1 ohms, check all connections on transformers (WP 0053).
g. Measure resistance between J31-5 and J31-6. If not 0.3 +/- 0.1 ohms,
replace PT2 (WP 0053).
h. Measure resistance between J31-6 and J31-7. If not 0.3 +/- 0.1 ohms,
replace PT3 (WP 0053).
i. On EMCP, set Engine Control Switch to OFF/RESET to clear bus fault.
STEP 4. Install fuses F1, F2, and F3 (WP 0055).
STEP 5. Start generator set and measure AC voltage between pins A3-26 and A3-28,
A3-28 and A3-30, and A3-26 and A3-30. Verify 95 to 120 Vac present at all three
locations.
STEP 6. If voltages not present, repair or replace generator (WP 0094 or WP 0095).

0010-12
 TM 9-6115-730-24 0010

TROUBLESHOOTING USING FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 7. Measure AC voltage between pins A3-20 and A3-22, A3-22 and A3-24, and
A3-20 and A3-24. Verify 190 to 240 Vac present at all three locations.
a. Repair wiring between DVR and generator, as required (WP 0044 and
WP 0088).
b. If the problem is not resolved, replace the DVR (WP 0042).
STEP 8. Verify the problem is resolved.

SYMPTOM
13. Code 901

MALFUNCTION
DVR Memory Failure (Severe Fault)

CORRECTIVE ACTION
STEP 1. Try to change and store a new parameter value in the DVR (WP 0083).
STEP 2. If code 901 is still present, replace the DVR (WP 0042).
STEP 3. Verify the problem is resolved.

END OF WORK PACKAGE

0010-13/14 blank
 TM 9-6115-730-24 0011

UNIT (FIELD) LEVEL TROUBLESHOOTING

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
FAILURES WITHOUT A FAULT CODE TROUBLESHOOTING PROCEDURES

INITIAL SETUP:

Tools and Special Tools Personnel Required

Connector/Adapter 3Y-2888 One

Engine Pressure Group IU-5470
Multimeter 146-4080 References
O-Ring Seal 3J-1907
Temperature Adapter 6V-9130 WP 0083
Multimeter 146-4080 TM 9-6115-730-10

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES

WARNING
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

High voltage is produced when this generator set is in operation. Make sure unit is completely
shut down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

SYMPTOM
1. Starting Motor Remains Engaged.

MALFUNCTION
Setpoints Incorrect.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. Carefully disconnect one of the push on terminal connectors from the starter
motor magnetic switch (SMMS) relay (Figure 1).

0011-1
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

CORRECTIVE ACTION - Continued

Figure 1. SMMS Relay Location

STEP 3. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn ENGINE CONTROL Switch to COOL DOWN/STOP.
STEP 4. If engine cranks, replace SMMS (WP 0055).
STEP 5. If engine does not crank, view and note value of setpoints P011 (Crank terminate
speed), P017 (Total cycle crank time), and P018 (Cycle crank time) refer to
WP 0083).
STEP 6. Compare setpoints and reprogram, as required (WP 0083).
STEP 7. Verify the problem has been resolved.

MALFUNCTION
Starting Motor Control Circuitry Malfunction (Engine Will Not Crank).

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to CRANK.
STEP 2. If engine cranks, proceed to STEP 17.
STEP 3. If engine does not crank, check for 24 Vdc at each terminal of CB-2 and ground.
STEP 4. If voltages are not present, replace CB-2.

0011-2
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 5. Check for 24 Vdc at each terminal of R4 Shunt and ground.
STEP 6. If voltages are not present, replace R4 Shunt.
STEP 7. Check for 24 Vdc at each terminal of diode D1 and ground.
STEP 8. If voltages are not present, replace diode D1.
STEP 9. With DEAD CRANK SWITCH in CRANK position, check for 24 Vdc at terminal 3
of the starter motor magnetic switch (SMMS) relay and ground.
STEP 10. If voltage present, check for ground at terminal 4 of the SMMS relay.
STEP 11. If voltage is not present, check for 24 Vdc at TB5-5 and ground.
STEP 12. If voltage present, check wiring or replace Battery Disconnect Switch (WP 0049).
STEP 13. If voltage is not present, check wiring or replace DEAD CRANK SWITCH
(WP 0055).
STEP 14. Check for 24 Vdc at pinion solenoid terminals 23A10 (+) wire and black jumper
wire (-).

NOTE
It may be necessary to remove cover from pinion solenoid to access solenoid terminals.

STEP 15. If voltage is not present, check wiring or replace SMMS relay (WP 0055).
STEP 16. If voltage is present, check cable at starter or replace starter (WP 0076).

NOTE
When completing CID 444 FMI 12 (WP 0009) do not reinstall fuse A1F4.

STEP 17. On EMCP set ENGINE CONTROL Switch to MANUAL START. If engine does
not crank, go to Generator Set Control (GSC) fault isolation for CID 444 FMI 12
(WP 0009).
STEP 18. Set ENGINE CONTROL Switch to MANUAL START observing the following
conditions:
a. Engine crank indicator K4 will appear on lower display of GSC for the
time duration (in seconds) described by setpoint P017.
b. Engine crank indicator K4 will extinguish for the same duration.
c. Engine crank indicator K4 will appear again for the P017 duration.
d. Cycle will cease when time exceeds P018 duration (in seconds).
STEP 19. If engine crank indicator K4 does not appear and extinguish properly, replace
GSC (WP 0041).
STEP 20. Verify the problem has been resolved.

0011-3
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

SYMPTOM
2. Engine Does Not Shut Down When A Shutdown Fault Occurs or Engine Shuts Down with No GSC Fault
Codes.

MALFUNCTION
Setpoint Programming Error.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn ENGINE CONTROL Switch to COOL DOWN/STOP.
STEP 2. View and record value of all GSC setpoints. If setpoints viewed do not agree with
programmed data, reprogram setpoints (WP 0083).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Unresolved Diagnostic Codes.

CORRECTIVE ACTION

Check for active diagnostic codes and correct malfunctions as required per WP 0008 and
WP 0009.

MALFUNCTION
GSC Relay Module Malfunction.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. Check if the yellow fault alarm indicator is on continuously. This alarm indicates
that the GSC has been programmed to override the normal shutdown signal.
Reprogram the setpoints that could override the shutdown signal (WP 0083).
STEP 3. Check if the red fault shutdown indicator is flashing. If this alarm indicator is off,
the GSC has been programmed to override the normal shutdown signal.
Reprogram the setpoints that could override the shutdown signal (WP 0083).
STEP 4. Check that the K1 symbol is displayed on the GSC display. If the K1 symbol is
present, repeat this entire procedure to verify fault, replace GSC (WP 0041).
STEP 5. With engine running, remove wire from GSC relay module (RM) A1-13 (FO-4,
sheet 5).
STEP 6. If engine does not stop running, shut down system by other means.
a. On EMCP press the PRESS TO STOP EMERGENCY STOP
pushbutton.
b. Set DEAD CRANK SWITCH to OFF.
c. Set Battery Disconnect Switch to OFF.

0011-4
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 7. Verify continuity of harness between GSC A1-13 and engine control module
(ECM) ENG-P1-23 and A1-14 and ECM ENG-P1-40 (FO-2, sheet 2).
a. Repair or replace harness as required (WP 0044 and WP 0088).
b. If harness is good, replace ECM (WP 0082).
STEP 8. Verify the problem has been resolved.

NOTE
GSC fault shutdown indicator flashes at four to five times per second. GSC displays may not be
responding. GSC does not respond to any position of the ECS. This is an internal fault of the
GSC which may be temporary or permanent. This condition may also be caused by severe
electromagnetic fields or radio frequency interference (RFI).

SYMPTOM
3. GSC Operation Is Erratic.

MALFUNCTION
Red Fault Shutdown Indicator Flashing.

CORRECTIVE ACTION
STEP 1. With the engine running, on EMCP set ENGINE CONTROL switch to
OFF/RESET.
a. If GSC does not power down, set DEAD CRANK SWITCH to OFF, then
back to NORMAL.
b. If GSC does not power down, press EMERGENCY STOP button. Set the
Battery Disconnect Switch to OFF and the DEAD CRANK SWITCH to OFF.
STEP 2. Replace GSC (WP 0041).
STEP 3. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 4. If GSC powers up normally, verify all programmed parameters (WP 0083) and
retry system.
STEP 5. Verify the problem has been resolved.

0011-5
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

NOTE
Zero volts or zero amperes is showing on the GSC display for one or more AC phases while the
generator set is running and the load is connected. Separate fault isolation is provided for zero
voltage and zero current readings.

SYMPTOM
4. Display Of Voltage on GSC is Zero For One or More Phases.

MALFUNCTION
GSC Malfunction.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Check fuses A5F1, A5F2, and A5F3 on AC transformer box (ATB) A5 (FO-4,
sheet 3). Replace fuses, as required (WP 0042).
STEP 3. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to MANUAL START. Do not connect a
load.

NOTE
Voltage should correspond with reconfiguration board settings line-to-line.

STEP 4. Measure the line-to-line voltage between the fuses on ATB A5. If voltages are not
correct, repair or replace wiring between generator and ATB A5 (WP 0044 and
WP 0088).
STEP 5. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 6. Disconnect P7 from rear of GSC (FO-4, sheet 1.
a. Measure resistance between P7-16 and P7-10. If resistance is not 6 to 8
ohms, replace ATB A5 (WP 0042).
b. Measure resistance between P7-16 and P7-11. If resistance is not 6 to 8
ohms, replace ATB A5 (WP 0042).
c. Measure resistance between P7-16 and P7-12. If resistance is not 6 to 8
ohms, replace ATB A5 (WP 0042).
STEP 7. Reconnect P7 to rear of GSC (FO-4, sheet 1).
STEP 8. Remove A5F1, A5F2 and A5F3 fuses from ATB A5.
a. Measure resistance between A5F1 and A5F2 on A5 side. If resistance is
not 2150 +/- 100 ohms, replace ATB A5 (WP 0042).
b. Measure resistance between A5F2 and A5F3 on A5 side. If resistance is
not 2150 +/- 100 ohms, replace ATB A5 (WP 0042).
c. Measure resistance between A5F1 and A5F3 on A5 side. If resistance is
not 2150 +/- 100 ohms, replace ATB A5 (WP 0042).

0011-6
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 9. If ATB A5 is good, replace GSC (WP 0041).
STEP 10. Verify the problem has been resolved.

SYMPTOM
5. Display of Current on GSC is Zero For One or More Phases.

MALFUNCTION
GSC Malfunction.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Tag and disconnect wire 151B16 from ATB A5 terminal TBC-51 (leave wire
disconnected until finished troubleshooting) (FO-4, sheet 3).
STEP 3. Measure resistance between end of wire and terminal TBC-50. If resistance is
not 4 to 6 ohms, replace ATB A5 (WP 0042).
STEP 4. Tag and disconnect wire from terminal TBC-52.
STEP 5. Measure resistance between end of wire and terminal TBC-50. If resistance is
not 4 to 6 ohms, replace ATB A5 (WP 0042).
STEP 6. Tag and disconnect wire from terminal TBC-53.
STEP 7. Measure resistance between end of wire and terminal TBC-50. If resistance is
not 4 to 6 ohms, replace ATB A5 (WP 0042).
STEP 8. Measure resistance between ATB A5 terminals TBC-51 and TBC-50. If
resistance is not less than 1 ohm, replace ATB A5 (WP 0042).
STEP 9. Measure resistance between ATB A5 terminals TBC-52 and TBC-50. If
resistance is not less than 1 ohm, replace ATB A5 (WP 0042).
STEP 10. Measure resistance between ATB A5 terminals TBC-53 and TBC-50.
a. If resistance not less than 1 ohm, replace ATB A5 (WP 0042).
b. If ATB A5 is good, replace GSC (WP 0041).
STEP 11. Disconnect P7 from rear of GSC (FO-4, sheet 1).
STEP 12. Measure resistance between pins P7-4 and P7-16.
a. If resistance is not 100 to 140 ohms, repair or replace wiring (WP 0044).
b. If wiring is good, replace ATB A5 (WP 0042).
STEP 13. Measure resistance between pins P7-5 and P7-16.
a. If resistance not 100 to 140 ohms, repair or replace wiring (WP 0044).
b. If wiring is good, replace ATB A5 (WP 0042).

0011-7
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 14. Measure resistance between pins P7-6 and P7-16.
a. If resistance not 100 to 140 ohms, repair or replace wiring (WP 0044).
b. If wiring is good, replace ATB A5 (WP 0042).
STEP 15. Verify the problem has been resolved.

SYMPTOM
6. Display of Voltage on GSC is Inaccurate.

MALFUNCTION
Setpoint Incorrect.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. View and record value of setpoint P020. If value does not agree with
programmed setpoint, reprogram GSC (WP 0083).
STEP 3. View and record value of setpoints in OP8 (WP 0083).
STEP 4. Open EMCP and record value of bar code setpoints located on AC transformer
box A5.
a. If OP8 values do not agree with bar code setpoints marked on ATB A5,
reprogram GSC (WP 0083).
b. If setpoints agree, on EMCP set ENGINE CONTROL switch to
OFF/RESET. Set Battery Disconnect Switch to OF. Set DEAD CRANK SWITCH
to OFF.
c. Replace GSC (WP 0041).
STEP 5. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 6. View and record value of setpoints in OP10.
a. If value does not agree with programmed setpoint, reprogram GSC
(WP 0083).
b. Retest the system.
STEP 7. Verify the problem has been resolved.

0011-8
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

SYMPTOM
7. Display of Current on GSC is Inaccurate.

MALFUNCTION
Setpoint Incorrect.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. View and record value of setpoint P021. If value does not agree with
programmed setpoint, reprogram GSC (WP 0083).
STEP 3. View and record value of setpoints in OP8 (WP 0083).
STEP 4 Open EMCP and record value of bar code setpoints located on ATB A5.
a. If values of OP8 setpoints do not agree with bar code setpoints marked
on ATB A5, reprogram GSC (WP 0083).
b. If setpoints agree, on EMCP set ENGINE CONTROL Switch to
OFF/RESET. Set Battery Disconnect Switch to OF. Set DEAD CRANK SWITCH
to OFF.
c. Replace GSC (WP 0041).
STEP 5. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 6. View and record value of setpoints in OP8.
a. If value does not agree with programmed setpoint, reprogram GSC
(WP 0083).
b. Retest the system.
STEP 7. Verify the problem has been resolved.

0011-9
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

SYMPTOM
8. Display of Power on GSC is Inaccurate.

MALFUNCTION
Setpoint Incorrect.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. Verify setpoints per WP 0083. If voltage and current readings are accurate,
power will be accurate unless the polarity of one or more of the current
transformers is incorrect. Carefully check all connections (FO-3, sheet 2).
STEP 3. If connections are correct, on EMCP set ENGINE CONTROL Switch to
OFF/RESET. Set Battery Disconnect Switch to OFF. Set DEAD CRANK
SWITCH to OFF.
STEP 4. Replace GSC (WP 0041).
STEP 5. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 6. Retest the system.
STEP 7. Verify the problem has been resolved.

WARNING
High voltages may be present at the generator terminals when the unit is rotating. Tools, equip-
ment, clothing, and your body must be kept clear of rotating parts and electrical connections.
Special precautions must be taken during troubleshooting since protective covers and safety
devices may be removed or disabled to gain access and perform tests. Be careful. Serious injury
or death can result from these hazards.

SYMPTOM
9. Generator Produces No Voltage or Voltage Builds Up Then Drops to Zero.

MALFUNCTION
DVR Malfunction.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Check fuse A1F4 and replace as required.
STEP 3. Connect DC voltmeter to relay field flash (KFF), pins 8(+) and 5(-) (FO-4,
sheet 2).
STEP 4. Set DEAD CRANK SWITCH to NORMAL and ENGINE CONTROL switch to
MANUAL START. Engine should crank.

0011-10
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 5. If 24 Vdc battery voltage is not indicated on voltmeter, check DC voltage between
relay KFF-14 (+) and 13 (-).
a. If 24 Vdc is present, replace relay KFF (WP 0042).
b. If 24 Vdc is not present, check for 24 Vdc at GSC RM-18 (+) and ground
with ENGINE CONTROL switch set to MANUAL START.
(1) If 24 Vdc is present, repair wiring between RM-18 and relay KFF-14.
(2) If 24 Vdc is not present, replace GSC (WP 0041).
STEP 6. Set ENGINE CONTROL switch to OFF/RESET.
STEP 7. Connect DC voltmeter to digital voltage regulator (DVR) pins A3-F1 (+) and A3-
F2 (-) (FO-4, sheet 3).
STEP 8. Set ENGINE CONTROL switch to MANUAL START. Engine should crank.
a. If 9 to 16 Vdc is not indicated on voltmeter, replace diode CRFF
(WP 0042).
b. If diode is good, replace 15 ohm 25W resistor on resistor assembly A7
(WP 0043).
STEP 9. Allow engine to start and verify generator is rotating at or near proper speed.
STEP 10. Measure DC generator excitation voltage at DVR pins A3-F1 (+) and A3-F2 (-).
a. If voltage is less than 9 Vdc, replace DVR (WP 0042).
b. If voltage is greater than 15 Vdc, replace generator (WP 0083).
STEP 11. Verify the problem has been resolved.

SYMPTOM
10. Generator Produces Low Voltage Under No Load Condition.

MALFUNCTION
DVR Malfunction.

CORRECTIVE ACTION
STEP 1. Check for DVR fault codes.
a. If DVR fault codes are present, troubleshoot DVR (WP 0010).
b. If DVR fault codes are not present, proceed to STEP 2.
STEP 2. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL Switch to MANUAL START.

0011-11
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 3. Check generator output at load connection board with a voltmeter.
a. If output is not the same as programmed value, reprogram DVR (WP
0083).
b. If reprogramming does not hold, on EMCP set ENGINE CONTROL
switch to OFF/RESET. Set Battery Disconnect Switch to OFF. Set DEAD
CRANK SWITCH to OFF.
c. Replace DVR (WP 0042).
STEP 4. Inspect all generator connections for corrosion or loose connections. Clean and
repair connections, as required.
STEP 5. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to MANUAL START.
STEP 6. Measure voltage at DVR B+ and B- terminals (FO-4, sheet 3).
a. If voltage not 18 to 32 Vdc, check power wiring between DVR and GSC.
Repair or replace as required (WP 0044).
b. Refer to troubleshooting procedures for GSC CID 168 E FMI 04 (WP
0009).
STEP 7. Check parameters programmed into DVR.
a. If parameters are not correct, reprogram DVR (WP 0083).
b. If the problem is not resolved, replace generator (WP 0095).
STEP 8. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to MANUAL START.
STEP 9. Check engine speed using GSC or tachometer. RPM should be: 1800 RPM
(60 Hz) 1500 RPM (50 Hz).
a. Verify GSC is set for 50 or 60 Hz operation. If not, reprogram GSC and
verify reprogramming (WP 0083).
b. Reprogram DVR (WP 0083).
c. If programming is correct or will not verify, on EMCP set ENGINE
CONTROL switch to OFF/RESET. Set Battery Disconnect Switch to OFF. Set
DEAD CRANK SWITCH to OFF.
d. Replace GSC (WP 0041).
STEP 10. Verify the problem has been resolved.

0011-12
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

NOTE
If low voltage occurs when load is first connected, excessive motor-starting currents in load may
be the fault. Compressor starting currents may be too great for generator set. Air conditioner,
refrigerator, and freezer compressor motors often require 5 to 10 times their rated current during
start-up. If all of these loads are started at the same time, generator overload is possible.

SYMPTOM
11. Generator Produces Low Voltage When Load is Applied.

MALFUNCTION
DVR Malfunction.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to MANUAL START.
STEP 2. Monitor current at instant of load connection. Current should be less than rated
current and the same in each leg.
STEP 3. If current is too close to rated current, generator is being overloaded. Reduce
load or add another generator set in parallel.
STEP 4. Check current in each leg of output.
STEP 5. If current is not equal in all legs, selectively turn off loads until balanced.
STEP 6. Reconfigure loads as necessary or check for load failure.
STEP 7. Measure voltage at load connection terminals. Measure voltage at load.
STEP 8. If voltage drop from generator to load is more than 10%, increase wire size
between generator set and load.
STEP 9. Check DVR parameter :30 (droop percentage). Voltage should not drop lower
than the droop percentage will allow.
a. If output goes lower than the droop percentage allows, on EMCP set
ENGINE CONTROL switch to OFF/RESET. Set Battery Disconnect Switch to
OFF. Set DEAD CRANK SWITCH to OFF.
b. Replace DVR (WP 0042) and retest system.
c. If DVR replacement does not resolve problem, replace generator (WP
0095).
STEP 10. Verify the problem has been resolved.

0011-13
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

SYMPTOM
12. Generator Produces Fluctuating Voltage.

MALFUNCTION
DVR Malfunction.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to MANUAL START.
STEP 2. Check current in each leg of output. Current should be much less than rated
current and the same in each leg.
STEP 3. If current is too close to rated current, generator is overloaded. Reduce load or
add generator set in parallel.
STEP 4. If current is not equal in all legs selectively turn off loads until balanced.
STEP 5. Reconfigure loads as necessary or check for load failure.
STEP 6. Check engine speed using tachometer: 1800 RPM (60 Hz) and stable. 1500
RPM (50 Hz) and stable.
STEP 7. If engine speed follows voltage fluctuations, go to Engine misfires, runs rough, or
is unstable troubleshooting procedure (SYMPTOM 21).
STEP 8. Check load(s) for fluctuations.
a. Disconnect one load at a time until unstable load is determined.
b. Repair or replace unstable load, or reconfigure system to accommodate
load.
c. If all loads are stable, on EMCP set ENGINE CONTROL switch to
OFF/RESET. Set Battery Disconnect Switch to OFF. Set DEAD CRANK
SWITCH to OFF.
d. Replace DVR (WP 0042) and retest system.
e. If DVR replacement does not resolve problem, replace generator (WP
0095).
STEP 9. Verify the problem has been resolved.

0011-14
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

SYMPTOM
13. Generator Produces High Voltage.

MALFUNCTION
DVR Malfunction.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to MANUAL START.
STEP 2. Check voltage at load connection terminals.
a. Check programming of GSC and DVR for the position of the
reconnection board (WP 0083 and WP 0014).
b. Reprogram as required (WP 0083).
STEP 3. Verify load connections. Reconfigure load connections for the desired voltage
(WP 0014) and TM 9-6115-730-10.
STEP 4. Check power factor of load. If not close to 1.0, excessive leading power factor
(capacitive load) can cause voltage to climb out of control. Reconfigure load.
STEP 5. Check voltage adjust potentiometer.
a. Adjust VOLTAGE potentiometer for lower voltage, as required.
b. If the problem is not resolved, on EMCP set ENGINE CONTROL switch
to OFF/RESET. Set Battery Disconnect Switch to OFF. Set DEAD CRANK
SWITCH to OFF.
c. Replace DVR (WP 0042) and retest system.
STEP 6. Verify the problem has been resolved.

0011-15
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

SYMPTOM
14. Generator is Overheating.

MALFUNCTION
Excessive Generator Load.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to MANUAL START.
STEP 2. Check ventilation screens. Unclog screens, as required.
STEP 3. Check ambient temperature. Improve ventilation, or reduce load.
STEP 4. Check temperature of air at intake. Improve ventilation, or reduce load.
STEP 5. Check current in each leg of output.
a. If not less than rated current, reduce load.
b. Add a generator set in parallel.
c. If load is unbalanced, reconfigure load to improve balance from leg to
leg.
STEP 6. Verify the problem has been resolved.

0011-16
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

SYMPTOM
15. Equipment Runs Normally on Other Source of Power (Utility or Other Generator Set), But Will Not Run on
This Generator Set.

MALFUNCTION
Improper Load.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to MANUAL START.
STEP 2. Verify output of generator set is proper voltage and frequency ± 10%. Reset GSC
and DVR parameters to obtain desired output (WP 0083).
STEP 3. Check nameplates of load equipment to verify generator set output programming
is correct for device(s). Delete load or reset GSC and DVR parameters to obtain
desired output (WP 0083).

NOTE
Analyze load. Excessive silicon controlled rectifier (SCR) (Thyristor) equipment connected to
generator set may distort waveform and equipment that will not run may be more sensitive to
waveform distortion than most. Example of SCR equipment would be anything with a variable
speed drive 1/4 HP or more. Lamp dimmers are also a source of the kind of noise that creates
problems with other equipment.
STEP 4. Disconnect SCR equipment and see if that improves operation.
STEP 5. May need isolation transformer for SCR or sensitive equipment to prevent
distortion on the generator output.
STEP 6. Verify the problem has been resolved.

0011-17
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

SYMPTOM
16. Undesirable Speed Decrease With Load Increase.

MALFUNCTION
Improper Engine Operation.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. On resistor assembly A7, verify position of ISOCHRONOUS/DROOP switch
(TM 9-6115-730-10, WP 0006) and (FO-4, sheet 5).
STEP 3. If in DROOP mode, go to STEP 4.
STEP 4. On load resistor assembly A7, measure continuity A7-2 A7-1 (FO-4, sheet 4). If
continuity exists, replace ISOCHRONOUS/DROOP switch (WP 0042).
STEP 5 If ISOCHRONOUS/DROOP switch is good, set to DROOP.
STEP 6. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn ENGINE CONTROL switch to MANUAL START.
STEP 7. Check for continuity between LSM module A4-14 and resistor assembly A7-1.
a. If continuity is present, proceed to STEP 8.
b. If continuity is not present, replace main load contactor K1 (WP 0049).
STEP 8. Try operating in ISOCHRONOUS mode.
a. Problem caused by improper engine operation. Engine may not be
developing enough horsepower.
b. Go to Low power/poor or no response to throttle troubleshooting
procedure (SYMPTOM 22).
STEP 9. Set ISOCHRONOUS/DROOP switch to DROOP.
STEP 10. Note position of droop potentiometer on LSM A4.
STEP 11. Rotate potentiometer counterclockwise (decrease droop percentage).
a. Problem caused by improper engine operation. Engine may not be
developing enough horsepower.
b. Go to Low power/poor or no response to throttle troubleshooting
procedure (SYMPTOM 22).
STEP 12. Verify the problem has been resolved.

0011-18
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

NOTE
Problems, which look like load sharing problems when generator sets are operated in parallel, are
often caused by erratic operation of one of the DVR units.

SYMPTOM
17. Load Sharing Module (LSM) A4 Erratic Operation.

MALFUNCTION
Load Gain Adjustment.

CORRECTIVE ACTION
STEP 1. Disconnect generator set completely from load.
STEP 2. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to MANUAL START.
STEP 3. Operate independently with load.
STEP 4. Verify operation of DVR.
a. If DVR operation is incorrect, on EMCP set ENGINE CONTROL switch to
OFF/RESET. Set Battery Disconnect Switch to OFF. Set DEAD CRANK
SWITCH to OFF.
b. Troubleshoot DVR (WP 0010).
STEP 5. Perform the load gain adjustment procedure except set the voltage to 3.0 Vdc
instead of 6 Vdc. Adjust LSM A4 load gain (WP 0042).
STEP 6. Verify the problem has been resolved.

0011-19
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

SYMPTOM
18. Engine Not Properly Sharing Load With Other Generator Sets (Parallel Operation).

MALFUNCTION
Load Sharing Module Malfunction.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to MANUAL START.
STEP 2. Apply full load to generator set.
STEP 3. Measure voltage LSM A4-22 (+) and A4-23 (-)(FO-4, sheet 2). If voltage is not
6.0 Vdc ± 1.0 Vdc at full load, perform LSM A4 load gain adjustment (WP 0042)
of each generator set running isochronously not paralleled.
STEP 4. Check frequency setting of all units when off line with no load. If not identical,
readjust frequency settings to be identical.
STEP 5. On Resistor Assembly A7 check position of ISOCHRONOUS/DROOP switch.
STEP 6. If in DROOP mode, go to STEP 7.
STEP 7. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 8. On LSM A4, measure continuity between A4-13 and A4-14.
a. If no continuity, replace ISOCHRONOUS/DROOP switch (WP 0042).
b. If ISOCHRONOUS/DROOP switch is good, replace main load contactor
K1 (WP 0049).
STEP 9. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to MANUAL START.
STEP 10. Try operating in ISOCHRONOUS mode.
a. Problem caused by improper engine operation. Engine may not be
developing enough horsepower.
b. Go to Low power/poor or no response to throttle troubleshooting
procedure (SYMPTOM 22).
STEP 11. Verify the problem has been resolved.

0011-20
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

WARNING
Batteries give off a flammable gas. Do not smoke or use open flame when performing
maintenance. Failure to comply can cause injury or death to personnel and equipment damage
due to flames and explosion.

Lifting batteries from the battery tray can cause back strain. Ensure proper lifting techniques are
used when lifting batteries. Failure to comply can cause serious personal injury.

Battery acid can cause burns to unprotected skin. Wear protective gloves and safety goggles.
Failure to comply can cause injury to personnel.

When disconnecting or removing batteries, disconnect the negative lead that connects directly to
the grounding stud first. Disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply can cause serious injury
to personnel.

SYMPTOM
19. Engine Will Not Crank (Starter Pinion Engages and Engine Does Not Turn Over).

MALFUNCTION
Starter Motor Defective.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Turn the ENGINE CONTROL switch to
COOL DOWN/STOP.
STEP 2. Check battery voltage on GSC display.
a. If battery voltage is 22 Vdc or greater, proceed to STEP 5.
b. If battery voltage is less than 22 Vdc, proceed to STEP 3.
STEP 3. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 4. Inspect cables between battery, Battery Disconnect Switch, and starter solenoid
(FO-1, sheet 2).
a. Clean and tighten cable ends, as required.
b. Replace cable(s), as required (WP 0048).

WARNING
NATO connector has 24 Vdc battery voltage available continuously. Use caution when
connecting DVM to NATO connector.

STEP 5. Connect DVM to NATO connector bottom terminal (+) and top terminal (-).

0011-21
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

CORRECTIVE ACTION - Continued

CAUTION
Crank engine only for a few seconds, long enough to read DVM, or damage to batteries or
starting motor may result.

STEP 6. Set DEAD CRANK SWITCH to CRANK and monitor voltage displayed on DVM.
a. If battery voltage is 18 Vdc or greater, charge batteries and proceed to
STEP 7.
b. If battery voltage is 16 Vdc or less, replace batteries (WP 0050).
STEP 7. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 8. Bench-test starting motor. If motor fails replace starter (WP 0076).
STEP 9. Verify free movement of generator. If generator does not turn freely, replace
generator G1 (WP 0095).
STEP 10. Verify timing bolt was not left in flywheel after setting valve lash. If timing bolt was
left in flywheel, remove pin (WP 0119).
STEP 11. Remove the injectors and check for fluid in the cylinders (hydraulic cylinder lock).
Remove fluid from cylinder (WP 0120).
STEP 12. Remove and disassemble engine accessories that can lock up the engine (oil
pump WP 0111 or fuel transfer pump WP 0102).
STEP 13. If the problem is not resolved, replace the engine (WP 0096).
STEP 14. Verify the problem has been resolved.

SYMPTOM
20. Engine Cranks But Will Not Start.

MALFUNCTION
Fuel Delivery Problem.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Check for a fuel supply problem and verify fuel pressure (WP 0013,
SYMPTOM 10).
STEP 3. Verify the problem has been resolved.

0011-22
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

MALFUNCTION
Engine Timing Incorrect.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. Verify engine speed during cranking using GSC readout of engine speed.
a. If speed is not greater than 50 rpm during cranking, perform load test on
batteries. Check batteries and cables as required. Replace as required
(WP 0050).
b. If batteries are good, replace starter (WP 0076).
STEP 3. Inspect and adjust engine timing sensors.
a. Inspect sensors and adjust if good (WP 0013, SYMPTOM 3).
b. If sensors are damaged, replace/adjust sensors (WP 0013, SYMPTOM
3).
STEP 4. Perform Engine Timing Sensor Calibration (WP 0013, SYMPTOM 8). Replace
defective injector (WP 0118), if necessary.
STEP 5. Verify the problem has been resolved.

MALFUNCTION
Personality Module Mismatch.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Check for correct installation of ECM to EMCP harness connector ENG-P1 to
ECM J1 and of engine harness connector ENG-P1 to ECM J2 (cables plugged in
to ECM) (FO-2, sheet 1 and sheet 2) and (WP 0088), Figure 2, sheet 3). Plug
connectors in securely.
STEP 3. Check engine harness timing sensor connectors ENG-P401 and ENG-P402 and
unit injector connector ENG-P300/J300. Plug connectors in securely.
STEP 4. Verify that CID 253 FMI 02 personality module mismatch is not displayed on the
GSC. If the ECM has a problem with the internal personality module, the engine
will crank, but will not start. Replace ECM (WP 0082).
STEP 5. Verify the problem has been resolved.

0011-23
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

MALFUNCTION
Ether Injection System Malfunction.

CORRECTIVE ACTION
STEP 1. Verify that Ether is enabled in the system configuration parameters (WP 0083).

NOTE
The Ether Injection System is active only during the following conditions:
The engine speed is less than 35 RPM.
The coolant temperature or the intake manifold air temperature is less than 32ºF
(0ºC).
STEP 2. If these conditions are present, troubleshoot Ether Injection System (WP 0013,
SYMPTOM 4).
STEP 3. If these conditions are not present, proceed to next malfunction.
STEP 4. Verify the problem has been resolved.

MALFUNCTION
Winterization Kit Malfunction.

CORRECTIVE ACTION
STEP 1 On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. If fuel-fired heater was on, check wiring and continuity between winterization kit
control panel and fuel-fired heater (FO-1, sheet 6).
a. Repair or replace wiring harness (WP 0088 and WP 0091).
b. Inspect and repair or replace heater hoses (WP 0091).
c. Repair or replace heater control box (WP 0089).
d. Replace fuel-fired heater (WP 0090).
STEP 3. Check for presence of congealed fuel (wax). If congealed fuel is found, drain tank
and replace fuel TM 9-6115-730-10 and fuel filters (WP 0061 and WP 0080).
STEP 4. Verify the problem has been resolved.

0011-24
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

WARNING
Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool
before performing checks, services, and maintenance. Failure to comply can cause injury or
death to personnel.

When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set, and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply can
cause injury or death to personnel.

SYMPTOM
21. Engine Misfires, Runs Rough, or is Unstable.

MALFUNCTION
Fuel Supply Problem.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Verify fuel quality. If fuel is not clean or if signs of wax are present, drain and
replace fuel TM 9-6115-730-10.
STEP 3. Check for a fuel supply problem and verify fuel pressure (WP 0013,
SYMPTOM 10).
STEP 4. If no fuel supply problem is found, engine has an internal problem. Replace the
engine (WP 0096).
STEP 5. Verify the problem has been resolved.

MALFUNCTION
Electrical Connections Faulty.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. Check DC voltage at slave relay (SRY) pin 87 (+) with respect to 86 (-) (FO-2,
sheet 2).
a. If voltage is not 24 Vdc, Measure voltage at SRY pin 30 (+) with respect
to 86 (-).
b. If voltage is 24 Vdc, measure SRY pin 85 (+) with respect to 86 (-).
c. If voltage is 24 Vdc, replace SRY (WP 0042).
d. If voltage is not 24 Vdc, replace GSC (WP 0041).
e. If voltage at SRY pin 30 is not 24 Vdc, measure voltage across CB-4.

0011-25
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

CORRECTIVE ACTION - Continued

f. If voltage is greater than 0.2 Vdc, replace CB-4 (WP 0055).
g. Verify voltage at batteries. Recharge or replace batteries as required
(WP 0050).
STEP 3. Check for correct installation of ECM to EMCP harness connector ENG-P1 to
ECM J1 and of engine harness connector ENG-P2 to ECM J2 (cables plugged
in to ECM) (FO-2, sheet 1 and sheet 2) and (WP 0088, figure 2, sheet 3). Plug
connectors in securely and torque the ENG-P1/J1 and ENG-P2/J2 connectors to
55 lb. in.
STEP 4. Check engine harness timing sensor connectors ENG-P401 and ENG-P402 and
unit injector connector ENG-P300/J300. Plug connectors in securely.
STEP 5. Verify connections between LSM pins A4-19 and A4-20 and the ECM input pins
ENG-P1-5 and ENG-P1-66 (FO-4, sheet 2 and FO-3, sheets 1 and 2). Look
specifically for intermittent connections FO-2, sheet 1. Repair or replace wiring,
as required (WP 0044 and WP 0088).
STEP 6. Verify the problem has been resolved.

MALFUNCTION
ECM may not be leaving cold mode operation.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to MANUAL START.
STEP 2. Check coolant temperature using GSC.
a. Coolant temperature should start at ambient temperature and rise above
64ºF (17ºC) as the engine warms up.
b. If GSC temperature reading does not increase properly, replace coolant
temperature sensor (WP 0098).
c. If engine does not warm up, replace engine coolant temperature
thermostat(s) (WP 0081).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Inlet Air or Exhaust Restrictions.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Check for dirty or clogged air filters. Replace air filters (WP 0071).
STEP 3. Check exhaust system for restrictions. Repair or replace components, as
required (WP 0069).
STEP 4. Verify the problem has been resolved.

0011-26
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

WARNING
Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/or liquids can result in burns and scalding. Shut down generator set, and allow system to cool
before performing checks, services, and maintenance. Failure to comply can cause injury or
death to personnel.

When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set, and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply can
cause injury or death to personnel.

SYMPTOM
22. Low Power/Poor or No Response to Throttle.

MALFUNCTION
Programmed Parameters Incorrect.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. Check all programmed parameters on GSC and DVR, and verify that they are
correct for the voltage selected by the reconnection board. Reprogram
parameters, as required (WP 0083).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Fuel Supply Problems.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Verify fuel quality. If fuel is not clean or if signs of wax are present, drain and
replace fuel and filters (WP 0061 and WP 0080).
STEP 3. Check air inlet turbo pipes and exhaust for restrictions and leaks.
a. Remove restrictions.
b. Clean air filters (WP 0071).
c. Repair air leaks found (WP 0072).
STEP 4. Check for a fuel supply problem and verify fuel pressure (WP 0013,
SYMPTOM 10).
STEP 5. If no fuel supply problem is found, engine has an internal problem. Replace the
engine (WP 0096).
STEP 6. Verify the problem has been resolved.

0011-27
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

MALFUNCTION
ECM may not be leaving cold mode operation.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
Turn ENGINE CONTROL switch to MANUAL START.
STEP 2. Check coolant temperature using GSC.
a. Coolant temperature should start at ambient temperature and rise above
64ºF (17ºC) as the engine warms up.

b. If GSC temperature reading does not increase properly, replace coolant

temperature sensor (WP 0098).
c. If engine does not warm up, replace engine coolant temperature
thermostat(s) (WP 0081).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Harness Connections Faulty.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Check for correct installation of ECM to EMCP harness connector ENG-P1 to
ECM J1 and of engine harness connector ENG-P2 to ECM J2 (cables plugged in
to ECM) (FO-2, sheet 1 and sheet 2). Plug connectors in and torque the ENG-
P1/J1 and ENG-P2/J2 connectors to 55 lb. in.
STEP 3. Check engine harness timing sensor connectors ENG-P401 and ENG-P402 and
unit injector connector ENG-P300/J300. Plug connectors in securely.
STEP 4. Verify connections between LSM pins A4-19 and A4-20 and the ECM input pins
ENG-P1-5 and ENG-P1-66 (FO-4, sheet 2 and FO-3, sheets 1 and 2). Look
specifically for intermittent connections (FO-2, sheet 1). Repair or replace wiring,
as required (WP 0044 and WP 0088).
STEP 5. Verify the problem has been resolved.

0011-28
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

NOTE
Use the following procedure whether the engine shuts down completely and had to be restarted
or if it falters and does not require restarting. If problem occurs only after engine is warmed up
and disappears after engine cools down, problem may be circuit breakers overheating. Check
carefully for hot spots and repair or replace, as required.

SYMPTOM
23. Intermittent Engine Shut Downs.

MALFUNCTION
Electrical Connections Faulty.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Check for correct installation of ECM to EMCP harness connector ENG-P1 to
ECM J1 and of engine harness connector ENG-P2 to ECM J2 (cables plugged in
to ECM) (FO-2, sheet 1 and sheet 2, and WP 0088, figure 2, sheet 3). Plug
connectors in and torque the ENG-P1/J1 and ENG-P2/J2 connectors to 55 lb. in.
STEP 3. Check engine harness timing sensor connectors ENG-P401 and ENG-P402 and
unit injector connector ENG-P300/J300. Plug connectors in securely.
STEP 4. Verify connections between LSM pins A4-19 and A4-20 and the ECM input pins
ENG-P1-5 and ENG-P1-66 (FO-4, sheet 2 and FO-3, sheets 1 and 2). Look
specifically for intermittent connections. Repair or replace wiring, as required
(WP 0044 and WP 0088).
STEP 5. Refer to Low power/poor or no response to throttle troubleshooting procedure
SYMPTOM 22.
STEP 6. Check load. Verify load is not causing problem. Replace or reconfigure load.
STEP 7. Verify the problem has been resolved.

SYMPTOM
24. Excessive Black Smoke.

MALFUNCTION
Air Inlet Problem.

CORRECTIVE ACTION
STEP 1. Check the air inlet and exhaust for restrictions and leaks.
a. Check for a restriction in the air inlet. Inspect and clear the obstruction.
b. Clean or replace air inlet filter (WP 0071).

0011-29
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

CORRECTIVE ACTION - Continued

c. Repair any air leaks in the air inlet system (WP 0072).
d. Check for loose clamps or broken expansion joints on all pipes between
the turbo and air-to-air after cooler and between the air-to-air aftercooler and
engine intake manifold.
e. If there are no problems with the air inlet system, replace failed
atmospheric or turbo inlet pressure sensor (WP 0098).
STEP 2. Check for failed turbocharger. Repair or replace turbocharger as required
(WP 0103).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Engine Timing.

CORRECTIVE ACTION
STEP 1. Inspect/adjust engine timing sensors.
a. Inspect sensors and install and adjust if good (WP 0013, SYMPTOM 3).
b. If sensors are damaged, replace and adjust sensors (WP 0013,
SYMPTOM 3).
STEP 2. Check valve adjustment.
a. Readjust valves, as required (WP 0119).
b. If any valves cannot be adjusted to specifications, replace the cylinder
head (WP 0120).
STEP 3. Check proper timing orientation between crankshaft and camshaft drive gears.
STEP 4. Verify the problem has been resolved.

MALFUNCTION
Fuel Supply Problem.

CORRECTIVE ACTION
STEP 1. Check for a fuel supply problem and verify fuel pressure (WP 0013,
SYMPTOM 10).
STEP 2. Verify the problem has been resolved.

0011-30
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set, and allow engine to cool before performing checks, services, and mainte-
nance. Wear gloves and additional protective clothing as required. Failure to comply can cause
injury or death to personnel.

SYMPTOM
25. Excessive White Smoke.

MALFUNCTION
Engine Temperature Low.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to MANUAL START.
STEP 2. Check coolant temperature using GSC. (ECM may not be leaving cold mode
operation.) Coolant temperature rises above 64°F (17°C) as engine heats up.

a. Verify actual temperature using temperature adapter 6V-9130 and

multimeter 146-4080.
b. If GSC temperature reading does not match reading on the temperature
adapter/multimeter, replace coolant temperature sensor (WP 0098).
c. If engine does not warm up, replace engine coolant temperature
thermostat(s) (WP 0081).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Engine Timing

CORRECTIVE ACTION
STEP 1. Inspect/adjust engine timing sensors.
a. Inspect sensors and adjust if good (WP 0098).
b. If sensors are damaged, replace and adjust sensors (WP 0098).
STEP 2. Check proper orientation between crankshaft and camshaft drive gears.
STEP 3. Verify the problem has been resolved.

0011-31
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

MALFUNCTION
Fuel Supply Problem

CORRECTIVE ACTION
STEP 1. Check for a fuel supply problem and verify fuel pressure (WP 0013,
SYMPTOM 10).
STEP 2. Verify the problem has been resolved.

MALFUNCTION
Coolant Leak

CORRECTIVE ACTION
Coolant leakage into the cylinder or exhaust system can produce symptoms similar to white
smoke emissions from unburned fuel. Replace the engine (WP 0096).

SYMPTOM
26. Can Not Reach Operating Engine RPM.

MALFUNCTION
Unresolved Codes.

CORRECTIVE ACTION
Check for fault codes that could cause engine degradation performance.

MALFUNCTION
Insufficient Inlet Air

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Check air filters for dirty or clogged filters. Replace air filters (WP 0071).
STEP 3. Check exhaust system for restrictions. Remove restrictions (WP 0069).
STEP 4. Verify the problem has been resolved.

MALFUNCTION
Throttle Malfunction

CORRECTIVE ACTION
STEP 1. Go to Poor Acceleration or Response SYMPTOM 27 within this work package.
STEP 2. If the problem is not resolved, perform Speed Control Test (WP 0013,
SYMPTOM 6).
STEP 3. Verify the problem has been resolved.

0011-32
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

MALFUNCTION
Fuel Supply Problem.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Check the fuel lines for restriction, collapsed lines, and pinched lines (WP 0016).
STEP 3. Check the fuel tank for foreign objects or debris which may block the fuel lines
( per TM 9-6115-730-10).
STEP 4. Prime the fuel system if any of the following have been performed.
a. Replacement of the fuel filters (WP 0061 AND WP 0080).
b. Service on the low pressure fuel supply circuit.
c. Replacement of unit (fuel) injectors (WP 0118).
STEP 5. Purge air from the low pressure fuel supply circuit.
STEP 6. Check the fuel pressure after the fuel filter while the engine is being cranked
(WP 0013, SYMPTOM 10). Perform steps for SYMPTOM 20, MALFUNCTION
Fuel Delivery Problem.
a. If the fuel pressure is low, replace the fuel filters (WP 0061 AND WP
0080).
b. If the fuel pressure is still low, check the following items.
(1) Fuel transfer pump (WP 0102).
(2) Fuel transfer pump coupling (WP 0102).
(3) Fuel pressure regulating valve (WP 0102).
STEP 7. Perform Injector Solenoid Test and Cylinder Cutout Test (WP 0013,
SYMPTOM 5).
STEP 8. Verify the problem has been resolved.

0011-33
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

MALFUNCTION
Engine Temperature

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to MANUAL START.
STEP 2. Check coolant temperature using GSC. (ECM may not be leaving cold mode
operation.). Coolant temperature rises above 64°F (17°C) as engine heats up.

a. Verify actual temperature using temperature adapter 6V-9130 and

multimeter 146-4080 or thermometer.
b. If GSC temperature reading does not match reading on the temperature
adapter/multimeter, replace coolant temperature sensor (WP 0098).
c. If engine does not warm up, replace engine coolant temperature
thermostat(s) (WP 0081).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Generator Faulty.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL Switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect generator for problem, which would place excess load on engine. Repair
or replace components, as required or replace generator (WP 0095).
STEP 3. If replacing generator does not correct the problem, there is an internal engine
problem. Replace the engine (WP 0096).
STEP 4. Verify the problem has been resolved.

0011-34
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TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

SYMPTOM
27. Poor Acceleration or Response.

MALFUNCTION
Throttle Malfunction

CORRECTIVE ACTION
STEP 1. Perform Speed Control Test (WP 0013, SYMPTOM 6).
STEP 2. Start generator set per TM 9-6115-730-10.
STEP 3. Monitor Fuel Position and Rated Fuel Limit during operation at full load. If Fuel
Position does not equal Rated Fuel Limit, check the following (WP 0013,
SYMPTOM 11):
a. Check Turbo Outlet Pressure Sensor and verify an approximate pressure
of 4 to 6 PSI (27.6 to 41.4 Kpa) (WP 0013, SYMPTOM 11).
b. Monitor atmospheric pressure (14.6 PSI (100.7 kpa)) and boost pressure
(approximately 18 PSI (124.1 Kpa)). If not correct, repair or replace turbocharger
(WP 0107).
STEP 4. Verify the problem is resolved.

MALFUNCTION
Engine Temperature Low.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to MANUAL START.
STEP 2. Check coolant temperature using GSC.
a. Coolant temperature should start at ambient temperature and rise above
64ºF (17ºC) as the engine warms up.
b. If GSC temperature reading does not increase properly, replace coolant
temperature sensor (WP 0098).
c. If engine does not warm up, replace engine coolant temperature
thermostat(s) (WP 0081).
STEP 3. Verify the problem has been resolved.

0011-35
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

MALFUNCTION
Electrical Connections Faulty

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Check for correct installation of ECM to EMCP harness connector ENG-P1 to
ECM J1 and of engine harness connector ENG-P2 to ECM J2 (cables plugged in
to ECM) (WP 0088 and FO-2, sheet 1 and sheet 2).
STEP 3. Check engine harness timing sensor connectors ENG-P401 and ENG-P402 and
unit injector connector ENG-P300/J300. Plug connectors in securely (WP 0088).
STEP 4. Verify connections between LSM A4 pins A4-19 and A4-20 and the ECM input
pins ENG-P1-5 and ENG-P1-66 (FO-4, sheet 2 and FO-3, sheets 1 and 2). Look
specifically for intermittent connections. Repair or replace wiring, as required
(WP 0088).
STEP 5. Verify the problem is resolved.

MALFUNCTION
Fuel Supply Problem.

CORRECTIVE ACTION
STEP 1. Perform Cylinder Cutout Test (WP 0013, SYMPTOM 5) to check for any non-
operable unit injectors. If necessary, replace faulty injectors (WP 0118).
STEP 2. Check for a fuel supply problem and verify fuel pressure (WP 0013,
SYMPTOM 10).
STEP 3. Verify the problem is resolved.

MALFUNCTION
Insufficient Inlet Air.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Check for dirty or clogged air filters. Replace air filters (WP 0071).
STEP 3. Check exhaust system for restrictions. Repair or replace components, as
required (WP 0069).
STEP 4. Verify the problem is resolved.

0011-36
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TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

SYMPTOM
28. Poor Fuel Consumption.

MALFUNCTION
Insufficient Inlet Air.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Check for dirty or clogged air filters. Replace air filters (WP 0071).
STEP 3. Check exhaust system for restrictions. Repair or replace components, as
required (WP 0069).
STEP 4. Verify the problem has been resolved.

MALFUNCTION
Electrical Connections.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect/adjust engine timing sensors.
a. Inspect sensor and install and adjust if good (WP 0098).
b. If sensors are damaged, replace/adjust sensors (WP 0013, SYMPTOM
3).
STEP 3. Check for correct installation of ECM to EMCP harness connector ENG-P1 to
ECM J1 and of engine harness connector ENG-P2 to ECM J2 (cables plugged in
to ECM) (FO-2, sheet 1 and sheet 2). Plug connectors in securely and torque
ENG-P1/J1 and ENG-P2/J2 connectors to 55 lb. in. (WP 0088).
STEP 4. Check engine harness timing sensor connectors ENG-P401 and ENG-P402 and
unit injector connector ENG-P300/J300. Plug connectors in securely (WP 0088).
STEP 5. Verify connections between LSM pins A4-19 and A4-20 and the ECM input pins
ENG-P1-5 and ENG-P1-66 (FO-4, sheet 2 and FO-3, sheets 1 and 2). Look
specifically for intermittent connections. Repair or replace wiring, as required
(WP 0088).
STEP 6. Verify the problem is resolved.

0011-37
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

MALFUNCTION
Fuel Supply Problem.

CORRECTIVE ACTION
STEP 1. Perform Injector Solenoid Test and Cylinder Cutout Test (WP 0013,
SYMPTOM 5). Replace faulty injectors (WP 0118).
STEP 2. Check for a fuel supply problem and verify fuel pressure (WP 0013,
SYMPTOM 10).

MALFUNCTION
Generator Malfunction.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect generator for problems or restrictions that would place excess load on
engine. Visually check generator rotor shaft for excessive play, vibration, or
noise. If necessary, replace generator (WP 0095).
STEP 3. Verify the problem has been resolved.
SYMPTOM
29. Engine Stalls at Low RPM.

MALFUNCTION
Electrical Connections Faulty.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL Switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Check for correct installation of engine harness ENG-P2 connector to ECM J2
and engine harness connector ENG-P300 to fuel injector harness connector
J300 (WP 0088).
STEP 3. Verify the problem has been resolved.

0011-38
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

MALFUNCTION
Fuel Supply Problem.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Check the fuel lines for restriction, collapsed lines, and pinched lines.
STEP 3. Check the fuel tank for foreign objects or debris which may block the fuel lines.
STEP 4. Prime the fuel system if any of the following have been performed (WP 0078).
a. Replacement of the fuel filters.
b. Service on the low pressure fuel supply circuit.
c. Replacement of unit (fuel) injectors.
STEP 5. Purge air from the low pressure fuel supply circuit using the fuel priming pump.
STEP 6. Check the fuel pressure after the fuel filter while the engine is being cranked
(WP 0013, SYMPTOM 10).
a. If the fuel pressure is low, replace the fuel filters (WP 0080).
b. If the fuel pressure is still low, check the following items (WP 0102).
(1) Fuel transfer pump
(2) Fuel transfer pump coupling.
(3) Fuel pressure regulating valve.
STEP 7. Perform the Injector Solenoid Test and the Cylinder Cutout Test (WP 0013,
SYMPTOM 5).
STEP 8. Verify the problem has been resolved.

MALFUNCTION
Generator Malfunction.

CORRECTIVE ACTION
Inspect generator for problems or restrictions that would place excess load on engine.
Visually check generator rotor shaft for excessive play, vibration, or noise (WP 0094). If
problem is not resolved, go to Engine Misfires, Runs Rough, or is Unstable (SYMPTOM 21).

0011-39
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

SYMPTOM
30. Auxiliary Fuel Pump Does Not Operate.

MALFUNCTION
Auxiliary Fuel Pump Solenoid Valve.

CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. Check for 24 Vdc across auxiliary fuel pump valve (AFPV) pins 1 and 2 with AUX
FUEL switch ON. Listen for a auxiliary fuel pump and AFPV operation.
a. If 24 Vdc is present, proceed to STEP 3.
b. If 24 Vdc is not present, proceed to STEP 7.
STEP 3. Set Battery Disconnect Switch to OFF/RESET. Set DEAD CRANK SWITCH to
OFF. On EMCP set ENGINE CONTROL switch to OFF/RESET.
STEP 4. On EMCP, set AUX FUEL switch to OFF (down).
STEP 5. Open left front doors, left rear doors, and right rear doors.
STEP 6. Verify continuity between auxiliary fuel pump valve (AFPV) pin 2 and TB5-21
(FO-1, sheet 3). Repair or replace wire harness (WP 0088).
STEP 7. Measure resistance between AFPV-1 and TB5-21. If resistance not between 40
and 80 ohms, replace AFPV (WP 0059).
STEP 8. Verify the problem has been resolved.

MALFUNCTION
Fuel Level Switch Assembly.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Measure resistance between fuel level switch assembly FL2B at J8-2 and relay
AFPR-8. If not less than 2 ohms, repair or replace wire harness (WP 0088).
STEP 3. Measure resistance between fuel level switch assembly FL2B at J8-1 and AUX
FUEL pump switch (AFPS) pin 1 (FO-1, sheet 3 and FO-4, sheet 5). If not less
than 2 ohms, repair or replace wire harness (WP 0088).
STEP 4. Check for continuity between J8-3 and AFPV pin 14.
a. If continuity exists, proceed to STEP 5.
b. If continuity does not exist, troubleshoot wiring (WP 0088).
STEP 5. Unplug connector P8 from fuel level switch assembly FL2 (WP 0056).
STEP 6. If fuel tank level indicator on EMCP shows between 3/4 and FULL, measure
continuity between J8-1 and J8-2. If not open circuit, replace fuel level switch
assembly (WP 0056).

0011-40
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 7. If fuel tank level is between 3/4 and FULL, measure continuity between J8-3 and
J8-2. If not open circuit, replace fuel level switch assembly (WP 0056).
STEP 8. If fuel tank level is below 1/2, measure continuity between J8-1 and J8-2. If not
short circuit, replace fuel level switch assembly (WP 0056).
STEP 9. If fuel tank level is below 1/2, measure continuity between J8-2 and J8-3. If not
short circuit, replace fuel level switch assembly (WP 0056).
STEP 10. If fuel tank level is above 5/8 measure continuity between J8-3 and J8-2. If not
open circuit, replace fuel level switch assembly (WP 0056).
STEP 11. Verify the problem has been resolved.

MALFUNCTION
Auxiliary Fuel Pump Relay.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Measure resistance between float level switch FL2B at J8-3 and TB5-21.
STEP 3. If not between 600 and 800 ohms, repair or replace wire harness (WP 0088) or
replace AFPR (WP 0059).
STEP 4. If between 600 and 800 ohms, check fuel level switch assembly (WP 0056).
STEP 5. Verify the problem has been resolved.

MALFUNCTION
Auxiliary Fuel Pump Faulty.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Open control box (WP 0020).
STEP 3. Measure resistance between relay AFPR-9 and TB3-10 (FO-4, sheet 2 and
sheet 4). If not between 40 and 80 ohms, repair or replace wire harness
(WP 0044).
STEP 4. Verify wire from auxiliary fuel pump is connected securely to AFPV-1 (WP 0059).
If not secure, repair wiring (WP 0088) or replace auxiliary fuel pump (WP 0059).
STEP 5. Verify the problem has been resolved.

0011-41
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

SYMPTOM
31. Engine Runs Out of Fuel With No LOW FUEL LEVEL Alarm.

MALFUNCTION
Fuel Level Switch Assembly.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. On EMCP, set AUX FUEL switch to OFF (down).
STEP 3. Open left front doors, left rear doors, and right rear doors.
STEP 4. Unplug P11 from low fuel alarm switch FL1 (WP 0056 and FO-1, sheet 3).
STEP 5. With fuel level above two inches or fuel level indicator on EMCP showing fuel,
measure resistance between J11-1 and J11-2 (FO-1, sheet 3). If not open circuit,
replace fuel level switch assembly (WP 0056).
STEP 6. With fuel level below two inches or fuel level indicator showing empty, measure
resistance between J11-1 and J11-2. If not less than 2 ohms, replace fuel level
switch assembly (WP 0056).
STEP 7. Verify the problem has been resolved.

0011-42
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

SYMPTOM
32. Alternator Does Not Charge Batteries.

MALFUNCTION
Alternator Drive Belt Loose or Defective.

CORRECTIVE ACTION
STEP 1. On EMCP set Engine Control switch to OFF/RESET. Set Battery Disconnect
Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect the condition of the alternator drive belt. If the alternator drive belt is worn
or damaged, replace drive belt (WP 0075).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Charging Circuit Defective.

CORRECTIVE ACTION
STEP 1. On EMCP set Engine Control switch to OFF/RESET. Set Battery Disconnect
Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect cables between battery, Battery Disconnect Switch, and starter solenoid
(FO-1, sheet 2).

a. Check shunt (R4) for loose/corroded connections. Clean and tighten as

required.
b. Clean and tighten battery cable ends, as required.
c. Replace cable(s), as required (WP 0047).
d. If voltage is correct, perform load test on batteries individually
(WP 0050).
e. If battery fails, replace battery (WP 0050).
f. If batteries pass load test, charge batteries fully (WP 0050).
g. If voltage is not correct, inspect Battery Disconnect Switch and battery
charging circuit (FO-1, sheet 2) or replace alternator (WP 0074).
STEP 3. Set Battery Disconnect Switch to on. Set DEAD CRANK switch to NORMAL.
Turn the ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 4. Observe and record battery voltage on GSC display.
a. Set Engine Control Switch to MANUAL START.
b. Observe battery voltage on GSC display. Battery voltage should be
2 Vdc higher than recorded voltage.
c. If voltage falls below minimum, replace alternator (WP 0074).
STEP 5. Verify the problem has been resolved.

0011-43
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

SYMPTOM
33. Coolant in Engine Oil.

MALFUNCTION
Oil Cooler Failure.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect oil cooler for leaks or damage. Replace oil cooler as required (WP 0108).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Cylinder Head Gasket Failure.

CORRECTIVE ACTION
STEP 1. Replace cylinder head gasket (WP 0120).
STEP 2. Verify the problem has been resolved.

MALFUNCTION
Cracked Cylinder Head.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL Switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect cylinder head for cracks. Replace cylinder head as required (WP 0120).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Water Pump Failure.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL Switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect the weep hole in the water pump for blockage. Check for signs of
leakage around water pump seals. Replace water pump as required (WP 0110).
STEP 3. Verify the problem has been resolved.

0011-44
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

MALFUNCTION
Internal engine leakage.

CORRECTIVE ACTION
STEP 1. Replace the engine (WP 0096).
STEP 2. Verify the problem has been resolved.
SYMPTOM
34. Coolant Temperature Too High.

MALFUNCTION
Excessive Load.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Ensure that the load is not excessive. Redistribute or disengage loads as
required.
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Radiator.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Ensure that the engines exhaust does not heat the radiator.
STEP 3. Ensure the air inlet area of the radiator is not obstructed.
STEP 4. Check the fins of the radiator for damage or obstructions. Repair/clean as
required (WP 0068).
STEP 5. Verify the problem has been resolved.

MALFUNCTION
Low Coolant Level.

CORRECTIVE ACTION
STEP 1. On EMCP set Engine Control switch to OFF/RESET. Set Battery Disconnect
Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Allow generator set to cool and check coolant level. Add coolant as required.
STEP 3. Pressurize the cooling system to 3 psi (20 kPa) greater than the coolant fill cap
rating (13 to 16 psi (90 to 800 kPa)).
STEP 4. Inspect all cooling system components for leaks. Repair or replace components
as required (WP 0064, WP 0067, WP 0068, WP 0110, and WP 0081).

0011-45
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TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 5. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to MANUAL START.
STEP 6. Run the engine to operating temperature. If coolant temperature is normal,
proceed to STEP 17.
STEP 7. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 8. Allow generator set to cool and check coolant level. Add coolant as required.
STEP 9. Check for presence of coolant in engine oil. If coolant is present in engine oil,
troubleshoot per SYMPTOM 33.
STEP 10. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to MANUAL START.
STEP 11. Run the engine to operating temperature. If coolant temperature is normal,
proceed to STEP 17
STEP 12. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 13. Allow generator set to cool and check coolant level. Add coolant as required.
STEP 14. Pressurize the cooling system to 3 psi (20 kPa) greater than the coolant fill cap
rating (13 to 16 psi (90 to 800 kPa)).
STEP 15. If pressure reading is not stable after five minutes, inspect all cooling system
components for leaks. Repair or replace components as required (WP 0064,
WP 0067, WP 0068, WP 0110, and WP 0081).
STEP 16. Pressurize the cooling system to 3 psi (20 kPa) greater than the coolant fill cap
rating (13 to 16 psi (90 to 800 kPa)). If pressure reading is not stable after five
minutes, replace the engine (WP 0096).
STEP 17. Verify the problem has been resolved.

MALFUNCTION
Air in Coolant.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect coolant fill cap for damage. Replace coolant fill cap as required.
STEP 3. If coolant has been replaced recently, ensure that air has been purged from the
cooling system by running the engine for a few minutes.
STEP 4. Verify the problem has been resolved.

0011-46
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

MALFUNCTION
Thermostat Malfunction.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Remove and inspect thermostat. Replace as required (WP 0081).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Water Pump Malfunction.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect alternator belt. Replace or tighten as required (WP 0075).
STEP 3. Inspect water pump impeller. Replace water pump if impeller is damaged
(WP 0110).
STEP 4. Verify the problem has been resolved.

MALFUNCTION
Engine Coolant Flow Restrictions.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. If a buildup of deposits in the cooling system is suspected, clean the cooling
system (WP 0067 and WP 0068).
STEP 3. If the flow of coolant through the engine is not sufficient, determine the cause of
obstruction and repair as required.
STEP 4. Verify the problem has been resolved.

MALFUNCTION
Exhaust Restriction.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect the exhaust pipes and muffler for damage that could cause restrictions.
Repair or replace as required (WP 0069).
STEP 3. Ensure that the exhaust gases are not being drawn into the intake air inlet.
STEP 4. Verify the problem has been resolved.

0011-47
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TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

MALFUNCTION
Combustion Gases in Coolant.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Check for combustion gases in coolant. Combustion gases in coolant can be
identified by small air bubbles in the coolant during engine operation. If
combustion gases are present, replace the engine (WP 0096).
STEP 3. Verify the problem has been resolved.

SYMPTOM
35. ECM Will Not Communicate With Other Systems or Display Modules.

MALFUNCTION
Wire or Connector Pins Corroded or Damaged.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Disconnect harness connector ENG-P1 from ECM connector J1, harness
connector CDC-P7, and harness connector ENG-P37 from generator connector
J37 (WP 0088).
STEP 3. Inspect harness connectors ENG-P1, CDC-P7, and ENG-P37, and generator
connector J37 for corrosion or damage. Repair or replace harness as required
(WP 0088).
STEP 4. Conduct Wiggle Test (WP 0013, SYMPTOM 1) on each of the harness wires that
are associated with the Cat data link (FO-2, sheet 2 and WP 0088). Repair or
replace harness as required (WP 0088).
STEP 5. Verify the problem has been resolved.

MALFUNCTION
Cat Data Link Circuitry Short Circuit.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL Switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Disconnect ENG-P1 harness connector from ECM connector J1.
STEP 3. Measure the resistance between ENG-P1 harness connector pin 8 and all other
connector pins. All measurements should indicate open, if not repair or replace
harness (WP 0088).

0011-48
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

CORRECTIVE ACTION - Continued

STEP 4. Measure the resistance between ENG-P1 harness connector pin 9 and all other
connector pins. All measurements should indicate open, if not repair or replace
harness (WP 0088).
STEP 5. Verify the problem has been resolved.

MALFUNCTION
Cat Data Link Circuitry Open Circuit.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Remove cap from harness connector CDC-P7. Disconnect ENG-P1 and
ENG-37.
STEP 3. Install a jumper wire between Cat data link harness connector CDC-P7 pins D
and E.
STEP 4. Measure the resistance between ENG-P1 harness connector pins 8 and 9. All
measurements should indicate a short, if not repair or replace harness
(WP 0088).
STEP 5. Measure the resistance between ENG-P37 harness connector pins 19 and 20.
All measurements should indicate a short, if not repair or replace harness
(WP 0088).
STEP 6. Measure the resistance between ENG-P37 pins 19 and 20. All measurements
should indicate a short, if not repair or replace harness (WP 0088) If the ECM
does not operate properly, replace ECM (WP 0082).
STEP 7. Remove jumper.
STEP 8. Verify the problem has been resolved.

SYMPTOM
36. Engine Oil in Coolant.

MALFUNCTION
Oil Cooler Failure.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect oil cooler for leaks or damage. Replace oil cooler as required (WP 0108).
STEP 3. Verify the problem has been resolved.

0011-49
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

MALFUNCTION
Cylinder Head Gasket Failure.

CORRECTIVE ACTION
STEP 1. Inspect cylinder head for signs of seepage, if present, replace cylinder head
gasket (WP 0120).
STEP 2. Verify the problem has been resolved.

MALFUNCTION
Cracked Cylinder Head Defect.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect cylinder head for cracks. Repair/replace cylinder head as required
(WP 0120).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Water Pump Failure.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect the weep hole in the water pump for blockage. Check for signs of
leakage around water pump seals. Replace water pump as required (WP 0110).
STEP 3. Verify the problem has been resolved.

SYMPTOM
37. Engine Oil in Exhaust System.

MALFUNCTION
Crankcase Ventilation System Failure.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect crankcase ventilation filter and replace if necessary (WP 0070).
STEP 3. Verify the problem has been resolved.

0011-50
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

MALFUNCTION
Turbocharger Seals Failure.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect the turbocharger inlet and exhaust manifolds for engine oil. If oil is
present, replace turbocharger (WP 0103).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Worn or Damaged Valve Guide Seals.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect valve guide seals for wear or damage. Replace cylinder head (WP 0120).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Internal engine oil leakage/Excessive Blow-by.

CORRECTIVE ACTION
STEP 1. Internal engine oil leakage is suspected. Replace engine (WP 0096).
STEP 2. Verify the problem has been resolved.

SYMPTOM
38. Engine Oil Temperature Too High.

MALFUNCTION
Incorrect Engine Oil Specification/Rating.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Verify correct engine oil type and temperature rating for rated engine (WP 0016).
STEP 3. Verify the problem has been resolved.

0011-51
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

MALFUNCTION
Incorrect Oil Level.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect engine oil level. Add correct engine oil as necessary (TM 9-6115-730-10,
WP 0016).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Coolant Temperature is Too High.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. See Coolant Temperature is Too High troubleshooting procedure (SYMPTOM
34).

MALFUNCTION
Engine Oil Cooler Bypass Valve.

CORRECTIVE ACTION
STEP 1. On EMCP set Engine Control switch to OFF/RESET. Set Battery Disconnect
Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Clean and inspect the engine oil cooler bypass valve. Clean the bore of the
bypass valve and ensure the valve is not stuck in the open position. Replace the
bypass valve if necessary (WP 0107).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Engine Oil Cooler Failure.

CORRECTIVE ACTION
STEP 1. On EMCP set Engine Control switch to OFF/RESET. Set Battery Disconnect
Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect for engine oil cooler for damage, blockage, or restrictions in the engine oil
cooler oil passages. Replace the engine oil cooler if necessary (WP 0108).
STEP 3. Verify the problem has been resolved.

0011-52
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

SYMPTOM
39. Engine Vibration.

MALFUNCTION
Engine Misfires or Runs Rough.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. See Engine misfires, runs rough, or is unstable troubleshooting procedure
(SYMPTOM 21).

MALFUNCTION
Engine Vibration Damper Defective.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect the engine vibration damper for damage. Inspect for loose, missing, or
damaged mounting bolts. Replace vibration damper or mounting bolts as
necessary (WP 0104).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Engine Shock Mounts Defective.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect the engine shock mounts and brackets with the engine running through
the speed range. Check for mounts and brackets that loose, missing parts, or
damaged. Tighten or replace engine shock mounts as necessary (WP 0096).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Generator Alignment Incorrect.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect for loose, missing, or damaged generator mounting hardware. Ensure
generator to engine connecting hardware is complete and secure (WP 0095).
STEP 3. Verify the problem has been resolved.

0011-53
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

SYMPTOM
40. Excessive Engine Oil Consumption.

MALFUNCTION
Oil Leaks.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect the engine for oil leaks. Repair oil leaks as required.
STEP 3. Check for dirty or clogged crankcase ventilation filters. Clean or replace filters
(WP 0070).
STEP 4. Verify the problem has been resolved.

MALFUNCTION
Engine Oil Cooler Defective.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Check for engine oil leaks around the engine oil cooler also check for engine oil
in engine coolant. Repair or replace engine oil cooler (WP 0108).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Turbocharger Defective.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect the air inlet manifold for engine oil. Check for engine oil leakage past the
seal rings in the impeller end of the turbocharger shaft. Replace the
turbocharger if engine oil leakage is found (WP 0103).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Valve Guides Defective.

CORRECTIVE ACTION
STEP 1. If valve guide wear is suspected, replace cylinder head assembly (WP 0120).
STEP 2. Verify the problem has been resolved.

0011-54
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

MALFUNCTION
Piston Rings Defective/Excessive Blowby.

CORRECTIVE ACTION
STEP 1. If piston ring wear or damage is suspected, replace the engine (WP 0096).
STEP 2. Verify the problem has been resolved.

SYMPTOM
41. Excessive Valve Lash.

MALFUNCTION
Lack of Lubrication to Rocker Shaft Assembly.

CORRECTIVE ACTION
Remove valve cover (WP 0100) and inspect for adequate engine oil at rocker shaft assembly
and valves. If rocker shaft assembly or valves lack engine oil, troubleshoot low engine oil
pressure (SYMPTOM 45).

MALFUNCTION
Valve Lash Adjustment Incorrect.

CORRECTIVE ACTION
STEP 1. Visually inspect rocker shaft and valve components for excessive wear. Replace
worn components as required (WP 0119).
STEP 2. If rocker shaft and valve components are not excessively worn, adjust valve lash
(WP 0119).
STEP 3. Verify the problem has been resolved.

SYMPTOM
42. Exhaust Temperature is Too High.

MALFUNCTION
Air Inlet and Exhaust Malfunctions.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect for air inlet for restrictions or leaks. Clear restrictions and repair leaks
(WP 0102).
STEP 3. Inspect for exhaust restrictions. Inspect for leaks between exhaust manifold and
turbocharger. Clear restrictions and repair leaks (WP 0115).
STEP 4. Verify the problem has been resolved.

0011-55
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

MALFUNCTION
Electrical Connections Faulty.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect harness connector ENG-P2 and ECM mating connector J2 and unit
injector cable connectors ENG-P300 and J300 (WP 0088). Ensure connectors
are properly seated and secure.
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Unresolved Diagnostic Codes.

CORRECTIVE ACTION
Check for inactive diagnostic codes in historical log that relate to exhaust temperature.
Correct malfunctions as required (WP 0008 and WP 0009).

SYMPTOM
43. Fuel in Engine Oil.

MALFUNCTION
Fuel Unit Injectors Leaking.

CORRECTIVE ACTION
STEP 1. Inspect unit injectors for leaking seals and damage and to ensure unit injectors
are secure. Tighten unit injectors or replace as required (WP 0118).
STEP 2. Verify the problem has been resolved.

MALFUNCTION
Fuel Lines Leaking.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Inspect fuel hose connected to the cylinder head for leaks. Replace seals or fuel
hoses as required (WP 0057).
STEP 3. Verify the problem has been resolved.

0011-56
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

MALFUNCTION
Crack in Cylinder Head.

CORRECTIVE ACTION
STEP 1. Inspect cylinder head for crack in fuel supply galley or around unit injectors.
STEP 2. Replace cylinder head as necessary (WP 0120).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Fuel Transfer Pump Defective.

CORRECTIVE ACTION
STEP 1. Inspect fuel transfer pump and fuel hoses for leaks.
STEP 2. Replace fuel transfer pump or fuel hoses as required (WP 0102 and WP 0057).
STEP 3. Verify the problem has been resolved.

SYMPTOM
44. Intermittent Low Power or Power Cutout.

MALFUNCTION
Unresolved Diagnostic Codes.

CORRECTIVE ACTION
Check inactive diagnostic codes. Correct malfunctions as required (WP 0008 and WP 0009).

MALFUNCTION
Throttle Malfunction.

CORRECTIVE ACTION
Verify that the status of the throttle position is stable and that the engine is able to reach high
idle speed. If any requirement is not met, perform Speed Control Test (WP 0013,
SYMPTOM 6).

0011-57
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

MALFUNCTION
Low Fuel Pressure.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Check fuel hoses for cuts, kinks, and other obstructions. Repair or replace fuel
hoses as required (WP 0057).
STEP 3. Inspect the fuel tank for foreign material that may block the fuel pickup tube or
fuel hoses. Remove contaminants and foreign objects from fuel tank (per TM 9-
6115-730-10).
STEP 4. Check for air in the fuel system. If air in the fuel is found, check that all fuel
fittings are tight and secure. Purge the air from the fuel system using the priming
pump.
STEP 5. Check for fault codes indicating fuel filter restrictions. Correct any faults indicated
(WP 0008 and WP 0009).
STEP 6. If fuel pressure is still low, replace fuel transfer pump (WP 0102).
STEP 7. Verify the problem has been resolved.

SYMPTOM
45. Low Engine Oil Pressure.

MALFUNCTION
Oil Level Too Low.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Check engine oil level. Add engine oil as necessary ( per TM 9-6115-730-10).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Oil Pressure Sensor Malfunction.

CORRECTIVE ACTION
STEP 1. Check for inactive diagnostic codes. Resolve codes as required.
STEP 2. Verify oil pressure with a 100 PSI minimum gauge connected to oil manifold near
oil pressure sensor. If oil pressure not correct, replace engine oil pressure
sensor WP 0098).
STEP 3. Verify the problem has been resolved.

0011-58
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

MALFUNCTION
Oil Filter Defective.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Replace the engine oil filter. Inspect the engine oil check valve in the oil filter
base. Clean or replace components as required (WP 0107).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Engine Oil Cooler Defective.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Check for engine oil leaks around the engine oil cooler also check for engine oil
in engine coolant. Repair or replace engine oil cooler (WP 0108).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Fuel in Engine Oil.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Refer to Fuel in Engine Oil procedure troubleshooting procedure
(SYMPTOM 43).

0011-59
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

MALFUNCTION
Camshaft or Crankshaft Defective.

CORRECTIVE ACTION
STEP 1. If the camshaft of crankshaft is suspected of being defective, replace the engine
(WP 0096).
STEP 2. Verify the problem has been resolved.

SYMPTOM
46. Mechanical Noise (Knock) in Engine.

MALFUNCTION
Valve Train Components Defective.

CORRECTIVE ACTION
STEP 1. Inspect the valve train components.
STEP 2. Replace damaged components as required (WP 0119).
STEP 3. If components are not damaged or worn, perform valve lash adjustment
(WP 0119).
STEP 4. Verify the problem has been resolved.

MALFUNCTION
Internal engine problem.

CORRECTIVE ACTION
STEP 1. Replace the engine (WP 0096).
STEP 2. Verify the problem has been resolved.

0011-60
 TM 9-6115-730-24 0011

TROUBLESHOOTING FAILURES WITHOUT FAULT CODES - Continued

SYMPTOM
47. Noise Coming From Cylinder.

MALFUNCTION
Unresolved Diagnostic Codes.

CORRECTIVE ACTION
Check for active diagnostic codes. Correct malfunctions as required (WP 0008 and
WP 0009).

MALFUNCTION
Fuel Supply Problem.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Verify the correct fuel is being used for current environmental conditions. Change
fuel as required (per TM 9-6115-730-10).
STEP 3. Verify the problem has been resolved.

MALFUNCTION
Unit Injector Malfunction.

CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Disconnect harness connector ENG-P1 from ECM connector J1, harness
connector P7 from GSC connector J7, and harness connector ENG-P300 from
valve cover connector J300 (WP 0088).
a. Perform Injector Solenoid Test (WP 0013, SYMPTOM 5). Repair as
required.
b. Thoroughly inspect harness connectors ENG-P1, P7, ENG-P37, and
generator connector J37 (WP 0088) for corrosion or damage. Repair or replace
harness as required (WP 0088).
STEP 3. Perform Cylinder Cutout test (WP 0013, SYMPTOM 5).
STEP 4. Verify the problem has been resolved.

END OF WORK PACKAGE

0011-61/62 blank
 TM 9-6115-730-24 0012

FIELD LEVEL TROUBLESHOOTING

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-807A/PU-807A
ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING SOFTWARE INSTALLATION

INTRODUCTION

Before using the Electronic Technician (ET) tool for fault isolation, make note and record all of the fault codes
available on the GSC and DVR. Also, note and record any fault lamps that are lit on the GSC and the alarm
module. Complete all other Field level troubleshooting. (WP 0004 thru WP 0011).

The failure analysis can begin with a single fault code indication. Because of extensive self-testing capability, a
single failure will often generate multiple fault codes. (e.g. a failure of a power supply will generate a failure code for
all of the sensors powered up by that power supply). It may be necessary to read through all of the associated fault
isolation procedures prior to starting in order to assess the fault location.

The voltages and currents in the 200 kW TQG are dangerous and capable of causing death instantaneously. The
engine and generator set are heavy and represent enormous mechanical power. Refer to the WARNING
SUMMARY before attempting to troubleshoot system. The following warnings, cautions, and notes should be read
and followed during all attempts at troubleshooting.

NOTE
100/200 kW TQG Cat ET software/program is for use on the 100/200 kW TQGs only. Loading 100/200
kW TQG Cat ET software will overwrite existing Cat ET software/program. If commercial Cat ET
software is to be reinstalled, record the licensing data prior to installing 100/200 kW TQG Cat ET
software/program. The licensing data must be reloaded when reinstalling the original (previous) Cat ET
software/program.

WARNING
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

High voltage is produced when this generator set is in operation. Make sure unit is completely
shut down and free of any power source before attempting any repair or maintenance on the
unit. Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

WARNING
Dangerously high voltage can exist across current transformer (CT) output with engine running.
CT could explode if disconnected from load with engine running. Do not disconnect CT with
generator rotating. Failure to comply can cause serious injury or death to personnel.

0012-1
 TM 9-6115-730-24 0012

TROUBLESHOOTING USING MAINTENANCE SUPPORT DEVICE (MSD) AND ELECTRONIC TECHNICIAN

(ET) TOOL

The MSD is a military laptop computer that interfaces with the TQG via a Caterpillar Communications Adapter
that is connected to the engine wire harness and the GSC.

NOTE
The MSD must be configured to interface the GSC/ECM.
Software for Caterpillar Communication Adapter II should be preloaded into MSD. Refer to
Caterpillar Service Tool Hardware and Software/User’s Manual Communication Adapter II, Ver
1.93 (1.9-B4) and CD NEHS0758.

To configure MSD to interface GSC/ECM, perform the following procedure:

STEP 1. On the EMCP, set ENGINE CONTROL switch to OFF/RESET. Set the Battery Disconnect Switch
to OFF. Set the DEAD CRANK SWITCH to OFF.

STEP 2. Connect data link cable between ECM to Electronic Modular Control Panel (EMCP) harness
connector CDC-P7 and communications adapter.

STEP 3. Connect serial PC cable to MSD COMM1 port. Connect power to the PC.

STEP 4. Start and operate TQG per TM 9-6115-730-10.

Figure 1. Connecting Caterpillar Communication Adapter.

0012-2
 TM 9-6115-730-24 0012

TROUBLESHOOTING USING MAINTENANCE SUPPORT DEVICE (MSD) AND ELECTRONIC TECHNICIAN

(ET) TOOL - Continued

NOTE
Software for Caterpillar Communication Adapter II should be preloaded into MSD. Refer to
Caterpillar Service Tool Hardware and Software/User’s Manual Communication Adapter II, Ver
1.93 (1.9-B4) and CD NEHS0758.

STEP 5. Press POWER switch on MSD and load CD ROM disc.

STEP 6. Select D:\ drive and open CD ROM disc.

END OF TASK

LOADING ELECTRONIC TECHNICIAN (ET) SOFTWARE

When you are directed to use Caterpillar proprietary Electronic Technician (ET) software from Unit (Field Level)
maintenance troubleshooting, you must load ET software into the MSD. The ET Getting Started Manual will be on
the CD ROM with the Communications Adapter interface software as ET 2002B Getting Started.pdf. There should
be no licensing or registration requirements while loading the Cat ET software/program.

STEP 1. Open Getting Started.pdf document on the CD ROM.

STEP 2. Install ET Caterpillar software media # EERE3500 as instructed in Caterpillar Service Tool
Software/Getting Started Manual.

STEP 3. For all other information pertaining to operation, troubleshooting, and transferring to another
computer, consult Caterpillar Service Tool Software/Getting Started Manual contained on the
CD ROM.

Caterpillar Electronic Service Tools are designed to help the service technician:
a. Obtain data.
b. Diagnose problems.
c. Read parameters.
d. Program parameters.
e. Calibrate sensors.

END OF TASK

0012-3
 TM 9-6115-730-24 0012

USING ELECTRONIC TECHNICIAN (ET) SOFTWARE

The basic Caterpillar ET operations are addressed in the instructions that follow. Figure 2 shows the
Caterpillar ET opening screen and Table 1 shows the primary navigation icons and their uses.

STEP 1. Select the Electronic Technician icon on the desktop of the MSD computer being used or select
the Electronic Technician program under Start/Programs/Caterpillar ET.

STEP 2. If a message This program is not licensed. License the program now? appears, select YES and
follow the on screen instructions or follow steps 4 through 12 in the previous section titled
TROUBLESHOOTING USING ELECTRONIC TECHNICIAN (ET).

STEP 3. On the ET screen, select the Connect icon (Table 1).

a. If the ET cannot communicate (CONNECT) with the ECM, check the ET communication
settings by selecting Utilities pull down menu, select Preferences. For communications with
the Caterpillar Communication Adapter II, COM 1 should be selected. Click on Advanced
button. The baud rate should be 57600.
b. Click OK to close the Baud Rate window. Click OK to close the Preferences window. Select
the Connect icon again.
STEP 4. At menu selection, choose the C-12 Industrial Engine.

STEP 5. After communications connection is established, the ECM Summary window is displayed. All of
the top tool bar ICONS (Table 1) should now be available.

STEP 6. Select Active Diagnostics Codes by clicking on the Active Diagnostics Codes icon or click on the
pull down menu for Diagnostics and selecting Active Diag. Codes.
a. The codes listed in the Active Diagnostics Code list are shown with the top priority code from
the top down. The first code shown is the most important and must be corrected first.
b. If other GSC codes have brought you to this ET screen for troubleshooting a problem, the top
priority Active Diagnostic Code problems must be corrected first.

STEP 7. Select Logged Diagnostic Codes by clicking on the Logged Diagnostic Codes icon or click on the
pull down menu for Diagnostics and selecting Logged Diag. Codes.
a. The codes listed in the Logged Diagnostics Code list are shown with the top priority code from
the top down. The first code shown is the most important and must be corrected first. These
codes are the same as the Active Diagnostic Codes except they are logged over time.
b. To CLEAR any or all of the Logged Diagnostic Codes, click on a Logged Diagnostic Code in
the list to highlight it. Click on the CLEAR button in the lower left corner of the page.
(1) A pop up window appears with the message Are you sure you want to clear the code?
(2) Click on the YES button to clear the code from the list.

0012-4
 TM 9-6115-730-24 0012

USING ELECTRONIC TECHNICIAN (ET) SOFTWARE - Continued

Figure 2. Caterpillar ET Opening Screen.

0012-5
 TM 9-6115-730-24 0012

USING ELECTRONIC TECHNICIAN (ET) SOFTWARE - Continued

Table 1. Caterpillar ET Tool Navigation Icons.

0012-6
 TM 9-6115-730-24 0012

USING ELECTRONIC TECHNICIAN (ET) SOFTWARE - Continued

STEP 8. To run the Diagnostic Tests, click on the pull down menu for Diagnostics, then select Diagnostic
Tests (Figure 3).
a. The Diagnostics Tests can run the following tests:
(1) Injector Solenoid Test
(2) Ether Injection System Test
(3) Override Parameters
(4) Cylinder Cutout Test
(5) Wiggle Test
b. Select the test called out in the troubleshooting work package and follow the on screen
instructions.

0012-7
 TM 9-6115-730-24 0012

USING ELECTRONIC TECHNICIAN (ET) SOFTWARE - Continued

Figure 3. Cat ET Diagnostic Tests.

END OF TASK

END OF WORK PACKAGE

0012-8
 TM 9-6115-730-24 0013

FIELD LEVEL TROUBLESHOOTING

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING

INITIAL SETUP:

Tools and Special Tools References

146-4080 Digital Multimeter or Equivalent WP 0083

Caterpillar Electronic Technician (Cat ET) WP 0088
Software Media # NEXG5039 and # JEBD3003 FO-2
EERE3500 Cat ET for Military 100 and 200 TQG FO-4
171-4400 Comm. Adapter II Group or Equivalent
4C-4911 Battery Load Tester or Equivalent Personnel Required

Materials/Parts One

18 gauge wire per M22759/16-18-9

88-21943 contacts
Engine oil, 2D-6392

ELECTRONIC TECHNICIAN (FIELD) LEVEL TROUBLESHOOTING

NOTE
100/200 kW TQG Cat ET software/program is for use on the 100/200 kW TQGs only. Loading
100/200 kW TQG Cat ET software will overwrite existing Cat ET software/program. If commercia l
Cat ET software is to be reinstalled, record the licensing data prior to installing 100/200 kW TQG
Cat ET software/program. The licensing data must be reloaded when reinstalling the original
(previous) Cat ET software/program.

WARNING
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

High voltage is produced when this generator set is in operation. Make sure unit is completely
shut down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

0013-1
 TM 9-6115-730-24 0013

ELECTRONIC TECHNICIAN (FIELD) LEVEL TROUBLESHOOTING - Continued

Field Level Troubleshooting for the Tactical Quiet Generator uses the Caterpillar Electronic Technician (ET)
software and the Caterpillar Communication Adapter Group as described in WP 0012. References to Caterpillar
ET are included in other sections of the Field level troubleshooting procedures. All other Field level troubleshooting
should be performed before progressing to the ELECTRONIC TECHNICIAN procedures.

ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING

SYMPTOM
1. Electrical Connectors Wiggle Test.

System Operation Description:

Most electrical problems are caused by poor connections. The following procedure will assist in detecting
problems with connectors and with wiring. If a problem is found correct the condition and verify that the problem
is resolved.

Intermittent electrical problems are sometimes resolved by disconnecting and reconnecting connectors. It is very
important to check for diagnostic codes immediately before disconnecting a connector. Also check for diagnostic
codes after reconnecting the connector. If the status of a diagnostic code is changed due to disconnecting and
reconnecting a connector, there are several possible reasons. The likely reasons are loose terminals, improperly
crimped terminals, moisture, corrosion, and inadequate mating of a connection.

NOTE
Perform the following test only after completing the tests in WP 0088.

MALFUNCTION
Electrical voltage or signal intermittent/erratic.
CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Connect the Cat ET to connector CDC-P7 (WP 0012).
STEP 3. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 4. Perform the Wiggle Test on the Cat ET.
a. Select the Wiggle Test from the Diagnostic Tests on Cat ET.
b. Choose the appropriate group of parameters to monitor.
c. Press the Start button for the Wiggle Test. Wiggle the wiring harness in
order to reproduce intermittent problems. If an intermittent problem exists,
the status will be highlighted and an audible beep will be heard.

0013-2
 TM 9-6115-730-24 0013

ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

d. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery

Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
(1) If no intermittent problems were indicated during the Wiggle Test, the
harness and connectors appear to be OK. If you were sent from another
procedure, return to the procedure and continue testing. If this test has
resolved the problem, return the engine to service.
(2) If at least one intermittent problem was indicated, repair the harness or
the connector (WP 0088).
(3) Verify that the repair eliminates the problem.

SYMPTOM
2. Electrical Power Supply Circuit Test.

System Operation Description:

Use this procedure and Figure 1 to troubleshoot any suspect problems with the electrical supply to the engine’s
Electronic Control Module (ECM). This procedure covers the following diagnostic code:

x 168-02 System voltage intermittent/erratic

x 168-03 System voltage above normal
x 168-04 System voltage below normal

A signal from the ENGINE CONTROL switch (ESC) is provided to generator set control (GSC) interface to the
ECM and tells the ECM the position of the ECS. When the ECM senses battery voltage to the GSC interface to
the ECM, the ECM will power up. The GSC receives battery voltage when the ECS is in the AUTO, MANUAL
START or COOL DOWN/STOP positions. If the voltage is removed from the GSC, the ECM will power down.
Cycling power to the GSC interface to the ECM will reset the ECM. The electrical power for the engine comes
through the CB4 circuit breaker and the slave relay to the battery terminals on the ECM. The presence of three
+battery connections and three battery connections to the ECM reduces harness resistance. All of these
connections must be complete in order to ensure proper engine operation. Figure 1 shows the electrical power
supply circuit.

0013-3
 TM 9-6115-730-24 0013

ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

SYMPTOM - Continued

Figure 1. 24 Vdc Electrical Circuits.

0013-4
 TM 9-6115-730-24 0013

ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

MALFUNCTION
168-02 code. Electrical system voltage intermittent/erratic.
168-03 code. Electrical system voltage above normal.
168-04 code. Electrical system voltage below normal.
CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Check the battery voltage.
a. Measure the open circuit voltage at the battery terminals.
b. Load test the batteries (WP 0050). Use the 4C-4911 battery load tester or
equivalent.
(1) If the no-load voltage at the batteries is at least 24 ± 1 Vdc, and the
batteries pass the load test. Proceed to STEP 3.
(2) If the battery voltage is incorrect and/or the battery fails the load test, the
batteries or the alternator are causing the problem. Recharge the
batteries or replace the batteries (WP 0050). Verify that the original
condition is resolved.
STEP 3. Check the voltage to the ECM.
a. Remove ECM connector ENG-P1.
b. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to
NORMAL. On EMCP set ENGINE CONTROL switch to COOL
DOWN/STOP.
c. Measure the voltage between ENG-P1-48 and ENG-P1-61.
d. Measure the voltage between ENG-P1-52 and ENG-P1-63.
e. Measure the voltage between ENG-P1-53 and ENG-P1-65.
f. Measure the voltage between ENG-P1-70 and ENG-P1-65.
g. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
h. Reconnect ECM connector ENG-P1.
(1) If the voltage measured at STEPS 3c., 3d., 3e., and 3f. is 24 ± 3 Vdc.
The ECM is receiving the correct voltage.
(2) On the ECM inputs from the ENGINE CONTROL switch, if the voltage is
not 24 ± 3 Vdc. Proceed to STEP 4.
(3) If the voltage is not 24 ± 3 Vdc at the +battery terminals on ECM
connector P1, proceed to STEP 5.

0013-5
 TM 9-6115-730-24 0013

ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

CORRECTIVE ACTION - Continued

STEP 4. Check the voltage inputs to ENGINE CONTROL switch and to ECM.
a. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to
NORMAL. On EMCP set ENGINE CONTROL switch to COOL
DOWN/STOP.
b. Check the voltage between engine ground and the test points in Table 1. If
voltage is not present at a test point, the problem is in the device, in the wire
or in the connector that precedes the point in the circuit. Refer to Figure 1
and FO-1, Sheet 2 as required).
(1) If the voltage is 24 ± 3 Vdc at all test points, the wire 800KEY001-P19-T
between ECM connector ENG-P1-70 and connector ENG-P37 is
defective. Repair wire 800KEY001-P19-T and/or connections between
connector ENG-P37 and ECM connector ENG-P1-70 (WP 0088).
(2) If the voltage is not 24 ± 3 Vdc at a test point, repair the device,
connectors and/or wiring (WP 0041, WP 0042, WP 0043, WP 0088,
FO-2, sheet 2; FO-4, sheets 1-4).
c. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.

Table 1. ECM Supply Voltage Test Points.

DEVICE (Figure 1) TERMINAL

Diode D1 Either side
DEAD CRANK SWITCH Terminals for NORMAL crank
J30/P30 connector 9
Resistor Assembly A7 11
Resistor Assembly A7 12
GSC RM2
ENGINE CONTROL switch 6
ENGINE CONTROL switch 10
GSC RM1
GSC RM39
TB-4 17-22
Connector ENG-P37 40

0013-6
 TM 9-6115-730-24 0013

ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

CORRECTIVE ACTION - Continued

STEP 5. Check the voltage to the + battery Inputs of the ECM.
a. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to
NORMAL. On EMCP set ENGINE CONTROL switch to COOL
DOWN/STOP.
b. Check the voltage between engine ground and the test points in Table 2. If
voltage is not present at a test point, the problem is in the device, in the wire
or in the connector that precedes the point in the circuit. Refer to Figure 3,
FO-2, sheet 2; and FO-4, sheets 1-4.
(1) If voltage is present on terminal 87 of the slave relay (SRY) but not
present at the ECM, repair the wires between the ECM and the SRY
(WP 0088; FO-3, sheet 1).
(2) If the voltage is not 24 ± 3 Vdc at a test point, check that voltage is
present at terminal 85 and terminal 30 of SRY and voltage is not present
on terminal 87 of SRY, verify that the wire from terminal 86 of SRY has
continuity to the battery. If the wire from terminal 86 of the SRY has
continuity to the battery, replace SRY (WP 0055). Repair the device,
connectors and/or wiring.

Table 2. + Battery Voltage Input to ECM Test Points.

DEVICE TERMINAL

J30/P30 connector 8

Slave relay (SRY) 85

Circuit breaker CB4 1

Circuit breaker CB4 2

SRY 30

SRY 87

c. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery

Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
(1) If voltage is present on terminal 87 of SRY but not present at the ECM,
repair the wires between the ECM and the slave relay (SRY)
(WP 0088, FO-3, sheet 1)).
(2) If the voltage is not 24 ± 3 Vdc at a test point, check that voltage is
present at terminal 85 and terminal 30 of SRY and voltage is not present
on terminal 87 of SRY, verify that the wire from terminal 86 of SRY has
continuity to the battery. If the wire from terminal 86 of SRY has
continuity to the battery, replace SRY (WP 0055). Repair the device,
connectors and/or wiring (WP 0041, WP 0042, WP 0043, WP 0088,
FO-2, Sheet 2; FO-4, Sheets 1-4).
d. Verify the problem has been resolved.

0013-7
 TM 9-6115-730-24 0013

ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

SYMPTOM
3. Engine Timing Sensor Circuit Test.

System Operation Description:

NOTE

The camshaft (top) engine timing sensor functions as the backup in the event the crankshaft
(bottom) engine timing sensor fails.

Use this procedure and Figure 2 to troubleshoot any suspect problems with the following sensors:

x Primary (crankshaft/bottom) engine timing sensor

x Secondary (camshaft/top) engine timing sensor

This procedure covers the following diagnostic codes:

x 190-E-02 Loss of Engine Speed Signal

x 190-E-11 Engine Speed Sensor mechanical failure
x 342-E-02 Loss of Secondary Engine Speed signal
x 342-E-11 Secondary Engine Speed Sensor mechanical failure

Figure 2. Engine Timing Circuit.

MALFUNCTION
Engine Timing Sensor. Erratic, Intermittent, or Incorrect Signal.
Engine Timing Sensor. Failure mode not identifiable (Mechanical Failure).
CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Connect the Cat ET to connector CDC-P7 (WP 0012).
STEP 3. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 4. Turn the ENGINE CONTROL switch to MANUAL START.

0013-8
 TM 9-6115-730-24 0013

ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

CORRECTIVE ACTION - Continued

NOTE
If the engine will not start, monitor the engine rpm on the Cat ET while the engine is being
cranked. The Cat ET may need to be powered from another battery while the engine is being
cranked.

STEP 5. Wait at least 30 seconds for activation of the diagnostic codes. Look for these
codes on the Cat ET:
x 190-E-02
x 190-E-11
x 342-E-02
x 342-E-11
a. If code 190-E-02 is active, refer to WP 0009, SYMPTOM 25, CID 190-E-02.
b. If code 342-E-02 is active, refer to WP 0009, SYMPTOM 39, CID 342-E-02.
c. If codes 190-E-11 and/or 342-E-11 are active, proceed to STEP 6.

NOTE
If the engine will not start and the Cat ET displayed 0 rpm during cranking, select No Engine rpm.

STEP 6. If Engine rpm is not indicated on the Cat ET, check the installation of the sensor
(Figure 3).
a. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
b. Visually inspect the sensor assemblies (Figure 3) without removing the
sensor assemblies from the engine. Flanges of crankshaft timing sensor
(Figure 3, Item 1) and camshaft timing sensor (Figure 3, Item 2) must be
flush against engine in order to ensure proper operation.
c. Inspect brackets (Figure 3, Item 3). Verify that the brackets securely hold the
flanges of the sensors flush against the engine. Verify that the brackets are
not bent. If the bracket is bent or if an obstruction is preventing the sensor
assembly from being installed correctly, the engine will not start.

NOTE
The bracket cannot be replaced separately.

d. Disconnect connector ENG P401 from the crankshaft engine timing (bottom)
sensor. Disconnect connector ENG P402 from the camshaft engine timing
(top) sensor. Remove bolt (Figure 5, Item 4) and washer (Figure 5, Item 5)
and remove the sensor assembly (Figure 5, Item 1 or Item 2) from the
engine.

0013-9
 TM 9-6115-730-24 0013

ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

CORRECTIVE ACTION - Continued

Figure 3. Timing Sensors.

e. Ensure that one O-ring (Figure 3, Item 6) is installed on each sensor. Check
the O-rings for damage. Replace the O-rings, if necessary.
f. If the sensors appear undamaged, perform the following steps.
(1) Lubricate each O-ring ring (Figure 3, Item 6) with clean engine oil.
(2) Fully seat the sensor assembly (Figure 3, Item 1 or Item 2) in the engine.

0013-10
 TM 9-6115-730-24 0013

ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

CORRECTIVE ACTION - Continued

NOTE
If the sensor assembly will not fully seat into the engine, replace the sensor assembly.

(3) Install the bracket bolt (Figure 3, Item 4) and washer (Figure 3, Item 5)
with bracket. Tighten the bracket bolt.
(4) Connect the sensor electrical connectors (ENG P401 to the crankshaft
(bottom) engine timing sensor and ENG P402 to the camshaft (top)
engine timing sensor (FO-2, Sheet 2). Verify that the connectors are
latched on both sides.
(5) Ensure that the harness is properly secured, and that the tie-wraps are
placed in the correct location. Proceed to STEP 7.
g. If one or both of the sensors are damaged, perform the following steps.
(1) Obtain a new sensor assembly.
(2) Lubricate each O-ring ring (Figure 3, Item 6) with clean engine oil.
(3) Fully seat the sensor assembly in the engine. Install the bracket bolt
(Figure 3, Item 4) and washer (Figure 3, Item 5) with bracket.
(4) Tighten the bracket bolt. If the sensor assembly will not fully seat into
the engine, inspect the bracket for damage. Replace the sensor
assembly with an undamaged assembly, if necessary.
(5) Connect the sensor electrical connectors (ENG P401 to the crankshaft
(bottom) engine timing sensor and ENG P402 to the camshaft (top)
engine timing sensor (FO-2, Sheet 2). Verify that the connectors are
latched on both sides.
(6) Ensure that the harness is properly secured, and that the tie-wraps are
placed in the correct location. Retest and verify that the problem is
resolved. Perform Engine Timing Sensor Calibration (WP 0013,
SYMPTOM 8). If the problem is not resolved, proceed to STEP 7.
STEP 7. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 8. Turn the ENGINE CONTROL switch to MANUAL START.
If the engine still will not start and the Cat ET displayed 0 rpm during cranking
perform the following steps.
a. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
b. Install a replacement ECM (WP 0082).
c. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to
NORMAL. On EMCP set ENGINE CONTROL switch to COOL
DOWN/STOP.
d. Turn the ENGINE CONTROL switch to MANUAL START. Verify the problem
is resolved. Perform Engine Timing Sensor Calibration (WP 0013,
SYMPTOM 8).

0013-11
 TM 9-6115-730-24 0013

ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

SYMPTOM
4. Ether Injection System Test.

System Operation Description:

Use this procedure to troubleshoot any suspect problems with the Ether System.

This procedure covers the following diagnostic codes:

x 545-E-05 Ether Start Relay open/short to +batt

x 545-E-06 Ether Start Relay short to ground

The ether injection system (Figure 4) will improve cold weather starting of the engine. The engine’s Electronic
Control Module (ECM) controls the ether injection system. The ether injection system is disabled if there is an
active engine shutdown. The ECM energizes the ether relay for a predetermined amount of time that is based on
the coolant temperature and the inlet manifold air temperature.

The ether injection system is enabled when all of the following conditions occur:

x Ether is enabled in the system configuration parameters.

x Engine speed is less than 35 rpm.
x Coolant temperature or Inlet Manifold air temperature is less than 0°C (32°F).

A test on the Caterpillar Electronic Technician (ET) allows the technician to activate the ether system. The test is
functional when the engine speed is 0 rpm. The test can be activated by selecting the Override Parameters
screen on Cat ET.

Figure 4. Ether Injection System Circuit.

0013-12
 TM 9-6115-730-24 0013

ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

MALFUNCTION
Current is below normal or circuit is open.
Current is above normal or circuit is grounded.
CORRECTIVE ACTION

CAUTION
The Ether Canister must be removed prior to activating this test.

STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery

Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Connect the Cat ET to connector CDC-P7 (WP 0012).
STEP 3. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to COOL DOWN/STOP.
a. Proceed to the Diagnostic Overrides screen on the Cat ET.
b. Activate the Ether Injection System. The Diagnostic Override will activate for
ten seconds.
c. Monitor the active diagnostic code screen on the Cat ET. Check and record
any active diagnostic codes.
d. If no diagnostic codes are active, and the ether system injected ether. The
problem may be intermittent. If the problem is intermittent, refer to WP 0088
and, Electrical Connectors Wiggle Test (WP 0013, SYMPTOM 1) for
information on connectors and wiring.
STEP 4. Ensure the Battery Disconnect Switch is not turned OFF.
STEP 5. Check for 24 Vdc on the ether relay terminal connected to the battery. If not
present, repair or replace the wire, as necessary (WP 0088). Verify the problem
has been resolved. If not, continue to the next step.
a. Locate the terminal with the wire connecting to the ether solenoid.
b. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to
NORMAL. On EMCP set ENGINE CONTROL switch to COOL
DOWN/STOP.
c. Proceed to the Diagnostic Overrides screen on the Cat ET.
d. Activate the Ether Injection System. The diagnostic override will activate for
ten seconds.
e. Measure 24 Vdc on the ether relay terminal connecting the wire to the ether
solenoid. If not, the ether relay is not operating. Proceed to STEP 6. If OK,
continue to the next step.
f. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
g. Verify continuity from the terminal on the ether solenoid to the ether relay.
Repair or replace if necessary (WP 0088). Verify the problem has been
resolved. If not, continue to the next step.

0013-13
 TM 9-6115-730-24 0013

ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

CORRECTIVE ACTION - Continued

h. Verify continuity from the other terminal on the ether solenoid to the Battery
Disconnect Switch, ENG-P213-2, and engine ground. Repair or replace if
necessary (WP 0088). Verify the problem has been resolved. If not,
continue to the next step.
i. If all continuity measurements are good and the problem has not been
resolved, replace the ether solenoid (WP 0073). Verify the problem has
been resolved. If not, continue to the next step.
STEP 6. Disconnect ENG-P213 from the ether relay (FO-2 Sheet 2).
a. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to
NORMAL. On EMCP set ENGINE CONTROL switch to COOL
DOWN/STOP.
b. Proceed to the Diagnostic Overrides screen on the Cat ET.
c. Activate the Ether Injection System. The diagnostic override will activate for
ten seconds.
d. Monitor the Active Diagnostic Codes screen on the Cat ET.
e. Check for an active 05 diagnostic code for the ether circuit.
STEP 7. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
a. Connect a jumper wire between ENG-P213-1 and ENG-P213-2.
b. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to
NORMAL. On EMCP set ENGINE CONTROL switch to COOL
DOWN/STOP.
c. Proceed to the Diagnostic Overrides screen on the Cat ET.
d. Activate the Ether Injection System. The diagnostic override will activate for
ten seconds.
e. Monitor the Active Diagnostic Codes screen on the Cat ET.
f. Check for an active 06 diagnostic code for the ether circuit.
g. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF. Remove
the wire jumper.
(1) If a 06 diagnostic code was active when the jumper wire is installed and
a 05 diagnostic code was active when the jumper wire is removed, the
engine harness and the ECM are OK.
(2) If the diagnostic codes do not change as stated above, verify continuity
between ENG-P213-1 and ENG-P1-21. Repair as necessary
(WP 0088). Verify the problem has been resolved. If not, replace the
ether relay (WP 0073).
(3) Verify the problem has been resolved. If not, replace the ECM
(WP 0082).
(4) Verify the problem has been resolved.

0013-14
 TM 9-6115-730-24 0013

ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

SYMPTOM
5. Injector Solenoid Circuit Test.

System Operation Description:

x An injector solenoid may have a problem.

x You have been directed to this procedure from WP 0011, Troubleshooting without a Diagnostic Code.
x There is an active diagnostic code for an injector solenoid.

Use this procedure for the following diagnostic codes:

x 1-E-11 Injector Cylinder 1 fault

x 2-E-11 Injector Cylinder 2 fault
x 3-E-11 Injector Cylinder 3 fault
x 4-E-11 Injector Cylinder 4 fault
x 5-E-11 Injector Cylinder 5 fault
x 6-E-11 Injector Cylinder 6 fault

Figure 5 shows the injector solenoid circuit. Perform the troubleshooting procedures under conditions that are
identical to the conditions that exist when the problem occurs. Typically, problems with the injector solenoid occur
when the engine is warmed up and/or when the engine is under vibration (heavy loads). These engines have
hydraulically actuated electronically controlled unit injectors (HEUI). The ENGINE CONTROL Module (ECM)
sends a 105 volt pulse to each injector solenoid. The pulse is sent at the proper time and at the correct duration
for a given engine load and speed. The solenoid is mounted on top of the fuel injector body. If an open is
detected in the solenoid circuit, a diagnostic code is generated. The ECM continues to try to fire the injector. If a
short is detected, a diagnostic code is generated. The ECM will disable the solenoid circuit. The ECM will
periodically try to fire the injector. If the short circuit remains, this sequence of events will be repeated until the
problem is corrected. When an injector is replaced, program the new injector code into the ECM. If the ECM is
replaced, all six injector codes must be programmed into the new ECM. Refer to Troubleshooting, Replacing the
ECM for the correct procedure. The Caterpillar Electronic Technician (ET) includes the following tests that aid in
troubleshooting the injector solenoids.

NOTE
Before running the Cylinder Cutout Test, all active diagnostic codes must be repaired.

Cylinder Cutout Test

The Cylinder Cutout Test is used on an engine in order to determine the individual cylinder performance while the
engine is running. As one or more cylinders are cut out during the test, the Cylinder Cutout Test uses the fuel
position of each injector in order to evaluate the performance of the remaining cylinders that are firing. As the
different cylinders are cut out, a comparison of the change in fuel position is used to identify cylinders that are
weak or misfiring. One reason for a cylinder that is weak or misfiring is an injector that is malfunctioning
mechanically. During the test, when a good injector is cut out, the fuel position of the remaining injectors will
show a consistent change. This consistent change in the fuel position is caused by the remaining injectors that
are compensating for the cut out injector. If a malfunctioning injector is cut out, the fuel position will not show a
proportional change. This unbalanced change is the result of the smaller quantity of fuel that is needed to
compensate for the power loss from the malfunctioning injector. The Cylinder Cutout Test is used to isolate a
malfunctioning injector in order to avoid replacement of injectors that are in good repair.

0013-15
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ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

Injector Solenoid Test

Use the Injector Solenoid Test and Figure 5 to aid in diagnosing an open circuit or a short circuit while the engine
is not running. The Injector Solenoid Test briefly activates each solenoid. A good solenoid will create an audible
click when the solenoid is activated. The Cat ET will indicate the status of the solenoid as OK, Open, or Short.

NOTE
Two injector solenoids share a common return wire (FO-2, sheet 2). For this reason, an open
circuit or a short circuit in a return wire could cause diagnostic codes for two injector solenoids.

Figure 5. Injector Solenoid Circuit.

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ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

MALFUNCTION
Cylinder 1 - 6 Injector Solenoids. Failure mode is not identifiable (Mechanical Failure).
CORRECTIVE ACTION
STEP 1. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 3. Connect the Cat ET to Connector CDC-P7 (WP 0012).
STEP 4. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 5. Monitor the logged diagnostic code screen on the Cat ET. Look for a FMI 11
code that is related to one of the unit injectors.
STEP 6. Turn the ENGINE CONTROL switch to MANUAL START. Allow the engine to
warm up to the normal operating temperature of 77 °C (171 °F).
STEP 7. Access the Cylinder Cutout Test on the Cat ET.
a. Enable the cooling fan, if the fan is not controlled by the ECM. If the ECM
controls the cooling fan, the cooling fan will start automatically when the test
begins.
b. Shut off all parasitic loads which could affect the results of the test.
STEP 8. Run the Cylinder Cutout Test.
a. Follow the instructions that are provided. The Cylinder Cutout Tests are
interactive so the procedure is guided to the finish.
b. Print a report of the test and evaluate the results.
c. If the results of the Cylinder Cutout Test indicate that all of the cylinders are
OK, suspect an electrical problem or a mechanical problem with another
system on the engine. If the engine is misfiring or if the engine has low
power, refer to WP 0011 Troubleshooting, Engine Misfires, Runs Rough or Is
Unstable and Low Power/Poor or No Response to Throttle in WP 0011.
d. If the Cylinder Cutout Test indicates that there is a weak cylinder. There may
be an injector solenoid that is partially shorted or there may be a mechanical
problem with the cylinder.
STEP 9. Monitor the logged diagnostic code screen on the Cat ET. Look for a FMI 11
code that is related to one of the unit injectors.
STEP 10. Use the Injector Solenoid Test to test the injector solenoids.
a. Ensure that the engine has warmed to the normal operating temperature of
77°C (171°F).
b. Stop the engine as follows: On EMCP set ENGINE CONTROL switch to
COOL DOWN/STOP. Set Battery Disconnect Switch to ON. Set DEAD
CRANK SWITCH to NORMAL. DO NOT START THE ENGINE.
c. Access the Injector Solenoid Test on the Cat ET.
d. Activate the test.

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ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

CORRECTIVE ACTION - Continued

NOTE
Do not confuse the Injector Solenoid Test with the Cylinder Cutout Test. The Cylinder Cutout
Test is used while the engine is running. The Injector Solenoid Test is used in order to actuate
the injector solenoids while the engine is stopped.

e. As each solenoid is energized by the ECM an audible click can be heard at

the valve cover. Listen for a click at each valve cover. A black square will
appear over the cylinder number on the Cat ET as each cylinder is being
fired.
f. Perform the Injector Solenoid Test at least two times.
g. In the previous test step, if the Cylinder Cutout Test indicated a problem with
one of cylinders, there may be a problem with the injector for the cylinder or
there may be a mechanical problem with the cylinder. If a problem with an
injector is suspected, replace the suspect injector with another injector on the
engine in order to confirm the problem. Perform the Cylinder Cutout Test
again. If the problem moves to the other cylinder with the suspect injector,
replace the injector (WP 0118). If the problem remains in the original
cylinder, there is a mechanical problem with the cylinder.

WARNING
A strong electrical shock hazard is present if the electrical power is not removed from the ECM.
The electronic unit injector system uses 90-120 volts. Failure to comply can cause injury or death
to personnel.

STEP 11. If the Injector Solenoid Test reported that one or more cylinders are SHORT,
record the cylinder numbers for the injectors that indicate SHORT.
a. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF. A strong
electrical shock hazard is present if the electrical power is not removed from
the ECM
b. Disconnect the connector ENG-P300 from injector harness ENG J300 at the
valve cover.
c. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to
NORMAL. On EMCP set ENGINE CONTROL switch to COOL
DOWN/STOP.
d. If the status of all cylinders indicates OPEN when the connector for the
injector harness is disconnected, there is not a short circuit in the Engine
Harness from the ECM connector to the connector for the injector harness.
Reconnect the connector for the injector harness. Proceed to STEP 11.
e. If at least one cylinder does not indicate OPEN when the connector for the
injector harness is disconnected, record the cylinder numbers that indicate a
short circuit.
(1) On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.

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ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

CORRECTIVE ACTION - Continued

(2) Disconnect engine harness connector ENG-P2 from ECM J2.
(3) Remove the suspect injector’s supply wire and return wire from the ENG-
P2 connector. Connect the ENG-P2 connector. Refer to Figure 5.
(4) Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to
NORMAL. On EMCP set ENGINE CONTROL switch to COOL
DOWN/STOP.
(5) Perform the Injector Solenoid Test at least two times. Record the results.

NOTE
The Cat ET will report an OPEN for the injector that shares the supply with the suspect injector.
Disregard the result for this injector.

(6) If the Injector Solenoid Test indicates OPEN for the suspect cylinder, the
short circuit is in the engine harness. Repair the engine harness or
replace the engine harness, as required (WP 0088). Verify that the repair
eliminates the problem.
(7) If the Injector Solenoid Test indicates SHORT for the suspect cylinder,
there is a problem with the ECM. Replace the ECM (WP 0082). Verify
that the repair eliminates the problem.
STEP 12. The Injector Solenoid Test reported that one or more cylinders are OPEN.
Record the cylinder numbers for the injectors that indicate OPEN.
a. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.

WARNING
A strong electrical shock hazard is present if the electrical power is not removed from the ECM.
The electronic unit injector system uses 90-120 volts. Failure to comply can cause injury or death
to personnel.

b. Disconnect connector ENG-P300 from injector harness ENG-J300 (Figure 5).

c. Fabricate a jumper wire that is long enough to jumper two connector pins at
the connector for the injector harness. Crimp connector sockets to each end
of the jumper wire.
d. Insert one end of a jumper wire onto the pin of the supply wire of the suspect
injector (Table 3). Insert the other end of the jumper wire onto the pin of the
return wire of the suspect injector. For example, if injector 5 is the problem
injector, insert the jumper onto terminal 5 and into terminal 8 of the connector
for the injector harness. Ensure that the ends of the jumper wire are not in
contact with any of the other terminals in the connector.
e. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to
NORMAL. On EMCP set ENGINE CONTROL switch to COOL
DOWN/STOP.
f. Using the Cat ET, perform the Injector Solenoid Test at least two times.

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ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

CORRECTIVE ACTION - Continued

Table 3. Injector Solenoid Harness Terminals.

TERMINAL
SIGNAL
(WP 0088, FO-2, Sheet 2)

1 Injector 1 Supply

2 Injector 2 Supply

3 Injector 3 Supply

4 Injector 4 Supply

5 Injector 5 Supply

6 Injector 6 Supply

7 Injector 6 Return

8 Injector 5 and 6 Return

10 Injector 3 and 4 Return

12 Injector 1 and 2 Return

g. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery

Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF. Repeat
this test for each suspect Injector. Ensure that the Injector Solenoid Test is
disabled before handling the jumper wires.

NOTE
The Cat ET may report a SHORT for the injector that shares the supply with the suspect injector.
Disregard the result for this injector.

h. If the Injector Solenoid Test indicates SHORT for the cylinder with the jumper
wire, the ECM and the engine harness are OK. Remove the jumper wire.
Reconnect the connector for the injector harness. Proceed to STEP 11.
i. If the Injector Solenoid Test indicates open for the cylinder with the jumper
wire. The problem is in the engine harness or in the ECM.
(1) If the problem has not been resolved, repair or replace the engine
harness (WP 0088). Verify the problem has been resolved.
(2) Install another ECM and retest. If the problem is resolved, install a
replacement ECM (WP 0082).
STEP 13. If the problem is not resolved, check the injector harness under the valve cover
for open or short circuits in the injector wires.

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ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

CORRECTIVE ACTION - Continued

WARNING
A strong electrical shock hazard is present if the electrical power is not removed from the ECM.
The electronic unit injector system uses 90-120 volts. Failure to comply can cause injury or death
to personnel.

a. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery

Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
b. Remove valve covers (WP 0100).
c. Disconnect the connector for the problem injector.
d. Attach a jumper wire to both terminals at the harness side of the injector
connector for the suspect injector (WP 0088, Figure 2, sheet 2).
e. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to
NORMAL. On EMCP set ENGINE CONTROL switch to COOL
DOWN/STOP.
f. Perform the Injector Solenoid Test at least two times. Record the results of
the test.

NOTE
The Cat ET may report a SHORT for the injector that shares the supply with the suspect injector.
Disregard the result for this injector.

g. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery

Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
(1) If the Injection Solenoid test indicates SHORT for the cylinder with the
suspect injector, the harness under the valve cover is OK. The problem
is in the windings of the injector solenoid. Replace the injector
(WP 0118). Verify that the repair eliminates the problem.
(2) If the Injection Solenoid Test does not report SHORT for the suspect
injector, the problem appears to be in the harness under the valve cover.
Repair or replace the harness under the valve cover (WP 0088). Run the
Injector Solenoid Test in order to check the installation of the new
harness before installing the valve covers. Verify that the repair
eliminates the problem.
h. If the short condition was not present, remove the jumper wire and place the
connector in a place that will not allow arcing during the test.
i. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to
NORMAL. On EMCP set ENGINE CONTROL switch to COOL
DOWN/STOP.

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ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

CORRECTIVE ACTION - Continued

j. Perform the Injector Solenoid Test at least two times.
(1) If the Injector Solenoid Test indicates OPEN for the suspect injector, the
harness under the valve cover is OK. The problem is in the windings of
the injector solenoid. Replace the injector (WP 0118). Verify that the
repair eliminates the problem.
(2) If the Injector Solenoid Test does not indicate OPEN for the suspect
injector, the problem appears to be in the engine harness under the
valve cover. Replace or repair the harness under the valve cover
(WP 0088). Run the Injector Solenoid Test in order to check the
installation of the new harness before installing the valve covers. Verify
that the repair eliminates the problem.
STEP 14. If the problem is not resolved, there may be a malfunctioning cylinder that is
caused by a mechanical problem. Replace the engine (WP 0096).

SYMPTOM
6. Speed Control Test.

System Operation Description:

The Load Sharing Module (LSM) A4 provides a throttle signal to the ECM. The output for rated speed is a pulse
width modulated (PWM) signal at a constant frequency. The speed signal varies with the position of the
FREQUENCY adjust knob. The output signal is referred to as a duty cycle or as a PWM signal. The output signal
is expressed as a percentage between 0 and 100 percent for the speed adjust. Figure 6 shows the Speed
Control Circuit.

NOTE
Desired speed can be adjusted from 1700 to 1900 rpm for a 60 Hz system and from 1400 to
1600 rpm for a 50 Hz system. The ECM calculates the desired engine rpm from the rated
speed signal and the droop signal. The rated speed signal is valid when the duty cycle is in the
range of 5 to 95 percent. If the ECM determines that the rated speed signal is invalid, the
engine rpm will be set to the programmed low idle.

MALFUNCTION
Throttle Position Signal. - Abnormal frequency, pulse width, or period.
+24 +/- 3 Vdc is not measured between terminal 15 (+) and terminal 16 (-) on the LSM A4).
CORRECTIVE ACTION
STEP 1. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 2. Measure the voltage between terminal 15 and terminal 16 on LSM A4 (Figure
FO-4, sheet 2). Connect one probe of a voltmeter to the + battery terminal of the
speed control unit. Connect the other voltmeter probe to the -battery terminal the
LSM A4.

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ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

CORRECTIVE ACTION - Continued

Figure 6. Speed Control Circuits.

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ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

CORRECTIVE ACTION - Continued

STEP 3. Measure the voltage to LSM A4 (Figure 6).
a. Verify that the ground wire on terminal 16 has continuity to ground.
b. Check the voltage between Engine Ground and the following test points in
Table 4. If voltage is not present at a test point, the problem is in the device,
in the wire or in the connector that precedes the point in the circuit.

Table 4. Speed Control Circuit Test Points.

DEVICE TERMINAL

Diode D1 Either side

DEAD CRANK SWITCH Terminals for NORMAL crank

J30/P30 connector 9

Resistor Assembly A7 11

Resistor Assembly A7 12

GSC RM2

ENGINE CONTROL Switch 6

ENGINE CONTROL Switch 10

GSC RM1

GSC RM39

TB-4 17-22

Connector ENG-P37 40

STEP 4. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery

Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
a. Connect the Cat ET to connector CDC-P7 (WP 0012).
STEP 5. If the voltage is not 24 ± 3 Vdc at a test point, repair the device, connectors
and/or wiring (WP 0041, WP 0042, WP 0043, WP 0088, FO-2, sheet 2; FO-4,
sheets 1-4).
STEP 6. After the voltage supply to LSM A4 is correct. Proceed to STEP 7.

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ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

CORRECTIVE ACTION - Continued

STEP 7. Check the throttle position using the Cat ET.
a. Observe the position of the throttle on the Cat ET.
b. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to
NORMAL. On EMCP set ENGINE CONTROL switch to COOL
DOWN/STOP.
c. Turn the FREQUENCY adjust knob to register the following:
x 60 Hz between 1700 and 1900 rpm
x 50 Hz between 1400 and 1600 rpm
d. Start at the low position. Slowly turn the FREQUENCY adjust knob in the
other direction. Monitor the position of the Throttle and the RPM on the Cat
ET.
e. If the throttle position shown on the Cat ET changes as the FREQUENCY
adjust knob is adjusted, LSM A4 is operating correctly.
f. If the throttle position and RPM reading shown on the Cat ET does not vary
as the FREQUENCY adjust knob is adjusted. Proceed to STEP 8.
STEP 8. Check LSM A4.
a. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
b. Remove wires from terminals 19 and 20 of LSM A4.
c. Connect DC voltmeter to terminals 19 and 20 on LSM A4.
d. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to
NORMAL. On EMCP set ENGINE CONTROL switch to COOL
DOWN/STOP.
e. Turn FREQUENCY adjust potentiometer up and down. Voltage will vary
from approximately 4.5 to 9.5 Vdc.
f. On EMCP set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
g. If voltage is incorrect, or erratic, repair wiring as necessary (WP 0088).
Verify the problem is resolved. If wiring is good, perform potentiometer test
on FREQUENCY adjust potentiometer (WP 0041). Replace potentiometer,
as required (WP 0041). Verify the problem is resolved.
h. If FREQUENCY adjust potentiometer is not defective, replace LSM A4
(WP 0042). Verify the problem is resolved.
i. If voltage is correct, remove ENG-P1 connector from the ECM. Measure
continuity from the wire on terminals 19 to ENG-P1-66 and the wire on
terminal 20 to ENG-P1-5. If continuity is good, replace ECM (WP 0082).
Verify the problem is resolved.

0013-25
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ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

SYMPTOM
7. Electronic Service Tool (Cat ET) will not communicate with ECM.

System Operation

If the Electronic Service Tool (Cat ET) will not communicate with the ECM the following possible problems are
listed in order of most probable first.

x Configuration for the communications adapter

x Electrical connectors
x Communication adapter and/or cables
x Electrical power supply to connector CDC-P7
x Caterpillar Electronic Technician (ET) and related hardware
x Electrical power supply to the Electronic Control Module (ECM)
x Flash file
x Cat Data Link
MALFUNCTION
The Cat ET will not communicate with the ECM.
CORRECTIVE ACTION
STEP 1. On EMCP, set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Connect the Cat ET to connector CDC-P7 (WP 0012).
STEP 3. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 4. Check the configuration for the communications adapter.
a. Access Preferences under the Utilities menu on Cat ET.
b. Verify that the correct communications interface device is selected.
c. Verify that the correct port is selected for use by the communication adapter.

NOTE
The most commonly used port is COM 1.

d. Under Advanced menu, verify the baud rate is set for 57600.
e. Check for any hardware that is utilizing the same port as the communications
adapter. If any devices are configured to use the same port, exit or close the
software programs for that device.
STEP 5. Check the electrical connectors.
a. Check for correct installation of the ENG-P1 and ENG-P2 ECM connectors
(WP 0088).
b. Check connector CDC-P7 (WP 0012).
c. Inspect all associated electrical wiring and connectors. Perform Wiggle Test
(SYMPTOM 1) if intermittent problem exist.

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ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

CORRECTIVE ACTION - Continued

STEP 6. Communication adapter and/or cables
a. If you are using a communication adapter II, ensure that the firmware and
driver files for the communication adapter are the most current files that are
available. If the firmware and driver files do not match, the communication
adapter will not communicate with Cat ET (WP 0012).
b. Disconnect the communication adapter and the cables from CDC-P7
connector. Reconnect the communication adapter to CDC-P7 connector.
c. Verify that the correct cable is being used between the communication
adapter and CDC-P7 connector.
STEP 7. Verify that battery voltage is present between terminals A and B of the service
tool connector (WP 0088, FO-2, sheet 2). If the communication adapter is not
receiving power, the display on the communication adapter will be blank.
STEP 8. In order to eliminate Cat ET and the related hardware as the problem, connect
Cat ET to a different engine. If the same problem occurs on a different engine,
check Cat ET and the related hardware in order to determine the cause of the
problem.
STEP 9. Check power to the ECM. Refer to Troubleshooting, Electrical Power Supply
Circuit Test.

NOTE
If the ECM is not receiving battery voltage, the ECM will not communicate.

STEP 10. Ensure that the correct flash file is properly installed in the ECM. (WP 0013
SYMPTOM 9).

NOTE
A new ECM is not programmed to any specific engine until a flash file has been installed. The
engine will not start and the engine will not communicate with Cat ET until the flash file has been
downloaded. Refer to Troubleshooting, Flash Programming (WP 0013 SYMPTOM 9).

STEP 11. Troubleshoot the Cat data link for possible problems. Refer to Troubleshooting,
WP 0009 SYMPTOM 26.
STEP 12. Verify the problem has been resolved.

0013-27
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ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

SYMPTOM
8. Engine Timing Sensor Calibrate.

This procedure is required if a 261-E-13 Engine Timing Calibration code is active. This procedure requires 2
people.

Also use this procedure if any of the following conditions exist:

The ECM has been replaced.

The Engine Timing sensors have been replaced.
The front engine gear group has been serviced.

The following tools (Table 5) are required:

Table 5. Required Tools

PART NUMBER DESCRIPTION

7X-1171 Transducer Adapter
6V-2197 Transducer
7X-1695 Cable Assembly
170-3519 Harness

MALFUNCTION
Engine timing is not calibrated.
CORRECTIVE ACTION
STEP 1. On EMCP, set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Remove timing calibration plug (Figure 7, item 1) from right side of engine.

CAUTION
If crankshaft counterweight is not positioned directly in front of timing calibration port when timing
calibration transducer is installed, damage to the timing calibration transducer will result when
engine is started.

STEP 3. One person use a flashlight to look for the crankshaft counterweight.
STEP 4 Second person rotates the engine by bumping the DEAD CRANK SWITCH
(quickly setting DEAD CRANK SWITCH to CRANK then back to OFF). Rotate
engine in increments until crankshaft counterweight is positioned directly in front
of the timing calibration port. Adjust crankshaft counterweight position as
required.
STEP 5. Install the 7X-1171 transducer adapter into the timing calibration port hole.

0013-28
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ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

CORRECTIVE ACTION - Continued

Figure 7. Timing Calibration Plug.

STEP 6. Install the 6V-2197 transducer as follows:

a. Apply clean engine oil to the 2D-6392 O-ring seal. Install the O-ring seal
onto the end of the 6V-2197 transducer.
b. Insert the 6V-2197 transducer through the 7X-1171 transducer adapter.
Insert the transducer until contact is made with the surface of the crankshaft
counterweight. Pull the transducer 0.04 inch (1.0 mm) away from the
crankshaft counterweight.
c. Tighten the nut on the transducer adapter.
d. Disconnect the ENG-J400 connector from ENG-P400 harness connector
(FO-2, sheet 1).
e. Connect the 7X-1695 cable assembly to the engine timing calibration
transducer and to the ENG-P400 timing calibration transducer connector
(FO-2, Sheet 1).
STEP 7. Connect the Cat ET to connector CDC-P7 (WP 0012).
STEP 8. Set the Battery Disconnect Switch to ON. Set the DEAD CRANK SWITCH to
NORMAL. On the EMCP, set the ENGINE CONTROL switch to MANUAL
START. Run the engine until the engine has exited cold mode operation.
STEP 9. Start the Cat ET (WP 0012). Access the TIMING CALIBRATION screen on the
Cat ET by going to drop-down menu SERVICE, then CALIBRATIONS, then
TIMING CALIBRATION.

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ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

CORRECTIVE ACTION - Continued

STEP 10. Disconnect wires from terminals 19 and 20 on LSM A4.
STEP 11. Select CONTINUE on the Cat ET. Wait until the Cat ET indicates that the timing
is calibrated.
STEP 12. On EMCP, set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.

NOTE
Disconnect the 7X-1695 Cable Assembly before exiting the TIMING CALIBRATION screen to
prevent diagnostic codes from activating.

STEP 13. Disconnect the 7X-1695 cable assembly.

STEP 14. Exit the TIMING CALIBRATION screen on the Cat ET.
STEP 15. On the EMCP, set the ENGINE CONTROL switch to OFF/RESET.
STEP 16. Remove the 6V-2197 transducer and the 7X-1171 transducer adapter.
STEP 17. Reinstall the timing calibration plug.
STEP 18. Verify the problem has been resolved.

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ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

SYMPTOM
9. Flash Programming

This is a method of programming or updating the flash file in an engine’s Electronic Control Module (ECM).
Caterpillar Electronic Technician (ET) is used to flash program a file into the memory of the engine’s ECM. Use
this procedure if original ECM flash files are missing or not available. To update configuration files, refer to
WP 0013, SYMPTOM 13.
MALFUNCTION
Personality Module Mismatch. ECM has an incorrect or outdated Flash File.
CORRECTIVE ACTION
STEP 1. On EMCP, set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Connect the Cat ET to connector CDC-P7 (WP 0012).
STEP 3. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 4. Establish communication between Cat ET and the engine’s ECM.
STEP 5. Select WinFlash from the Utilities menu on Cat ET.

NOTE
If WinFlash utility will not communicate with the ECM, refer to Troubleshooting, Electronic Service
Tool (Cat ET) Will Not Communicate with ECM.

STEP 6. Program the flash file into the ECM.

a. Select the engine ECM under the Detected ECMs.
b. Press the Browse button in order to select the name of the flash file that will
be programmed into the ECM.

NOTE
The Flash Files are located on a CD provided with the Cat ET software.

c. When the correct flash file is selected, press the Open button.
d. Verify that the File Values match the application. If the File Values do not
match the application, obtain the correct flash file.
e. When the correct flash file is selected, press the Begin Flash button.
f. Cat ET will indicate when flash programming has been successfully
completed.
STEP 7. Turn the ENGINE CONTROL switch to MANUAL START. Check for proper
operation. Repair any active diagnostic or event codes.

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ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

SYMPTOM

10. Engine Fuel Pressure Reading.

This procedure is required if a fuel pressure problem is suspected.

MALFUNCTION
Poor engine performance. Low fuel pressure is suspected.
CORRECTIVE ACTION
STEP 1. On EMCP, set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Connect the Cat ET to connector CDC-P7 (WP 0012).
STEP 3. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to MANUAL START.
STEP 4. Establish communication between Cat ET and the engine’s ECM.
STEP 5. Select STATUS from the icons list on the Cat ET.
STEP 6. Select a group of engine sensors that include the fuel pressure. Read the fuel
pressure with the engine running.
a. The pressure should be 85 to 90 psi (586 to 655 kPa) during both normal
operating conditions and load conditions.
b. The pressure should be 85 to 90 psi (586 to 655 kPa) at low idle.
c. If the fuel pressure is not within spec, troubleshoot the restriction and replace
components as required (WP 0057 thru WP 0061).
STEP 7. Verify the problem has been resolved.

0013-32
 TM 9-6115-730-24 0013

ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

SYMPTOM
11. Engine Status

This procedure is required if an engine operating parameter is needed to troubleshoot a performance problem.
MALFUNCTION
Poor engine performance. Need to verify engine operating parameters.
CORRECTIVE ACTION
STEP 1. On EMCP, set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Connect the Cat ET to connector CDC-P7 (WP 0012).
STEP 3. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to MANUAL START.
STEP 4. Establish communication between Cat ET and the engine’s ECM.
STEP 5. Select STATUS from the icons list on the Cat ET.
STEP 6. Select a group of engine sensors that include the needed parameter. Read the
parameter with the engine running.
STEP 7. Use the status data to assist in troubleshooting a problem.

0013-33
 TM 9-6115-730-24 0013

ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

SYMPTOM

12. Load Injector Code.

When an injector is replaced, program the new injector code into the ECM. If the ECM is replaced, all six injector
codes must be programmed into the new ECM.

MALFUNCTION
Injector codes must be programmed into ECM after injector replacement or ECM replacement.
CORRECTIVE ACTION
STEP 1. On EMCP, set ENGINE CONTROL switch to OFF/RESET. Set Battery
Disconnect Switch to OFF. Set DEAD CRANK SWITCH to OFF.
STEP 2. Connect the Cat ET to connector CDC-P7 (WP 0012).
STEP 3. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL.
On EMCP set ENGINE CONTROL switch to COOL DOWN/STOP.
STEP 4. Establish communication between Cat ET and the engine’s ECM.
STEP 5. On the Cat ET top menu bar, select the SERVICE pull down menu. Select
CALIBRATIONS. Select INJECTOR CODES CALIBRATION.
a. The screen will display a list of 6 injectors and their codes.
b. Select the injector that required a code change.
c. Click the CHANGE button in the lower left corner of the screen. A window
will pop up (named Change Parameter Value).
d. Enter the new code in the New Value location. Click on the OK button. A
small window appears asking: “Are you sure you want to program this
parameter?” Select YES.
e. The new injector code (parameter) should be displayed in the list of injectors
and their codes.
STEP 6. On EMCP set ENGINE CONTROL switch to MANUAL START. Verify the engine
is running properly.

SYMPTOM

13. Copy Configuration/ECM Replacement

When replacing ECM, the configuration data from the old ECM needs to be copied and loaded into the
replacement ECM.
MALFUNCTION
Replacement ECM requires configuration data.

0013-34
 TM 9-6115-730-24 0013

ELECTRONIC TECHNICIAN (ET) TROUBLESHOOTING - Continued

CORRECTIVE ACTION
STEP 1. Record the configuration data.
a. Connect Cat ET to the CDC-P7.
b. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to
NORMAL. On EMCP set ENGINE CONTROL switch to COOL
DOWN/STOP.
c. Use the Copy Configuration/ECM Replacement feature that is found under
the Service menu on Cat ET. Select Load from ECM in order to copy the
configuration data from the suspect ECM.
d. Print the parameters from the Configuration screen on Cat ET. If a printer is
unavailable, record all of the parameters. Record any logged diagnostic
codes and logged event codes for your records.

NOTE
If the Copy Configuration process fails and the parameters were not obtained in Step 1.c, the
parameters must be obtained elsewhere. Some of the parameters are stamped on the engine
information plate. Most of the parameters must be obtained from the factory. If this condition
exists, the flash file can be loaded and the ECM will set the configuration parameters to default
settings. The configuration parameters can then be manually updated.

STEP 2. After the ECM has been replaced (WP 0082) perform the following steps to copy
the configuration data into the replacement ECM.

NOTE
When an ECM is replaced, the system configuration parameters must be programmed into the
new ECM. A new ECM will allow these parameters to be programmed ONCE without
factory passwords. After the initial programming, some parameters are protected by factory
passwords.
a. Connect Cat ET to the CDC-P7.
b. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to
NORMAL. On EMCP set ENGINE CONTROL switch to COOL
DOWN/STOP.
c. Flash program the flash file into the ECM. Refer to WP 0013, SYMPTOM 9.
d. If the Copy Configuration process from Step 1.c was successful, return to the
Copy Configuration/ECM Replacement screen on Cat ET and select
Program ECM.
e. If the Copy Configuration process from Step 1.c was unsuccessful, manually
program the ECM parameters.

END OF WORK PACKAGE

0013-35/36 blank
 TM 9-6115-730-24

CHAPTER 3

UNIT (FIELD) LEVEL

MAINTENANCE INSTRUCTIONS
 TM 9-6115-730-24

CHAPTER 3

UNIT (FIELD) LEVEL MAINTENANCE INSTRUCTIONS

WORK PACKAGE INDEX

Title WP Sequence No.

SERVICE UPON RECEIPT..................................................................................................................... 0014

PMCS INTRODUCTION......................................................................................................................... 0015
PMCS, INCLUDING LUBRICATION INSTRUCTIONS ........................................................................... 0016
GENERAL MAINTENANCE INSTRUCTIONS ............................................................................................ 0017
RIGHT BATTERY ACCESS DOOR ASSEMBLY MAINTENANCE ............................................................ 0018
LEFT BATTERY ACCESS DOOR ASSEMBLY MAINTENANCE ............................................................... 0019
CONTROL BOX DOOR ASSEMBLY MAINTENANCE ............................................................................... 0020
LEFT FRONT DOOR ASSEMBLY (LATCH) MAINTENANCE .................................................................... 0021
LEFT REAR DOOR ASSEMBLY MAINTENANCE ...................................................................................... 0022
LEFT REAR DOOR ASSEMBLY (LATCH) MAINTENANCE ...................................................................... 0023
LOAD BOARD DOOR ASSEMBLY MAINTENANCE ................................................................................. 0024
RIGHT FRONT DOOR ASSEMBLY (LATCH) MAINTENANCE ................................................................. 0025
RIGHT FRONT DOOR ASSEMBLY MAINTENANCE ................................................................................ 0026
RIGHT REAR DOOR ASSEMBLY MAINTENANCE ................................................................................... 0027
RIGHT REAR DOOR ASSEMBLY (LATCH) MAINTENANCE..................................................................... 0028
ACCESS COVERS MAINTENANCE .......................................................................................................... 0029
FRONT ROOF SECTION HOUSING ASSEMBLY MAINTENANCE .......................................................... 0030
REAR ROOF SECTION HOUSING ASSEMBLY MAINTENANCE ............................................................ 0031
ENGINE GENERATOR COMPARTMENT CEILING ASSEMBLY MAINTENANCE .................................. 0032
GENERATOR ACCESS COVER ASSEMBLY MAINTENANCE ................................................................ 0033
FRONT SECTION HOUSING ASSEMBLY MAINTENANCE ...................................................................... 0034
REAR SECTION HOUSING ASSEMBLY MAINTENANCE ........................................................................ 0035
LEFT CENTER PANEL ASSEMBLY MAINTENANCE ................................................................................ 0036
RIGHT CENTER PANEL ASSEMBLY MAINTENANCE ............................................................................. 0037
RIGHT REAR PANEL ASSEMBLY MAINTENANCE................................................................................... 0038
LEFT REAR PANEL ASSEMBLY MAINTENANCE .................................................................................... 0039
DOOR SUPPORT ASSEMBLY MAINTENANCE ........................................................................................ 0040
CONTROL BOX PANEL ASSEMBLY MAINTENANCE .............................................................................. 0041
CONTROL BOX ASSEMBLY MAINTENANCE............................................................................................ 0042
RESISTOR ASSEMBLY A7 MAINTENANCE ............................................................................................. 0043
CONTROL BOX HARNESS ASSEMBLY MAINTENANCE ........................................................................ 0044
RECONNECTION TERMINAL BOARD ASSEMBLY MAINTENANCE ...................................................... 0045
LOAD TERMINAL BOARD ASSEMBLY MAINTENANCE .......................................................................... 0046
BATTERY CABLE ASSEMBLIES MAINTENANCE .................................................................................... 0047
POWER CABLE ASSEMBLIES MAINTENANCE ....................................................................................... 0048
MAIN LOAD CONTACTOR MAINTENANCE............................................................................................... 0049
BATTERIES MAINTENANCE ..................................................................................................................... 0050
BATTERY DISCONNECT SWITCH MAINTENANCE ................................................................................. 0051
CURRENT TRANSFORMERS MAINTENANCE ........................................................................................ 0052
POTENTIAL TRANSFORMER MAINTENANCE ........................................................................................ 0053
SLAVE RECEPTACLE MAINTENANCE ..................................................................................................... 0054
ELECTRICAL INSTALLATION MAINTENANCE ........................................................................................ 0055
 TM 9-6115-730-24

Title WP Sequence No.

FUEL LEVEL SWITCH ASSEMBLY MAINTENANCE ................................................................................ 0056

FUEL HOSES MAINTENANCE ................................................................................................................... 0057
FUEL PICKUP TUBE ASSEMBLY MAINTENANCE ................................................................................... 0058
AUXILIARY FUEL PUMP ASSEMBLY MAINTENANCE ............................................................................. 0059
FUEL COOLER MAINTENANCE ................................................................................................................ 0060
WATER SEPARATOR FILTER AND BRACKET MAINTENANCE ............................................................. 0061
FUEL LEVEL SENDER MAINTENANCE .................................................................................................... 0062
FUEL TANK MAINTENANCE ...................................................................................................................... 0063
COOLANT RECOVERY SYSTEM MAINTENANCE ................................................................................... 0064
SURGE TANK MAINTENANCE ................................................................................................................... 0065
FAN AND FAN GUARDS MAINTENANCE .................................................................................................. 0066
COOLANT HOSE ASSEMBLIES MAINTENANCE...................................................................................... 0067
RADIATOR ASSEMBLY MAINTENANCE .................................................................................................. 0068
EXHAUST SYSTEM MAINTENANCE ......................................................................................................... 0069
CRANKCASE VENTILATION FILTER MAINTENANCE ............................................................................. 0070
AIR CLEANER FILTER MAINTENANCE .................................................................................................... 0071
AIR CLEANER SYSTEM MAINTENANCE .................................................................................................. 0072
ETHER INJECTION ASSEMBLY MAINTENANCE...................................................................................... 0073
ALTERNATOR MAINTENANCE ................................................................................................................. 0074
ALTERNATOR BELT MAINTENANCE ....................................................................................................... 0075
STARTER MAINTENANCE ......................................................................................................................... 0076
TENSIONER MAINTENANCE ..................................................................................................................... 0077
FUEL PRIMING PUMP MAINTENANCE .................................................................................................... 0078
OIL FILTER MAINTENANCE AND OIL CHANGE ....................................................................................... 0079
FUEL FILTER MAINTENANCE ................................................................................................................... 0080
THERMOSTAT MAINTENANCE ................................................................................................................. 0081
ENGINE CONTROL MODULE MAINTENANCE ......................................................................................... 0082
REPROGRAMMING .................................................................................................................................... 0083
INSTALLATION OF GENERATOR SET ON TRAILER .............................................................................. 0084
PREPARATION FOR STORAGE OR SHIPMENT ..................................................................................... 0085
ILLUSTRATED LIST OF MANUFACTURED ITEMS ................................................................................... 0086
TORQUE LIMITS.......................................................................................................................................... 0087
WIRE LISTS ................................................................................................................................................ 0088
 TM 9-6115-730-24 0014

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
SERVICE UPON RECEIPT

INITIAL SETUP:

Tools and Special Tools References

Tool Kit, General Mechanic’s (WP 0123, Item 1) AFTO Form 22

DA Form 2028-2
Materials/Parts DA PAM 750-8
DD Form 1397
Breakthrough cleaning solvent (WP 0124, Item 45) SF Form 361
Foam damping sheet (WP 0124, Item 11) SF Form 368
TM 9-6115-730-10
Personnel Required TM 9-6115-730-24P
TO 00-5-1
One

CHECKING UNPACKED EQUIPMENT

1. Read and follow all instructions on DD Form 1397 attached to conspicuous part of TQG.

2. Remove metal strapping, plywood, tapes, seals, and wrappings, if necessary.

WARNING
Cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye
protection are required when working in contact with cleaning solvent. Avoid repeated or
prolonged contact. Work in ventilated area only. Failure to comply can cause injury or death to
personnel.

3. Remove rust preventive compound from coated exterior parts with breakthrough cleaning solvent.

4. Inspect equipment for damage incurred during shipment. If equipment has been damaged, report damage on
SF Form 361, Transportation Discrepancy Report.

5. Check equipment against packing slip to see if shipment is complete. Report all discrepancies in accordance
with applicable service instructions (see DA PAM 750-8).

6. Check to see if equipment has been modified.

PRELIMINARY CHECKS AND ADJUSTMENT OF EQUIPMENT

1. (US Army and Air Force) Inspect equipment for possible damage incurred during shipment. If equipment has
been damaged, report damage on SF Form 368, Product Quality Deficiency Report.

2. (US Army) Check equipment against packing slip to see if shipment is complete. Report all differences using
procedure given in DA PAM 750-8.

0014-1 Change 1
 TM 9-6115-730-24 0014

PRELIMINARY CHECKS AND ADJUSTMENT OF EQUIPMENT - Continued

3. (US Army and Air Force) Perform Preventive Maintenance Checks and Services (PMCS) (TM 9-6115-
730-10).

4. If there is a recommended change to equipment technical publications, complete form DA 2028-2 and forward
it by email <AMSEL-LC-LEO-PUBS-CHG@mail1.Monmouth.army.mil>, fax to 732-532-3421, or mail to
Commander, U.S. Army Communications-Electronics Life Cycle Management Command, ATTN: AMSEL-LC-
LEO-D-CS-CFO, Fort Monmouth, New Jersey 07703-5000. For Air Force, use AFTO Form 22 in accordance
with TO 00-5-1 and mail directly to Commander, WR-ALC/LEET, Robins AFB, GA, 31098. You may also e-
mail your form to <http://wralc.tilta.afto@robins.af.mil>.

OUTPUT VOLTAGE SETTING

WARNING
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely
shut down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is set to OFF/RESET, and DEAD CRANK
SWITCH is OFF before proceeding.

2. Set Battery Disconnect Switch to OFF.

3. Remove four nuts (Figure 1, Item 1), washers (Figure 1, Item 2), and clear protective panel (Figure 1, Item 3)
from the reconnection board.

4. Remove 12 nuts (Figure 1, Item 4) and reconnection board (Figure 1, Item 5).

5. Align the arrow on the reconnection board (Figure 1, Item 5) with the arrow on the base corresponding to the
desired generator output voltage(s).

Change 1 0014-2
 TM 9-6115-730-24 0014

OUTPUT VOLTAGE SETTING - Continued

6. Install reconnection board (Figure 1, Item 5) and secure with 13 nuts (Figure 1, Item 4). Torque nuts
(Figure 1, Item 4) to 20 lb-ft (27 Nm).

7. Install clear protective panel (Figure 1, Item 3) and secure with four washers (Figure 1, Item 2) and nuts
(Figure 1, Item 1).

8. Close right rear doors.

9. Reprogram DVR and GSC, as required per WP 0083.

Figure 1. Reconnection Terminal Board Voltage Setting.

END OF WORK PACKAGE

0014-3/4 blank Change 1

 TM 9-6115-730-24 0015

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
PMCS INTRODUCTION

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s One

(WP 0123, Item 1)
References
Materials/Parts
DA Form 5988-E
Breakthrough cleaning solvent PAM 750-8
(WP 0124, Item 45) TM 9-2330-376-14&P
Wiping rags (WP 0124, Item 35) TM 750-254
TM 9-6115-730-24P

0015-1
 TM 9-6115-730-24 0015

INTRODUCTION

PMCS are performed to keep the TQG in operating condition. Inspect the TQG within specified intervals so defects
are found and corrected or problems are reported before any serious damage or failure occurs. Do the PMCS per
WP 0016, Table 1. Pay attention to WARNINGs and CAUTIONs. A WARNING means someone might be killed or
injured. A CAUTION means equipment could be damaged.

CAUTION
Designated intervals are performed under usual operating conditions. PMCS intervals must be
performed more frequently when operating under unusual conditions, to prevent premature
engine failure.

1. Always perform preventive maintenance in the same order so it gets to be a habit. Once you have had some
practice, you will spot anything wrong in a hurry.

2. Tools included with the TQG are to be used when doing the PMCS. Wiping rags are needed to remove dirt or
grease.

3. If you find something wrong when performing the PMCS, fix it if you can, using troubleshooting procedures
(see WP 0004 thru WP 0011) and/or maintenance procedures (see Chapter 3).

4. If something appears to be wrong and you cannot repair it, write it down on your DA Form 5988-E. If you find
something seriously wrong, report it to DS maintenance as soon as possible.

5. Item numbers in column 1 of WP 0016, PMCS Table 1 indicate the PMCS sequence. Use these item
numbers for the TM number column on DA Form 5988-E.

6. Information in column 6 of WP 0016, Table 1 lists conditions that make the TQG not ready/available. Write up
items not repaired on DA Form 5988-E for DS maintenance. For further information on how to use these
forms, see DA PAM 750-8.

7. Ensure all Operator PMCS has been performed, see TM 9-6115-730 -10.

FLUID LEAKAGE

Wetness around seals, gaskets, fittings, or connections indicates leakage. A stain also denotes leakage. If a fitting
or connector is loose, tighten it. If a fitting or connector is broken or defective, repair it.

Leak Definition for PMCS

CAUTION
Operation is allowable with class I and II leakage. However, any wetness or leakage of fuel is
classified as a class III leak and the TQG must be shut down immediately and the problem
corrected. All other class III leaks must be repaired immediately or reported to your supervisor.
When operating with class I or class II leaks, check fluid levels more frequently. Failure to do this
will result in damage to the 200 kW TQG.

1. Class I - Leakage indicated by wetness or discoloration, but not great enough to form drops.

2. Class II - Leakage great enough to form drops, but not enough to cause drops to drip from item being
checked/inspected.

3. Class III - Leakage great enough to form drops that fall from the item being checked/inspected.

0015-2
 TM 9-6115-730-24 0015

INSPECTION

Look for signs of a problem or trouble. You can feel, smell, hear, or see many problems. Be alert when in or around
the TQG.

Inspect the TQG to see if items are in good condition. Are they correctly assembled, stowed, and secured;
excessively worn, leaking, or corroded; or properly lubricated? Correct any problems found or notify DS
maintenance.

There are some common items to check all over the TQG. These include the following:

WARNING
Metal jewelry can conduct electricity and become entangled in generator set components.
Remove all metal jewelry when working on generator set. Failure to comply can cause injury or
death to personnel by electrocution.

High voltage is produced when this generator set is in operation. Make sure unit is completely
shut down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

WARNING
Cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye
protection are required when working in contact with cleaning solvent. Avoid repeated or
prolonged contact. Work in ventilated area only. Failure to comply can cause injury or death to
personnel.

1. Dirt, grease, oil, and debris: They only get in the way and may cover up a serious problem. Keep the equip-
ment clean. Clean as you work and as needed. Use Breakthrough cleaning solvent to clean metal surfaces.
Use soap and water to clean rubber or plastic material.

2. Bolts, clamps, nuts, and screws: Continuously check for looseness. Look for chipped paint, bare metal, rust,
or corrosion around bolt and screw heads and nuts. Tighten them when you find them loose (see WP 0085).

3. Welds: Many items on the TQG are welded. To check these welds, look for chipped paint, rust, corrosion, or
gaps. When these conditions exist, notify DS maintenance on DA Form 5988-E.

4. Electrical wires, connectors, and harnesses: Tighten loose connectors. Look for cracked or broken insulation,
bare wires, and broken connectors.

5. Hoses and fluid lines: Check hoses and fluid lines for wear, damage, and leaks. Ensure clamps and fittings
are tight.

6. Hinges: Check hinges for security and operation.

7. Data plates: Check data, caution, and warning plates for security and legibility.

0015-3
 TM 9-6115-730-24 0015

PMCS COLUMN DESCRIPTIONS (TABLE 1)

ITEM NO. - Lists order in which PMCS should be performed; also used as a source of item numbers for the TM
number column on DA Form 5988-E when recording results of PMCS.

INTERVAL - Indicates when each check is to be performed.

MANHOUR - Lists approximate time required to perform check.

ITEM TO BE CHECKED OR SERVICED - Lists item to be checked or serviced.

PROCEDURE - Provides brief description of procedure as well as any information required to accomplish each
check or service.

EQUIPMENT NOT READY/AVAILABLE IF - Lists condition in which TQG should not be operated or accepted.

END OF WORK PACKAGE

0015-4
 TM 9-6115-730-24 0016

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
PMCS, INCLUDING LUBRICATION INSTRUCTIONS

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

Table 1. Preventive Maintenance Checks and Services.

ITEM TO BE
CHECKED EQUIPMENT
ITEM MAN- OR NOT READY/
NO. INTERVAL HOUR SERVICED PROCEDURE AVAILABLE IF:
200 kW TQG
1 First 100 Engine Oil/Oil Change engine oil and oil filter Engine oil change/
hours Filter (WP 0079). filter change not
accomplished.
2 Quarterly or XM1061E1 Perform quarterly PMCS Any failed inspection.
300 hours Trailer (if (TM 9-2330-376-14&P).
mounted)
TQG EXTERIOR
3 Quarterly or Housing Check the entire housing, to include Any doors, panels,
300 hours doors, panels, latches, and hinges, for latches, or hinges
damage, missing parts, and secure damaged, loose, or
mounting. Check mounting points for missing parts.
rust or corrosion and loose or missing Mounting points
parts (WP 0018 thru WP 0040). loose.

0016-1
 TM 9-6115-730-24 0016

Table 1. Preventive Maintenance Checks and Services - Continued.

ITEM TO BE
CHECKED EQUIPMENT
ITEM MAN- OR NOT READY/
NO. INTERVAL HOUR SERVICED PROCEDURE AVAILABLE IF:
TQG INTERIOR
4 Quarterly or Control Box Check panel gauges, switches, Any gauges,
300 hours Assembly controls, decals/data plates for switches, controls,
damage, missing parts, readability, decals/data plates
and secure mounting (WP 0041, damaged or missing
WP 0042). parts. Any gauges or
decals/data plates
not readable. Any
loose components.
5 Quarterly or Reconnection Check reconnection terminal board Terminal board
300 hours Terminal for damage, rust, corrosion, missing damaged or missing
Board parts, and secure mounting parts. Terminal
(WP 0045). board cannot be
securely mounted.
6 Quarterly or Load Terminal Check load terminal board for Terminal board
300 hours Board damage, rust, corrosion, missing damaged or missing
parts, and secure mounting parts. Terminal
(WP 0046). board cannot be
securely mounted.
7 Quarterly or Battery Check battery cables for damage, Battery cables
300 hours Cables corrosion, missing parts, and secure damaged, corroded,
mounting. Check cables for fraying, or missing parts.
cuts, or nicks (WP 0047). Cables cannot be
securely mounted.
8 Quarterly or Batteries Clean battery terminals. Check Battery terminals
300 hours terminals for looseness, breaks, or loose, broken, or
damage (WP 0050). damaged. Batteries
will not hold charge.
9 Quarterly or Batteries (if Check electrolyte level; add distilled Electrolyte level
300 hours lead-acid water as required. below top of plates.
type)
10 Quarterly or Power Cables Check power cables for damage, Power cables
300 hours corrosion, missing parts, and secure damaged, corroded,
mounting. Check cables for fraying, or missing parts.
cuts, or nicks (WP 0048). Cables cannot be
securely mounted.

0016-2
 TM 9-6115-730-24 0016

Table 1. Preventive Maintenance Checks and Services - Continued.

ITEM TO BE
CHECKED EQUIPMENT
ITEM MAN- OR NOT READY/
NO. INTERVAL HOUR SERVICED PROCEDURE AVAILABLE IF:
11 Quarterly or Main Load Check main load contactor for Any defect that would
300 hours Contactor K1 corrosion, loose or missing parts, prevent operation.
loose cable connections, evidence of
arcing, or loose mounting (WP 0049).
12 Quarterly or Current Check seven current transformers for Any defect that would
300 hours Transformers corrosion, loose or missing parts, prevent operation.
loose connections, evidence of arcing
or overheating, leaking, or loose
mounting (WP 0052).
13 Quarterly or Power Check two potential transformers for Any defect that would
300 hours Transformers corrosion, loose or missing parts, prevent operation.
loose connections, evidence of arcing
or overheating, leaking, or loose
mounting (WP 0053).
14 Quarterly or Slave Check slave receptacle for corrosion, Any defect that would
300 hours Receptacle loose or missing parts, loose prevent operation.
connections, evidence of arcing or
overheating, or loose mounting
(WP 0054).
15 Quarterly or Electrical Check electrical components for Any defect that would
300 hours Installation corrosion, loose or missing parts, prevent operation.
loose connections, evidence of arcing
or overheating, or loose mounting
(WP 0055).
ENGINE
16 Quarterly or Engine Oil/Oil Change engine oil and oil filter Engine oil change/
300 hours Filter (WP 0079). filter change not
accomplished.
17 Quarterly or Oil Pan Check magnetic plug for metal Metal particles found
300 hours particles (WP 0079). on plug.
18 Quarterly or Fuel System Check fuel system for secure Any leaks or defect
300 hours mounting, leaks, damaged tubes or that would prevent
hoses (WP 0056 thru WP 0063). operation. Any leak
from fuel system.

0016-3
 TM 9-6115-730-24 0016

Table 1. Preventive Maintenance Checks and Services - Continued.

ITEM TO BE
CHECKED EQUIPMENT
ITEM MAN- OR NOT READY/
NO. INTERVAL HOUR SERVICED PROCEDURE AVAILABLE IF:
19 Quarterly or Fuel Filter Replace fuel filter (WP 0080). Fuel filter has not
300 hours been replaced as
required. Any leak.
20 Quarterly or Auxiliary Fuel Clean strainer (WP 0059). Strainer has not been
300 hours Pump Strainer cleaned as required.
Any leak.
21 Quarterly or Water Replace water separator filter element Water separator filter
300 hours Separator (WP 0061). has not been
Filter replaced as required.
Any leak.
22 Quarterly or Cooling Check radiator, coolant hoses, surge Any damage that will
300 hours System tank, fan and fan guards for damage prevent operation.
and secure mounting. Check radiator Any part that cannot
for damage or leaks. Use be securely mounted.
compressed air to remove debris from Radiator leaking or
radiator (WP 0064 thru WP 0068). damaged.
23 Quarterly or Cooling Check coolant level and add coolant Any discoloration,
300 hours System mixture as required. Inspect coolant rust, or
for discoloration, rust, or contamination.
contamination (WP 0064).
24 Quarterly or Muffler Check muffler for leaks, restrictions, Muffler leaks, is
300 hours accumulation of carbon deposits, and damaged, or loose.
loose hardware. Replace muffler if
required (WP 0069).
25 Quarterly or Winterization Check winterization kit components Any damage that will
300 hours Kit (if for rust, corrosion, missing parts, prevent operation.
installed) leaks, and secure mounting Any part that cannot
(WP 0089 thru WP 0093). be securely mounted.
Any leak.
26 Quarterly or Generator Check generator for damage, wear, Generator damaged,
300 hours rust, corrosion, missing parts, and worn, rusted, or
secure mounting. corroded. Parts
missing or loose
mounting.
27 Semiannually Air Cleaner Check air cleaner for cleanliness, Air cleaner clogged,
or 750 hours damage and secure mounting. damaged, or loose.
Clean or replace air filter element
(WP 0071). Clean housing with clean
cloth.

0016-4
 TM 9-6115-730-24 0016

Table 1. Preventive Maintenance Checks and Services - Continued.

ITEM TO BE
CHECKED EQUIPMENT
ITEM MAN- OR NOT READY/
NO. INTERVAL HOUR SERVICED PROCEDURE AVAILABLE IF:
28 Semiannually Crankcase Check crankcase ventilation filter for Filter clogged,
or 750 hours Ventilation cleanliness, damage, and secure damaged, or loose.
Filter mounting. Clean or replace filter
element (WP 0070).
29 Annually or Fan Belts Replace fan belts (WP 0075). Fan belts not
1500 hours replaced as required.
30 Annually or Cooling Drain and flush cooling system (see Cooling system has
1500 hours System TM 750-254). Add proper coolant not been flushed as
mixture (WP 0068). required.
31 Annually or Engine Inspect engine mounts for cracks, Any parts missing.
2000 hours Mounts worn, loose, or missing hardware, or Mounts loose or
loose mounting. broken.
32 Annually or Engine Clean engine exterior. Pay attention Engine dirty so that
2000 hours Cleanliness to areas which reveal leakage or leaks or damage
damage. cannot be detected.

0016-5
 TM 9-6115-730-24 0016

Table 2. PMCS Mandatory Replacement Parts List.

PART
ITEM NUMBER
NO. (CAGEC) NSN NOMENCLATURE QTY
QUARTERLY (300 HOURS)
1 1R0716 2940-00-125-9544 Oil Filter 1
(11083)
2 1R0749 2910-01-455-4730 Fuel Filter 1
(11083)
3 133-5671 2910-01-533-4447 Water Separator Filter Element with 1
(11083) Gasket
SEMIANNUAL (750 HOURS)
1 P182049 2940-01-254-9890 Air Cleaner Primary Filter Element 1
(18265)
2 P116446 2940-01-027-2217 Air Cleaner Safety Filter Element 1
(18265)
3 P105740 5330-01-027-9446 Gasket 1
(18265)
ANNUAL (1500 HOURS)
1 7M4707 3030-01-336-5525 Alternator V-Belt, Matched Set 1
(11083)

LUBRICATION INSTRUCTIONS

These lubrication instructions are for unit (O) maintenance. Lubrication intervals (on-condition or hard time) are
based on normal operation. Lubricate more frequently during constant use, and less during inactive periods. The
task-hour specified is the time you need to do all the services prescribed for a particular interval. Use correct
grade of lubricant for seasonal temperature expected. The lubrication intervals and symbols are listed below:

300 hours = Quarterly 1000 hours = Annually 2000 hours = Bi-Annually

0016-6
 TM 9-6115-730-24 0016

LUBRICATION INSTRUCTIONS - Continued

WARNING
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

High voltage is produced when this generator set is in operation. Make sure unit is completely
shut down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set, and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply can
cause injury or death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination.

Before you start your lubrications:

Always Never
a. Use Lubrication Instructions as your guide. a. Use wrong type/grade lubricant.
b. Use correct type/grade lubricant. b. Use too much lubricant.
c. Clean area where lubricant is to be applied to c. Apply lubricant to dirty components.
prevent buildup of dirt, grit, and contaminants.

Authorized lubricants and fluids are listed in Tables 3 through 6.

0016-7
 TM 9-6115-730-24 0016

LUBRICATION INSTRUCTIONS - Continued

Table 3. Engine Oil.

AMBIENT Degrees F -50 -30 -10 +10 +30 +50 +70 +90 +110 +130
TEMPERATURE Degrees C -46 -34 -23 -12 -1 10 21 32 43 54

MIL-PRF-46167 OEA

MIL-PRF-2104 OE/HDO-10

MIL-PRF-2104 OE/HDO-30

MIL-PRF-2104 OE/HDO-40

MIL-PRF-2104 OE/HDO-15/40

Winterization kit required below -25°F (-32°C).

Table 4. Engine Coolant.

AMBIENT
TEMPERATURE RADIATOR COOLANT RATIO NOTES
-50 to +120 degrees F A-A-52624 antifreeze/ Antifreeze 60% This offers the best freeze
(-46 to +49 degrees C) water Water 40% protection (-60 degrees F)
and the best boil protect-
tion (+232 degrees F).

40 to +120 degrees F Water with MIL-A-53009 35:1 No freeze or boil protec-

(+4 to +49 degrees C) corrosion inhibitor tion.

Table 5. Fuel.

AMBIENT Degrees F -50 -25 -15 0 +5 +15 +20 +30 +40 +70 +90 +110 +120
TEMP Degrees C -46 -32 -26 -18 -15 -9 -7 -1 +4 +21 +32 +38 +49

A-A-52557 DF-1

A-A-52557 DF-2

MIL-PFR-5624 JP-5
MIL-T-83133 JP-8

0016-8
 TM 9-6115-730-24 0016

LUBRICATION INSTRUCTIONS - Continued

Table 6. Lubrication Requirements.

INTERVAL USAGE CAPACITY LUBRICANT

First 100 hours Engine oil and oil filter 30 quarts (27.3 L) Engine Oil (see Table 3)
change (WP 0079)

Quarterly or 300 hours Engine oil and oil filter 30 quarts (27.3 L) Engine Oil (see Table 3)
change (WP 0079)

Annually or 1000 hours Door hinges N/A Engine oil (see Table 3)

Annually or 1000 hours Cooling system drain and 38 quart (36 L) Coolant mixture (see
flush (WP 0064) Table 4)

END OF WORK PACKAGE

0016-9/10 blank
 TM 9-6115-730-24 0017

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
GENERAL MAINTENANCE INSTRUCTIONS

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, One

Common No. 1 (WP 0123, Item 2)
Tool Kit, General Mechanic’s (WP 0123, Item 1) References

Materials/Parts TC 9-237
TM 9-6115-730-24P
Breakthrough cleaning solvent (WP 0124, Item 45)
Crocus cloth (WP 0124, Item 9)
Marker tags (WP 0124, Item 49)
Wiping rags (WP 0124, Item 35)

SCOPE

These general maintenance instructions contain general shop practices you must be familiar with to properly
maintain the TQG. You should read and understand these practices and methods before starting unit maintenance
tasks.

WORK SAFETY

Before starting any task, find out how much repair or replacement is needed to fix the equipment as described in
this manual. Sometimes the reason for equipment failure can be obvious and complete teardown is not necessary.
Disassemble equipment only as far as necessary to repair or replace damaged or broken parts.

All tags and forms attached to the equipment must be checked to learn the reason for removal from service. Also,
check Technical Bulletins (TB) for equipment changes and updates.

In some cases a part may be damaged by removal. If the part appears to be good and other parts behind it are not
defective, leave it on and continue the procedure.

CLEANING INSTRUCTIONS

Cleaning instructions will be the same for the majority of parts and components which make up the TQG.

The importance of cleaning must be thoroughly understood by maintenance personnel. Great care and effort are
required during cleaning. Dirt and foreign material are a constant threat to satisfactory maintenance. The following
should apply to all cleaning, inspection, repair, and assembly operations:

1. Clean all parts before inspection, after repair, and before assembly.

0017-1
 TM 9-6115-730-24 0017

CLEANING INSTRUCTIONS - Continued

2. Hands should be kept free of any accumulation of grease which can collect dust, dirt, and grit.

3. After cleaning, all parts should be covered or wrapped to protect them from dust and dirt.

Castings, Forgings, and Machined Metal Parts

WARNING
Cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye
protection are required when working in contact with cleaning solvent. Avoid repeated or
prolonged contact. Work in ventilated area only. Failure to comply can cause injury or death to
personnel.

1. Clean inner and outer surfaces with breakthrough cleaning solvent.

2. Remove grease and accumulated deposits with a stiff bristle brush.

WARNING
Cleaning with compressed air can cause flying particles. When using compressed air, wear
protective glasses and use clean, low pressure air, less than 30 psi (208 kPa). Failure to comply
can cause eye injury to personnel.

3. Blow out all tapped (threaded) holes with compressed air to remove dirt and cleaning fluids.

Electrical Cables and Rubber Components

CAUTION
Do not wash rubber components and electrical cables with breakthrough cleaning solvents or
mineral spirits; they will cause serious damage or destroy the material.

Wash electrical cables and rubber components with water and mild soap solution and wipe dry with rag.

INSPECTION INSTRUCTIONS

All components and parts must be carefully checked to determine the following:

1. If they are serviceable for reuse.

2. If they can be repaired.

3. If they must be replaced.

Drilled and Tapped (Threaded) Holes

1. Inspect for wear, distortion, cracks, or any other damage in or around holes.

2. Inspect threaded areas for wear, distortion (stretching), or evidence of cross-threading.

3. Mark all damaged areas for repair or replacement.

0017-2
 TM 9-6115-730-24 0017

INSPECTION INSTRUCTIONS - Continued

Castings, Forgings, and Machined Metal Parts

1. Inspect machined surfaces for nicks, burrs, raised metal, wear, or other damage.

2. Check all inner and outer surfaces for breaks or cracks.

3. Mark all damaged material for repair or replacement.

TAGGING INSTRUCTIONS

When tagging is required during the removal procedure, remove tags during the installation procedure.

REPAIR INSTRUCTIONS

NOTE
Refer to Source, Maintenance, and Recoverability (SMR) Codes assigned to support items listed
in the RPSTL (see TM 9-6115-730-24P).

Any repair procedure peculiar to a specific part or component is covered in the work package relating to that item.
After repair, clean all parts thoroughly to prevent dirt, metal chips, or other foreign material from entering working
parts.

Castings, Forgings, and Machined Metal Parts

1. Minor cracked castings or forgings may possibly be repaired. Refer to TC 9-237.

2. Repair minor damage to machined surfaces with a fine mill file or crocus cloth dipped in breakthrough
cleaning solvent.

3. Machined surfaces which are deeply nicked could affect the assembly operation and should be replaced.

4. Minor damage to threaded capscrew holes should be repaired with thread tap of same size to prevent cutting
oversize.

END OF WORK PACKAGE

0017-3/4 blank
 TM 9-6115-730-24 0018

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
RIGHT BATTERY ACCESS DOOR ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Foam damping sheet (WP 0124, Item 11) TM 9-6115-730-24P

Seal

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

1. Turn two latches (Figure 1, Item 1) and open right battery access door (Figure 1, Item 2).

2. Remove eight locknuts (Figure 1, Item 3), washers (Figure 1, Item 4), screws (Figure 1, Item 5), and right
battery access door (Figure 1, Item 2).

3. If necessary, remove seal.

END OF TASK

DISASSEMBLY

1. Remove seven locknuts (Figure 1, Item 6), screws (Figure 1, Item 7), and hinge (Figure 1, Item 8) from right
battery access door (Figure 1, Item 2).

2. Remove eight nuts (Figure 1, Item 9), screws (Figure 1, Item 10), and two latches (Figure 1, Item 1).

0018-1
 TM 9-6115-730-24 0018

DISASSEMBLY - Continued

Figure 1. Right Battery Access Door Assembly.

0018-2
 TM 9-6115-730-24 0018

DISASSEMBLY - Continued

3. Remove four nuts (Figure 1, Item 11), screws (Figure 1, Item 12), holding rod bracket (Figure 1, Item 13),
door holding rod (Figure 1, Item 14), and door holding bracket.

4. If necessary, remove foam damping.

END OF TASK

ASSEMBLY

1. If necessary, use old foam damping as template to cut new foam damping sheet.

2. Install foam damping.

3. Install door holding bracket (Figure 1, Item 15), door holding rod (Figure 1, Item 14), and holding rod bracket
(Figure 1, Item 13) and secure with four screws (Figure 1, Item 12) and nuts (Figure 1, Item 11).

4. Install two latches (Figure 1, Item 1) and secure with eight screws (Figure 1, Item 10) and nuts (Figure 1,
Item 9).

5. Install hinge (Figure 1, Item 8) and secure with seven screws (Figure 1, Item 7) and locknuts (Figure 1, Item
6).

END OF TASK

INSTALLATION

1. If removed, replace seal.

2. Install right battery access door (Figure 1, Item 2) and secure with seven screws (Figure 1, Item 5), washers
(Figure 1, Item 4), and locknuts (Figure 1, Item 3).

3. Close right battery access door (Figure 1, Item 2) and secure by rotating and closing two latches (Figure 1,
Item 1).

END OF TASK

END OF WORK PACKAGE

0018-3/4 blank
 TM 9-6115-730-24 0019

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
LEFT BATTERY ACCESS DOOR ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Foam damping sheet (WP 0124, Item 11) TM 9-6115-730-24P

Seal

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

1. Turn two latches (Figure 1, Item 1) and open right and left battery access doors (Figure 1, Item 2) and
(Figure 1, Item 3).

2. Remove eight locknuts (Figure 1, Item 4), screws (Figure 1, Item 5), and left battery access door (Figure 1,
Item 3).

3. If necessary, remove seal.

END OF TASK

DISASSEMBLY

1. Remove seven locknuts (Figure 1, Item 6), screws (Figure 1, Item 7), and hinge (Figure 1, Item 8) from left
battery access door (Figure 1, Item 3).

0019-1
 TM 9-6115-730-24 0019

DISASSEMBLY - Continued

Figure 1. Left Battery Access Door Assembly.

0019-2
 TM 9-6115-730-24 0019

DISASSEMBLY - Continued

2. Remove four screws (Figure 1, Item 9), nuts (Figure 1, Item 10), holding rod bracket (Figure 1, Item 11), door
holding rod (Figure 1, Item 12), and door holding bracket (Figure 1, Item 13).

3. If necessary, remove six screws (Figure 1, Item 14), spacers (Figure 1, Item 15), and foam damping
(Figure 1, Item 16).

END OF TASK

ASSEMBLY

1. If necessary, use old foam damping as template to cut new foam damping sheet.

2. Install foam damping (Figure 1, Item 16) on left battery access door (Figure 1, Item 3) and secure with six
spacers (Figure 1, Item 15) and screws (Figure 1, Item 14).

3. Install door holding bracket (Figure 1, Item 13), door holding rod (Figure 1, Item 12), and holding rod bracket
(Figure 1, Item 11) and secure with four nuts (Figure 1, Item 10) and screws (Figure 1, Item 9).

4. Install hinge (Figure 1, Item 8) and secure with seven screws (Figure 1, Item 7) and locknuts (Figure 1, Item
6).

END OF TASK

INSTALLATION

1. If removed, install seal.

2. Install left battery access door (Figure 1, Item 3) and secure with seven screws (Figure 1, Item 5) and
locknuts (Figure 1, Item 4).

3. Close left and right battery access doors (Figure 1, Item 3) and (Figure 1, Item 2) and secure by rotating and
closing two latches (Figure 1, Item 1).

END OF TASK

END OF WORK PACKAGE

0019-3/4 blank
 TM 9-6115-730-24 0020

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
CONTROL BOX DOOR ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

References

TM 9-6115-730-24P

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

1. Turn two latches (Figure 1, Item 1) and open control box door (Figure 1, Item 2).

2. Remove eight lockwashers (Figure 1, Item 3), washers (Figure 1, Item 4), screws (Figure 1, Item 5), and
control box door (Figure 1, Item 2).

END OF TASK

DISASSEMBLY

1. Remove eight nuts (Figure 1, Item 6), screws (Figure 1, Item 7), and two latches (Figure 1, Item 1).

2. Remove eight locknuts (Figure 1, Item 8), screws (Figure 1, Item 9), and hinge (Figure 1, Item 10).

END OF TASK

0020-1
 TM 9-6115-730-24 0020

ASSEMBLY

1. Install hinge (Figure 1, Item 10) on control box door (Figure 1, Item 2) and secure with eight screws (Figure 1,
Item 9) and locknuts (Figure 1, Item 8).

2. Install two latches (Figure 1, Item 1) and secure with eight screws (Figure 1, Item 7) and nuts (Figure 1,
Item 6).

END OF TASK

INSTALLATION

1. Install control box door (Figure 1, Item 2) and secure with eight lockwashers (Figure 1, Item 5), washers
(Figure 1, Item 4), and screws (Figure 1, Item 3).

2. Close control box door (Figure 1, Item 2) and secure by rotating and closing two latches (Figure 1, Item 1).

0020-2
 TM 9-6115-730-24 0020

INSTALLATION - Continued

Figure 1. Control Box Door Assembly.

END OF TASK

END OF WORK PACKAGE

0020-3/4 blank
 TM 9-6115-730-24 0021

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
LEFT FRONT DOOR ASSEMBLY (LATCH) MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Foam damping sheet (WP 0124, Item 10) TM 9-6115-730-24P

Foam damping sheet (WP 0124, Item 11)
Seal

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

1. Turn two latches (Figure 1, Item 1) and open left front door assembly (latch) (Figure 1, Item 2).

2. Remove thirteen screws (Figure 1, Item 3), and lockwashers (Figure 1, Item 4), washers (Figure 1, Item 5),
left front door assembly (latch) (Figure 1, Item 2).

3. If necessary, remove seal.

END OF TASK

DISASSEMBLY

1. Remove six foam damping sheets as required.

0021-1
 TM 9-6115-730-24 0021

DISASSEMBLY - Continued

Figure 1. Left Front Door Assembly (Latch).

0021-2
 TM 9-6115-730-24 0021

DISASSEMBLY - Continued

2. Remove two wing nuts (Figure 1, Item 6) and two locknuts (Figure 1, Item 7) and two rod retainer latches
(Figure 1, Item 8).

3. Remove eleven screws (Figure 1, Item 9), lockwashers (Figure 1, Item 10), washers (Figure 1, Item 11), and
duct (Figure 1, Item 12).

4. Remove eight nuts (Figure 1, Item 13), screws (Figure 1, Item 14), and two latches (Figure 1, Item 1).

5. Remove four nuts (Figure 1, Item 15), screws (Figure 1, Item 16), holding rod bracket (Figure 1, Item 17),
door holding rod (Figure 1, Item 18), and door holding bracket (Figure 1, Item 19).

6. Remove eight locknuts (Figure 1, Item 20), screws (Figure 1, Item 22), washers (Figure 1, Item 21), and two
rod retainer brackets (Figure 1, Item 23).

7. Remove thirteen locknuts (Figure 1, Item 24), screws (Figure 1, Item 25), and hinge (Figure 1, Item 26).

END OF TASK

ASSEMBLY

1. Install hinge (Figure 1, Item 26) and secure with thirteen screws (Figure 1, Item 25) and locknuts (Figure 1,
Item 24).

2. Install two latches (Figure 1, Item 1) and secure with eight screws (Figure 1, Item 14) and nuts (Figure 1,
Item 13).

3. Install two rod retainer brackets (Figure 1, Item 23) and secure with eight screws (Figure 1, Item 22), washers
(Figure 1, Item 21), and locknuts (Figure 1, Item 20).

4. Install door holding bracket (Figure 1, Item 19), door holding rod (Figure 1, Item 18), holding rod bracket
(Figure 1, Item 17) and secure with four screws (Figure 1, Item 16) and nuts (Figure 1, Item 15).

5. Install duct (Figure 1, Item 12) and secure with eleven washers (Figure 1, Item 11), lockwashers (Figure 1,
Item 10), and screws (Figure 1, Item 9).

6. Install two rod retainer latches (Figure 1, Item 8) and secure with two locknuts (Figure 1, Item 7) and two wing
nuts (Figure 1, Item 6).

7. If necessary, use old foam damping sheets as templates to cut new foam damping sections.

8. Install six foam damping sheets.

END OF TASK

0021-3
 TM 9-6115-730-24 0021

INSTALLATION

1. If necessary, install seal.

2. Install left front door assembly (latch) (Figure 1, Item 2) and secure with thirteen screws (Figure 1,
Item 3), lockwashers (Figure 1, Item 4), and washers (Figure 1, Item 5).

3. Close left front door assembly (latch) (Figure 1, Item 2) and secure by rotating and closing two latches
(Figure 1, Item 1).

END OF TASK

END OF WORK PACKAGE

0021-4
 TM 9-6115-730-24 0022

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
LEFT REAR DOOR ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Foam damping sheet (WP 0124, Item 10) TM 9-6115-730-24P

Seal

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

1. Turn two latches (Figure 1, Sheet 1, Item 1) and open left rear doors (Figure 1, Sheet 1, Item 2) and
(Figure 1, Sheet 1, Item 3).

2. Remove ten screws (Figure 1, Sheet 1, Item 4), lockwashers (Figure 1, Sheet 1, Item 5), washers (Figure 1,
Sheet 1, Item 6), and left rear door assembly (Figure 1, Sheet 1, Item 3).

3. If necessary, remove seal.

END OF TASK

DISASSEMBLY

1. Remove fifteen screws (Figure 1, Sheet 1, Item 10), lockwashers (Figure 1, Sheet 1, Item 11), washers
(Figure 1, Sheet 1, Item 12), duct (Figure 1, Sheet 1, Item 13), and door holding rod (Figure 1, Sheet 1,
Item 14).

0022-1
 TM 9-6115-730-24 0022

DISASSEMBLY - Continued

Figure 1. Left Rear Door Assembly (Sheet 1 of 2).

0022-2
 TM 9-6115-730-24 0022

DISASSEMBLY - Continued

Figure 1. Left Rear Door Assembly (Sheet 2 of 2).

0022-3
 TM 9-6115-730-24 0022

DISASSEMBLY - Continued

2. Remove eight screws (Figure 1, Sheet 2, Item 15), lockwashers (Figure 1, Sheet 2, Item 16), washers
(Figure 1, Sheet 2, Item 17), and deflector (Figure 1, Sheet 2, Item 18).

3. Remove four screws (Figure 1, Sheet 2, Item 19), lockwashers (Figure 1, Sheet 2, Item 20), washers
(Figure 1, Sheet 2, Item 21), and baffle (Figure 1, Sheet 2, Item 22).

4. Remove eight screws (Figure 1, Sheet 2, Item 23), lockwashers (Figure 1, Sheet 2, Item 24), washers (Figure
1, Sheet 2, Item 25), and baffle (Figure 1, Sheet 2, Item 26).

5. Remove twenty foam damping sheets as required.

6. Remove ten locknuts (Figure 1, Sheet 1, Item 7), screws (Figure 1, Sheet 1, Item 8), and hinge (Figure 1,
Sheet 1, Item 9).

END OF TASK

ASSEMBLY

1. If necessary, use old foam damping sheets as templates to cut new foam damping sections.

2. Install twenty foam damping sheets.

3. Install baffle (Figure 1, Sheet 2, Item 26) on duct (Figure 1, Sheet 1, Item 13), and secure with four washers
(Figure 1, Sheet 2, Item 25), lockwashers (Figure 1, Sheet 2, Item 24), and screws (Figure 1, Sheet 2,
Item 23).

4. Install baffle (Figure 1, Sheet 2, Item 22) on duct (Figure 1, Sheet 1, Item 13), and secure with four washers
(Figure 1, Sheet 2, Item 21), lockwashers (Figure 1, Sheet 2, Item 20), and screws (Figure 1, Sheet 2,
Item 19).

5. Install deflector (Figure 1, Sheet 2, Item 18) on duct (Figure 1, Sheet 1, Item 13), and secure with four
washers (Figure 1, Sheet 2, Item 17), lockwashers (Figure 1, Sheet 2, Item 16), and screws (Figure 1,
Sheet 2, Item 15).

6. Install duct (Figure 1, Sheet 1, Item 13) on rear door assembly (Figure 1, Sheet 1, Item 3) and secure with
fifteen washers (Figure 1, Sheet 1, Item 12), lockwashers (Figure 1, Sheet 1, Item 11), and screws (Figure 1,
Sheet 1, Item 10). Install door holding rod (Figure 1, Sheet 1, Item 14).

7. Install hinge (Figure 1, Sheet 1, Item 9), and secure with ten screws (Figure 1, Sheet 1, Item 8), and locknuts
(Figure 1, Sheet 1, Item 7).

END OF TASK

0022-4
 TM 9-6115-730-24 0022

INSTALLATION

1. If necessary, install seal.

2. Install left rear door assembly (Figure 1, Sheet 1, Item 3) and secure with ten washers (Figure 1, Sheet 1,
Item 6), lockwashers (Figure 1, Sheet 1, Item 5), and screws (Figure 1, Sheet 1, Item 4).

3. Close left rear doors (Figure 1, Sheet 1, Item 3) and (Figure 1, Sheet 1, Item 2), and secure by rotating two
latches (Figure 1, Sheet 1, Item 1).

END OF TASK

END OF WORK PACKAGE

0022-5/6 blank
 TM 9-6115-730-24 0023

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
LEFT REAR DOOR ASSEMBLY (LATCH) MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Foam damping sheet (WP 0124, Item 10) TM 9-6115-730-24P

Seal

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

1. Turn two latches (Figure 1, Sheet 1, Item 1) and open left rear door assembly (latch) (Figure 1, Sheet 1,
Item 2).

2. Remove ten lockwashers (Figure 1, Sheet 1, Item 3), washers (Figure 1, Sheet 1, Item 4), screws (Figure 1,
Sheet 1, Item 5), and left rear door assembly (latch) (Figure 1, Sheet 1, Item 2).

3. If necessary, remove seal.

END OF TASK

DISASSEMBLY

1. Remove eight nuts (Figure 1, Sheet 1, Item 9), screws (Figure 1, Sheet 1, Item 10), and two latches (Figure 1,
Sheet 1, Item 1).

0023-1
 TM 9-6115-730-24 0023

DISASSEMBLY - Continued

Figure 1. Left Rear Door Assembly (Latch) (Sheet 1 of 2).

0023-2
 TM 9-6115-730-24 0023

DISASSEMBLY - Continued

Figure 1. Left Rear Door Assembly (Latch) (Sheet 2 of 2).

0023-3
 TM 9-6115-730-24 0023

DISASSEMBLY - Continued

2. Remove door holding rod (Figure 1, Sheet 1, Item 11).

3. Remove 14 screws (Figure 1, Sheet 1, Item 12), washers (Figure 1, Sheet 1, Item 13), lockwashers (Figure 1,
Sheet 1, Item 14), and duct (Figure 1, Sheet 1, Item 15).

4. Remove eight nuts (Figure 1, Sheet 2, Item 16), screws (Figure 1, Sheet 2, Item 17), and storage box
(Figure 1, Sheet 2, Item 18).

5. Remove four screws (Figure 1, Sheet 2, Item 19), washers (Figure 1, Sheet 2, Item 20), lockwashers
(Figure 1, Sheet 2, Item 21), and baffle (Figure 1, Sheet 2, Item 22).

6. Remove six screws (Figure 1, Sheet 2, Item 23), washers (Figure 1, Sheet 2, Item 24), lockwashers (Figure 1,
Sheet 2, Item 25), and baffle (Figure 1, Sheet 2, Item 26).

7. Remove nine foam damping sheets as required.

8. Remove ten locknuts (Figure 1, Sheet 1, Item 6), screws (Figure 1, Sheet 1, Item 7), and hinge (Figure 1,
Sheet 1, Item 8).

END OF TASK

ASSEMBLY

1. Install hinge (Figure 1, Sheet 1, Item 8) and secure with ten screws (Figure 1, Sheet 1, Item 7), and locknuts
(Figure 1, Sheet 1, Item 6).

2. If necessary, use old foam damping sheets as templates to cut new foam damping sections.

3. Install nine foam damping sheets.

4. Install baffle (Figure 1, Sheet 2, Item 26) on duct (Figure 1, Sheet 1, Item 15) and secure with six lockwashers
(Figure 1, Sheet 2, Item 25), washers (Figure 1, Sheet 2, Item 24), and screws (Figure 1, Sheet 2, Item 23).

5. Install baffle (Figure 1, Sheet 2, Item 22) on duct (Figure 1, Sheet 1, Item 15) and secure with four
lockwashers (Figure 1, Sheet 2, Item 21), washers (Figure 1, Sheet 2, Item 20), and screws (Figure 1,
Sheet 2, Item 19).

6. Install storage box (Figure 1, Sheet 2, Item 18) on duct (Figure 1, Sheet 1, Item 15) and secure with eight
screws (Figure 1, Sheet 2, Item 17) and nuts (Figure 1, Sheet 2, Item 16).

7. Install duct (Figure 1, Sheet 1, Item 15) and secure with 14 lockwashers (Figure 1, Sheet 1, Item 14), washers
(Figure 1, Sheet 1, Item 13), and screws (Figure 1, Sheet 1, Item 12).

8. Install door holding rod (Figure 1, Sheet 1, Item 11).

9. Install two latches (Figure 1, Sheet 1, Item 1) and secure with eight screws (Figure 1, Sheet 1, Item 10) and
nuts (Figure 1, Sheet 1, Item 9).

END OF TASK

0023-4
 TM 9-6115-730-24 0023

INSTALLATION

1. Install left rear door assembly (latch) (Figure 1, Sheet 1, Item 2) and secure with ten screws (Figure 1,
Sheet 1, Item 5), washers (Figure 1, Sheet 1, Item 4), and lockwashers (Figure 1, Sheet 1, Item 3).

2. Close left rear door assembly (latch) (Figure 1, Sheet 1, Item 2) and secure by rotating two latches (Figure 1,
Sheet 1, Item 1).

END OF TASK

END OF WORK PACKAGE

0023-5/6 blank
 TM 9-6115-730-24 0024

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
LOAD BOARD DOOR ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Foam damping sheet (WP 0124, Item 10) TM 9-6115-730-24P

Foam damping sheet (WP 0124, Item 11)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

1. Turn latch (Figure 1, Item 1) and open load board door assembly (Figure 1, Item 2).

2. Remove four screws (Figure 1, Item 3), washers (Figure 1, Item 4), lockwashers (Figure 1, Item 5), and load
board door assembly (Figure 1, Item 2).

END OF TASK

DISASSEMBLY

1. Remove three nuts (Figure 1, Item 6) and screws (Figure 1, Item 7).

2. Remove four nuts (Figure 1, Item 8), screws (Figure 1, Item 9), and latch (Figure 1, Item 1).

3. Remove nut (Figure 1, Item 10), screw (Figure 1, Item 11), wrench (Figure 1, Item 12), cord (Figure 1,
Item 13), and hinge (Figure 1, Item 14).

0024-1
 TM 9-6115-730-24 0024

DISASSEMBLY - Continued

Figure 1. Load Board Door Assembly.

0024-2
 TM 9-6115-730-24 0024

DISASSEMBLY - Continued

4. Remove four nuts (Figure 1, Item 15), screws (Figure 1, Item 16), and wrench mounting plate (Figure 1,
Item 17).

5. Remove foam damping sheets as required.

END OF TASK

ASSEMBLY

1. If necessary, use old foam damping sheets as template to cut new foam damping sheets.

2. Install foam damping sheets.

3. Install wrench mounting plate (Figure 1, Item 17), four screws (Figure 1, Item 16), and nuts (Figure 1,
Item 15).

4. Install hinge (Figure 1, Item 14), cord (Figure 1, Item 13) and wrench (Figure 1, Item 12), and secure with
screw (Figure 1, Item 11) and nut (Figure 1, Item 10).

5. Install latch (Figure 1, Item 1) and secure with four screws (Figure 1, Item 9) and nuts (Figure 1, Item 8).

6. Install three screws (Figure 1, Item 7) and nuts (Figure 1, Item 6).

END OF TASK

INSTALLATION

1. Install load board door assembly (Figure 1, Item 2) and secure with four lockwashers (Figure 1, Item 5),
washers (Figure 1, Item 4), and screws (Figure 1, Item 3).

2. Close load board door assembly (Figure 1, Item 2) and secure by rotating and closing latch (Figure 1, Item 1).

END OF TASK

END OF WORK PACKAGE

0024-3/4 blank
 TM 9-6115-730-24 0025

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
RIGHT FRONT DOOR ASSEMBLY (LATCH) MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Foam damping sheet (WP 0124, Item 10) TM 9-6115-730-24P

Foam damping sheet (WP 0124, Item 11)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

1. Turn two latches (Figure 1, Item 1) and open right front door assembly (latch) (Figure 1, Item 2).

2. Remove thirteen screws (Figure 1, Item 3), washers (Figure 1, Item 4), lockwashers (Figure 1, Item 5), and
right front door assembly (latch) (Figure 1, Item 2).

END OF TASK

DISASSEMBLY

1. Remove thirteen locknuts (Figure 1, Item 6), screws (Figure 1, Item 7), and hinge (Figure 1, Item 8) from right
front door assembly (latch) (Figure 1, Item 2).

2. Remove eight nuts (Figure 1, Item 9), screws (Figure 1, Item 10), and two latches (Figure 1, Item 1).

3. Remove four nuts (Figure 1, Item 11), screws (Figure 1, Item 12), door holding bracket (Figure 1, Item 13),
door holding rod (Figure 1, Item 14), and holding rod bracket (Figure 1, Item 15).

0025-1
 TM 9-6115-730-24 0025

DISASSEMBLY - Continued

Figure 1. Right Front Door Assembly (Latch).

0025-2
 TM 9-6115-730-24 0025

DISASSEMBLY - Continued

4. Remove twelve screws (Figure 1, Item 16), washers (Figure 1, Item 17), lockwashers (Figure 1, Item 18), and
duct (Figure 1, Item 19).

5. Remove eight foam damping sheets as required.

END OF TASK

ASSEMBLY

1. If necessary, use old foam damping sheets as templates to cut new foam damping sheets.

2. Install eight damping sheets.

3. Install duct (Figure 1, Item 19) and secure with twelve lockwashers (Figure 1, Item 18), washers (Figure 1,
Item 17), and screws (Figure 1, Item 16).

4. Install holding rod bracket (Figure 1, Item 15), door holding rod (Figure 1, Item 14), door holding bracket
(Figure 1, Item 13), and secure with four screws (Figure 1, Item 12), and nuts (Figure 1, Item 11).

5. Install two latches (Figure 1, Item 1) and secure with eight screws (Figure 1, Item 10) and nuts (Figure 1,
Item 9).

6. Install hinge (Figure 1, Item 8) and secure with thirteen screws (Figure 1, Item 7) and locknuts (Figure 1,
Item 6).

END OF TASK

INSTALLATION

1. Install right front door assembly (latch) (Figure 1, Item 2) and secure with thirteen lockwashers (Figure 1,
Item 5), washers (Figure 1, Item 4), and screws (Figure 1, Item 3).

2. Close right front door assembly (latch) (Figure 1, Item 2) and secure by rotating and closing two latches
(Figure 1, Item 1).

END OF TASK

END OF WORK PACKAGE

0025-3/4 blank
 TM 9-6115-730-24 0026

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
RIGHT FRONT DOOR ASSEMBLY AND STORAGE BOX ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Foam damping sheet (WP 0124, Item 11) TM 9-6115-730-24P

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

Right Front Door Assembly

1. Turn two latches (Figure 1, Item 1) and open right front doors (Figure 1, Item 2) and (Figure 1, Item 3).

2. Remove thirteen screws (Figure 1, Item 4), washers (Figure 1, Item 5), lockwashers (Figure 1, Item 6), and
right front door assembly (Figure 1, Item 3).

3. Remove seal as required.

0026-1
 TM 9-6115-730-24 0026

REMOVAL - Continued

Figure 1. Right Front Door Assembly.

END OF TASK

0026-2
 TM 9-6115-730-24 0026

DISASSEMBLY

Right Front Door Assembly

1. Remove twelve screws (Figure 1, Item 15), washers (Figure 1, Item 16), lockwashers (Figure 1, Item 17), and
duct (Figure 1, Item 18).

2. Remove four nuts (Figure 1, Item 10), screws (Figure 1, Item 11), door holding bracket (Figure 1, Item 12),
door holding rod (Figure 1, Item 13), and holding rod bracket (Figure 1, Item 14).

3. Remove thirteen locknuts (Figure 1, Item 7), screws (Figure 1, Item 8), and hinge (Figure 1, Item 9) from right
front door assembly (Figure 1, Item 3).

4. Remove six foam damping sheets as required.

END OF TASK

ASSEMBLY

Right Front Door Assembly

1. Install hinge (Figure 1, Item 9) and secure with thirteen screws (Figure 1, Item 8) and locknuts (Figure 1,
Item 7).

2. Install seal as required.

3. If necessary, use old foam damping sheets as templates to cut new foam damping sheets.

4. Install six damping sheets.

5. Install duct (Figure 1, Item 18) on right front door assembly (Figure 1, Item 3), and secure with eighteen
lockwashers (Figure 1, Item 17), washers (Figure 1, Item 16), and screws (Figure 1, Item 15).

6. Install holding rod bracket (Figure 1, Item 14), door holding rod (Figure 1, Item 13), door holding bracket
(Figure 1, Item 12), and secure with four screws (Figure 1, Item 11) and nuts (Figure 1, Item 10).

END OF TASK

INSTALLATION

Right Front Door Assembly

1. Install right front door assembly (Figure 1, Item 3) and secure with thirteen lockwashers (Figure 1, Item 6),
washers (Figure 1, Item 5), and screws (Figure 1, Item 4).

2. Close right front doors (Figure 1, Item 3) and (Figure 1, Item 2) and secure by rotating and closing two latches
(Figure 1, Item 1).

END OF TASK

0026-3
 TM 9-6115-730-24 0026

REMOVAL

Storage Box Assembly

1. Open right front generator housing doors.

2. Remove six screws (Figure 1, Item 1), and storage box assembly (Figure 1, Item 2).

END OF TASK

DISASSEMBLY

Storage Box Assembly

1. Remove screws (Figure 2, Item 3), nut (Figure 2, Item 4), and latch (Figure 2, Item 5).

2. Remove four screws (Figure 2, Item 6), nuts (Figure 2, Item 7), and storage box door (Figure 2, Item 8).

3. Remove three nuts (Figure 2, Item 9), screws (Figure 2, Item 10), and hinge (Figure 2, Item 11).

END OF TASK

ASSEMBLY

Storage Box Assembly

1. Install hinge (Figure 2, Item 11) and secure with three screws (Figure 2, Item 10) and nuts (Figure 2, Item 9).

2. Install storage box door (Figure 2, Item 8) using four screws (Figure 2, Item 6), nuts (Figure 2, Item 7).

3. Install latch (Figure 2, Item 5), and secure with screw (Figure 2, Item 3) and nut (Figure 2, Item 4).

END OF TASK

INSTALLATION

Storage Box Assembly

1. Install storage box assembly (Figure 2, Item 2) using six screws (Figure 2, Item 1).

2. Close right front generator set housing doors.

0026-4
 TM 9-6115-730-24 0026

INSTALLATION - Continued

Figure 2. Storage Box Assembly.

END OF TASK

END OF WORK PACKAGE

0026-5/6 blank
 TM 9-6115-730-24 0027

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
RIGHT REAR DOOR ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Foam damping sheet (WP 0124, Item 11) TM 9-6115-730-24P

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

1. Turn two latches (Figure 1, Item 1) and open right rear doors (Figure 1, Item 2) and (Figure 1, Item 3).

2. Remove nine lockwashers (Figure 1, Item 4), washers (Figure 1, Item 5), screws (Figure 1, Item 6), and right
rear door assembly (Figure 1, Item 3).

3. Remove seal as required.

END OF TASK

DISASSEMBLY

1. Remove eleven screws (Figure 1, Item 10), lockwashers (Figure 1, Item 11), washers (Figure 1, Item 12), and
duct (Figure 1, Item 13).

2. Remove nine locknuts (Figure 1, Item 7), screws (Figure 1, Item 8), and hinge (Figure 1, Item 9).

0027-1
 TM 9-6115-730-24 0027

DISASSEMBLY - Continued

Figure 1. Right Rear Door Assembly.

0027-2
 TM 9-6115-730-24 0027

DISASSEMBLY - Continued

3. Remove door holding rod (Figure 1, Item 14).

4. Remove six foam damping sheets as required.

END OF TASK

ASSEMBLY

1. Install hinge (Figure 1, Item 9) and secure with nine screws (Figure 1, Item 8) and locknuts (Figure 1, Item 7).

2. If necessary, use old foam damping sheets as templates to cut new foam damping sheets.

3. Install six foam damping sheets.

4. Install door holding rod (Figure 1, Item 14).

5. Install duct (Figure 1, Item 13) and secure with eleven washers (Figure 1, Item 12), lockwashers (Figure 1,
Item 11), and screws (Figure 1, Item 10).

END OF TASK

INSTALLATION

1. Install seal as required.

2. Install right rear door assembly (Figure 1, Item 3) and secure with nine screws (Figure 1, Item 6), washers
(Figure 1, Item 5), and lockwashers (Figure 1, Item 4).

3. Close right rear doors (Figure 1, Item 3) and (Figure 1, Item 2) and secure by rotating two latches (Figure 1,
Item 1).

END OF TASK

END OF WORK PACKAGE

0027-3/4 blank
 TM 9-6115-730-24 0028

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
RIGHT REAR DOOR ASSEMBLY (LATCH) MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Foam damping sheet (WP 0124, Item 11) TM 9-6115-730-24P

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

1. Turn two latches (Figure 1, Item 1) and open right rear door assembly (latch) (Figure 1, Item 2).

2. Remove nine screws (Figure 1, Item 3), washers (Figure 1, Item 4), lockwashers (Figure 1, Item 5), and right
rear door assembly (latch) (Figure 1, Item 2).

3. Remove seal as required.

END OF TASK

DISASSEMBLY

1. Remove twelve screws (Figure 1, Item 9), lockwashers (Figure 1, Item 10), washers (Figure 1, Item 11), and
duct (Figure 1, Item 12).

2. Remove four nuts (Figure 1, Item 13), screws (Figure 1, Item 14), door holding bracket (Figure 1, Item 15),
door holding rod (Figure 1, Item 16), and holding rod bracket (Figure 1, Item 17).

0028-1
 TM 9-6115-730-24 0028

DISASSEMBLY - Continued

Figure 1. Right Rear Door Assembly (Latch).

0028-2
 TM 9-6115-730-24 0028

DISASSEMBLY - Continued

3. Remove eight nuts (Figure 1, Item 18), screws (Figure 1, Item 19), and two latches (Figure 1, Item 1).

4. Remove five foam damping sheets as required.

5. Remove nine locknuts (Figure 1, Item 6), screws (Figure 1, Item 7), and hinge (Figure 1, Item 8).

END OF TASK

ASSEMBLY

1. Install hinge (Figure 1, Item 8) and secure with nine screws (Figure 1, Item 7) and locknuts (Figure 1, Item 6).

2. If necessary, use old foam damping sheets as templates to cut new foam damping sheets.

3. Install five foam damping sheets.

4. Install two latches (Figure 1, Item 1), and secure with eight screws (Figure 1, Item 19) and nuts (Figure 1,
Item 18).

5. Install holding rod bracket (Figure 1, Item 17), door holding rod (Figure 1, Item 16), and door holding bracket
(Figure 1, Item 15), and secure with four screws (Figure 1, Item 14) and nuts (Figure 1, Item 13).

6. Install duct (Figure 1, Item 12) and secure with twelve washers (Figure 1, Item 11), lockwashers (Figure 1,
Item 10), and screws (Figure 1, Item 9).

END OF TASK

INSTALLATION

1. Install seal as required.

2. Install right rear door assembly (latch) (Figure 1, Item 2) and secure with nine lockwashers (Figure 1, Item 5),
washers (Figure 1, Item 4), and screws (Figure 1, Item 3).

3. Close right rear door assembly (latch) (Figure 1, Item 2) and secure by rotating and closing two latches
(Figure 1, Item 1).

END OF TASK

END OF WORK PACKAGE

0028-3/4 blank
 TM 9-6115-730-24 0029

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
ACCESS COVERS MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Foam damping sheet (WP 0124, Item 11) TM 9-6115-730-24P

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

1. Remove four screws (Figure 1, Item 1), lockwashers (Figure 1, Item 2), washers (Figure 1, Item 3), and right
side access cover (Figure 1, Item 4).

2. Remove four screws (Figure 1, Item 5), lockwashers (Figure 1, Item 6), washers (Figure 1, Item 7), and roof
mounted access cover (Figure 1, Item 8).

END OF TASK

DISASSEMBLY

Remove foam damping sheet as required.

END OF TASK

0029-1
 TM 9-6115-730-24 0029

ASSEMBLY

If necessary, use old foam damping sheet as template to cut new foam damping sheet. Install foam damping sheet.

END OF TASK

INSTALLATION

1. Install roof mounted access cover (Figure 1, Item 8) and secure with eight washers (Figure 1, Item 7),
lockwashers (Figure 1, Item 6), and screws (Figure 1, Item 5).

2. Install right side mounted access cover (Figure 1, Item 4) and secure with eight washers (Figure 1, Item 3),
lockwashers (Figure 1, Item 2), and screws (Figure 1, Item 1).

0029-2
 TM 9-6115-730-24 0029

INSTALLATION - Continued

Figure 1. Access Covers.

END OF TASK

END OF WORK PACKAGE

0029-3/4 blank
 TM 9-6115-730-24 0030

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
FRONT ROOF SECTION HOUSING ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Tool Kit, General Mechanic’s (WP 0123, Item 1) TM 9-6115-730-24P

Materials/Parts Equipment Condition

Foam damping sheet (WP 0124, Item 12) Roof mounted access cover removed (WP 0029)
Foam damping sheet (WP 0124, Item 14)
Foam damping sheet (WP 0124, Item 15)

Personnel Required

Two

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

WARNING
Top housing panels can get very hot. Allow panels to cool down before performing maintenance.
Failure to comply can result in severe burns to personnel.

WARNING
Front roof section weighs more than 37 pounds (17 kg) and requires a two-person lift. Lifting front
roof section can cause back strain. Ensure proper lifting techniques are used when lifting front
roof section. Failure to comply can cause injury to personnel.

0030-1
 TM 9-6115-730-24 0030

REMOVAL

1. On EMCP, set ENGINE CONTROL switch to OFF/RESET; set Battery Disconnect Switch to OFF; set DEAD
CRANK SWITCH to OFF.

2. Remove 62 screws (Figure 1, Sheet 1, Item 1), washers (Figure 1, Sheet 1, Item 2), and lockwashers
(Figure 1, Sheet 1, Item 3).

3 Loosen clamp (Figure 1, Sheet 1, Item 5) connecting coolant filler hose (Figure 1, Item, 6) to bottom of coolant
filler neck (Figure 1, Sheet 1, Item 7) and disconnect hose.

4. Remove clamp (Figure 1, Sheet 1, Item 8) from overflow hose (Figure 1, Sheet 1, Item 9) at coolant filler neck
(Figure 1, Sheet 1, Item 7) and pull hose back through hole in front roof section (Figure 1, Sheet 1, Item 4).

5. Remove exhaust clamp (Figure 1, Sheet 1, Item 10) by removing two screws (Figure 1, Sheet 1, Item 11) and
lockwashers (Figure 1, Sheet 1, Item 12) (access through access hole).

NOTE
Sufficient force is required for removal. Use slide and lift motion to release front roof housing
section.

6. Using two persons, slide front roof section housing assembly (Figure 1, Sheet 1, Item 4) toward front of
generator set in order to separate exhaust out tube assembly (Figure 1, Sheet 2, Item 21) from muffler. Lift
and remove front roof section housing assembly.

END OF TASK

DISASSEMBLY

1. If necessary, remove 119 clips (Figure 1, Sheet 2, Item 13), 75 push-on nuts (Figure 1, Sheet 2, Item 14), and
14 foam damping sheets.

2. Remove eight screws (Figure 1, Sheet 2, Item 15), washers (Figure 1, Sheet 2, Item 16), lockwashers
(Figure 1, Sheet 2, Item 17), and exhaust cover (Figure 1, Sheet 2, Item 18).

3. Remove four screws (Figure 1, Sheet 2, Item 19) and washers (Figure 1, Sheet 2, Item 20) and remove
exhaust out tube assembly (Figure 1, Sheet 2, Item 21) from front roof section housing (Figure 1, Sheet 2,
Item 4).

4. Remove four screws (Figure 1, Sheet 2, Item 22), nuts (Figure 1, Sheet 2, Item 23) and coolant filler neck
(Figure 1, Sheet 2, Item 7).

0030-2
 TM 9-6115-730-24 0030

DISASSEMBLY - Continued

Figure 1. Front Roof Section Housing Assembly (Sheet 1 of 2).

0030-3
 TM 9-6115-730-24 0030

DISASSEMBLY - Continued

Figure 1. Front Roof Section Housing Assembly (Sheet 2 of 2).

END OF TASK

0030-4
 TM 9-6115-730-24 0030

ASSEMBLY

1. Install four screws (Figure 1, Sheet 2, Item 22), nuts (Figure 2, Sheet 1, Item 23) and coolant filler neck (Figure
1, Sheet 2, Item 7).

2. Install exhaust out tube assembly (Figure 1, Sheet 2, Item 21) into front roof section (Figure 1, Sheet 1, Item
4) with four screws (Figure 1, Sheet 2, Item 19), and lockwashers (Figure 1, Sheet 1, Item 20).

3. Install exhaust cover using eight screws (Figure 1, Sheet 2, Item 15), lockwashers (Figure 1, Sheet 2, Item 16)
and washers (Figure 1, Sheet 2, Item 17) into front roof section (Figure 1, Sheet 1, Item 4).

4. If necessary, use old foam damping sheets as templates to cut new foam damping sheets. Install 14 foam
damping sheets, 75 push-on nuts (Figure 1, Sheet 2, Item 14), and 119 clips (Figure 1, Sheet 2, Item 13).

END OF TASK

INSTALLATION

1. Using two persons, align exhaust out tube assembly and install front roof section housing assembly (Figure 1,
Sheet 1, Item 4).

2. Install exhaust clamp (Figure 1, Sheet 1, Item 10) loosely between muffler and exhaust out tube assembly
(Figure 1, Sheet 1, Item 21) while front roof section is loose.

3. Secure front roof section housing assembly (Figure 1, Sheet 1, Item 4) with 62 washers (Figure 1, Sheet 1,
Item 3), lockwashers (Figure 1, Sheet 1, Item 2), and screws (Figure 1, Sheet 1, Item 1).

4. Install and tighten two screws (Figure 1, Sheet 1, Item 11) and lockwashers (Figure 1, Sheet 1, Item 12) on
exhaust muffler clamp (Figure 1, Sheet 1, Item 10) (access through access hole in cover).

5. Connect hose (Figure 1, Sheet 1, Item 6) to bottom of coolant filler neck (Figure 1, Sheet 1, Item 7) and tighten
clamp (Figure 1, Sheet 1, Item 5).

6. Route overflow hose (Figure 1, Sheet 1, Item 9) back through hole in front roof section (Figure 1, Sheet 1, Item
4) and connect hose to coolant filler neck (Figure 1, Sheet 1, Item 7) tighten clamp (Figure 1, Sheet 1, Item 8).

7. Install access covers (WP 0029).

END OF TASK

END OF WORK PACKAGE

0030-5/6 blank
 TM 9-6115-730-24 0031

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
REAR ROOF SECTION HOUSING ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Tool Kit, General Mechanic’s (WP 0123, Item 1) TM 9-6115-730-24P

Materials/Parts Equipment Condition

Foam damping sheet (WP 0124, Item 12) Roof-mounted access cover removed
Foam damping sheet (WP 0124, Item 14) (WP 0029)
Foam damping sheet (WP 0124, Item 15) Front roof section removed (WP 0030)

Personnel Required

One

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

1. Remove 20 screws (Figure 1, Item 1), washers (Figure 1, Item 2), lockwashers (Figure 1, Item 3).

2. Remove nine screws (Figure 1, Item 5), washers (Figure 1, Item 6), and lockwashers (Figure 1, Item 7).

3. Remove nine screws (Figure 1, Item 8), washers (Figure 1, Item 9), and lockwashers (Figure 1, Item 10).

4. Remove rear roof section housing assembly (Figure 1, Item 4).

0031-1
 TM 9-6115-730-24 0031

REMOVAL - Continued

Figure 1. Rear Roof Section Housing Assembly.

END OF TASK

0031-2
 TM 9-6115-730-24 0031

DISASSEMBLY

1. Remove eight screws (Figure 1, Item 11), lockwashers (Figure 1, Item 12), and washers (Figure 1, Item 13)
four brackets (Figure 1, Item 14) and grate (Figure 1, Item 15).

2. If necessary, remove 40 clips (Figure 1, Item 16), 20 push-on nuts (Figure 1, Item 17), and remove five foam
damping sections as required.

END OF TASK

ASSEMBLY

1. If necessary, use old foam damping sheets as templates to cut new foam damping sheets.

2. Install five foam damping sheets, 20 push-on nuts (Figure 1, Item 17), and 40 clips (Figure 1, Item 16).

3. Install grate (Figure 1, Item 15) and four brackets (Figure 1, Item 14) using eight screws (Figure 1, Item 11),
lockwashers (Figure 1, Item 12), and washers (Figure 1, Item 13).

END OF TASK

INSTALLATION

1. Install rear roof section housing assembly (Figure 1, Item 4).

2. Install nine screws (Figure 1, Item 8), lockwashers (Figure 1, Item 9), and washers (Figure 1, Item 10).

3. Install nine screws (Figure 1, Item 5), lockwashers (Figure 1, Item 6), and washers (Figure 1, Item 7).

4. Install 20 screws (Figure 1, Item 1), lockwashers (Figure 1, Item 2), and washers (Figure 1, Item 3).

5. Install front roof section housing assembly (WP 0030).

6. Install roof-mounted access covers (WP 0029).

END OF TASK

END OF WORK PACKAGE

0031-3/4 blank
 TM 9-6115-730-24 0032

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
ENGINE GENERATOR COMPARTMENT CEILING ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Tool Kit, General Mechanic’s (WP 0123, Item 1) TM 9-6115-730-24P

Materials/Parts Equipment Condition

Foam damping sheet (WP 0124, Item 12) Front roof section housing assembly removed
(WP 0030)
Personnel Required Rear roof section housing assembly removed
Two (WP 0031)
Exhaust system removed (WP 0069)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

WARNING
Top housing panels can get very hot. Allow panels to cool down before performing maintenance.
Failure to comply can result in severe burns to personnel.

WARNING
The engine generator compartment ceiling weighs more than 37 pounds (17 kg) and requires a
two-person lift. Lifting engine generator compartment ceiling can cause back strain. Ensure
proper lifting techniques are used when lifting engine generator compartment ceiling. Failure to
comply can cause injury to personnel.

0032-1 Change 1
 TM 9-6115-730-24 003 2

REMOVAL

1. Remove nine screws (Figure 1, Item 1), washers (Figure 1, Item 2), and lockwashers (Figure 1, Item 3) from
engine compartment ceiling assembly (Figure 1, item 4).

2. Remove 43 screws (Figure 1, Item 5), lockwashers (Figure 1, Item 6), and washers (Figure 1, Item 7) from
engine compartment ceiling assembly (Figure 1, Item 4) (21 sets on the right side and 22 sets on the left).

3. Remove two screws (Figure 1, Item 8), lockwashers (Figure 1, Item 9), and washers (Figure 1, Item 10)
securing bracket (Figure 1, Item 11) to air cleaner bracket (Figure 1, Item 12).

4. Remove engine generator compartment ceiling assembly (Figure 1, Item 4).

END OF TASK

DISASSEMBLY

1. Remove sixteen nuts (Figure 1, Item 13), screws (Figure 1, Item 14), lockwashers (Figure 1, Item 15),
washers (Figure 1, Item 16) and two brackets (Figure 1, Item 17).

2. If necessary, remove 126 clips (Figure 1, Item 18), 63 push-on nuts (Figure 1, Item 19) and remove foam
damping section.

END OF TASK

ASSEMBLY

1. If necessary, use old foam damping section as template to cut new foam damping section. Install foam
damping section, 63 push-on nuts (Figure 1, Item 19), and 126 clips (Figure 1, Item 18).

2. Install two brackets (Figure 1, Item 17) using16 washers (Figure 1, Item 16), lockwashers (Figure 1, Item 15),
screws (Figure 1, Item 14), and nuts (Figure 1, Item 13).

END OF TASK

INSTALLATION

1. Install engine generator compartment ceiling assembly (Figure 1, Item 4).

2. Install bracket (Figure 1, Item 11) onto air cleaner bracket (Figure 1, Item 12) using two washers (Figure 1,
Item 10), lockwashers (Figure 1, Item 9), and screws (Figure 1, Item 8).

3. Install engine compartment ceiling assembly (Figure 1, Item 4) using 43 washers (Figure 1, Item 7),
lockwashers (Figure 1, Item 6), and screws (Figure 1, Item 5) (21 sets on the right side and 22 sets on the
left).

Change 1 0032-2
 TM 9-6115-730-24 0032

INSTALLATION - Continued

Figure 1. Engine Generator Compartment Ceiling Assembly.

0032-3 Change 1
 TM 9-6115-730-24 0032

INSTALLATION - Continued

4. Install nine lockwashers (Figure 1, Item 3), washers (Figure 1, Item 2), and screws (Figure 1, Item 1).

5. Install exhaust system (WP 0069).

6. Install rear roof section housing assembly (WP 0031).

7. Install front roof section housing assembly (WP 0030).

END OF TASK

END OF WORK PACKAGE

Change 1 0032-4
 TM 9-6115-730-24 0033

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
GENERATOR ACCESS COVER ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Foam damping sheet (WP 0124, Item 11) TM 9-6115-730-24P

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

Remove 22 screws (Figure 1, Item 1), washers (Figure 1, Item 2), lockwashers (Figure 1, Item 3), and generator
access panel assembly (Figure 1, Item 4).

END OF TASK

DISASSEMBLY

Remove foam damping sheet as required.

END OF TASK

0033-1
 TM 9-6115-730-24 0033

ASSEMBLY

1. If necessary, use old foam damping sheet as template to cut new foam damping sheet.

2. Install foam damping sheet.

END OF TASK

INSTALLATION

Install generator access panel assembly (Figure 1, Item 4) and secure with 20 lockwashers (Figure 1, Item 3),
washers (Figure 1, Item 2), and screws (Figure 1, Item 1).

0033-2
 TM 9-6115-730-24 0033

INSTALLATION - Continued

Figure 1. Generator Access Cover Assembly.

END OF TASK

END OF WORK PACKAGE

0033-3/4 blank
 TM 9-6115-730-24 0034

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
FRONT SECTION HOUSING ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Equipment Condition

Tool Kit, General Mechanic’s (WP 0123, Item 1) Right battery access door assembly removed
(WP 0018)
Materials/Parts Left battery access door assembly removed
(WP 0019)
Foam damping sheet (WP 0124, Item 11) Left front door assembly (latch) removed
Foam damping sheet (WP 0124, Item 12) (WP 0021)
Right front door assembly (latch) removed
Personnel Required (WP 0025)
Front roof section housing removed (WP 0030)
One Engine generator compartment ceiling removed
(WP 0032)
References Batteries removed (WP 0050)
Battery disconnect switch removed (WP 0051)
TM 9-6115-730-24P Slave receptacle removed (WP 0054)
Winterization heater assembly removed, if
applicable (WP 0090)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the u nit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

1. Remove six screws (Figure 1, Sheet 1, Item 1), lockwashers (Figure 1, Sheet 1, Item 2), washers (Figure 1,
Sheet 1, Item 3), and nuts (Figure 1, Sheet 1, Item 4).

0034-1
 TM 9-6115-730-24 0034

REMOVAL - Continued

Figure 1. Front Section Housing Assembly (Sheet 1 of 2).

0034-2
 TM 9-6115-730-24 0034

REMOVAL - Continued

Figure 1. Front Section Housing Assembly (Sheet 2 of 2).

2. Remove six screws (Figure 1, Sheet 2, Item 10), lockwashers (Figure 1, Sheet 2, Item 11), washers (Figure 1,
Sheet 2, Item 12), nuts (Figure 1, Sheet 2, Item 13) and front section housing assembly (Figure 1, Sheet 2,
Item 14).

END OF TASK

0034-3
 TM 9-6115-730-24 0034

NOTE
DISASSEMBLY should not be done until front section housing assembly has been removed.

DISASSEMBLY

1. Remove six screws (Figure 1, Sheet 2, Item 15), lockwashers (Figure 1, Sheet 2, Item 16), washers (Figure 1,
Sheet 2, Item 17), and vane assembly (Figure 1, Sheet 2, Item 18).

2. Remove fourteen screws (Figure 1, Sheet 2, Item 19), lockwashers (Figure 1, Sheet 2, Item 20), washers
(Figure 1, Sheet 2, Item 21), and plate assembly (Figure 1, Sheet 2, Item 22).

3. Remove seven screws (Figure 1, Sheet 2, Item 23), lockwashers (Figure 1, Sheet 2, Item 24), washers
(Figure 1, Sheet 2, Item 25), and bracket (Figure 1, Sheet 2, Item 26).

4. Remove fourteen screws (Figure 1, Sheet 2, Item 27), lockwashers (Figure 1, Sheet 2, Item 28), washers
(Figure 1, Sheet 2, Item 29), and two brackets (Figure 1, Sheet 2, Item 30).

5. Remove 8 screws (Figure 1, Sheet 1, Item 5), lockwashers (Figure 1, Sheet 1, Item 6), washers (Figure 1,
Sheet 1, Item 7), nuts (Figure 1, Sheet 1, Item 8) and door flanges (Figure 1, Sheet 1, Item 9).

6. Remove three foam damping sheets as required.

END OF TASK

ASSEMBLY

1. If necessary, use old foam damping sheets as templates to cut new foam damping sheets.

2. Install door flanges (Figure 1, Sheet 1, Item 9) and secure with 8 screws (Figure 1, Sheet 1, Item 5),
lockwashers (Figure 1, Sheet 1, Item 6), washers (Figure 1, Sheet 1, Item 7), and nuts (Figure 1, Sheet 1,
Item 8).

3. Install three foam damping sheets.

4. Install two brackets (Figure 1, Sheet 2, Item 30), fourteen washers (Figure 1, Sheet 2, Item 29), lockwashers
(Figure 1, Sheet 2, Item 28), and screws (Figure 1, Sheet 2, Item 27).

5. Install bracket (Figure 1, Sheet 2, Item 26), seven washers (Figure 1, Sheet 2, Item 25), lockwashers
(Figure 1, Sheet 2, Item 24), and screws (Figure 1, Sheet 2, Item 23).

6. Install plate assembly (Figure 1, Sheet 2, Item 22) and secure with fourteen washers (Figure 1, Sheet 2,
Item 21), lockwashers (Figure 1, Sheet 2, Item 20), and screws (Figure 1, Sheet 2, Item 19).

7. Install vane assembly (Figure 1, Sheet 2, Item 18) and secure with six washers (Figure 1, Sheet 2, Item 17),
lockwashers (Figure 1, Sheet 2, Item 16), and screws (Figure 1, Sheet 2, Item 15).

END OF TASK

0034-4
 TM 9-6115-730-24 0034

INSTALLATION

1. Install front section housing assembly (Figure 1, Sheet 2, Item 14) and secure with six screws (Figure 1,
Sheet 2, Item 10), lockwashers (Figure 1,Sheet 2, Item 11), washers (Figure 1, Sheet 2, Item 12), , and
locknuts (Figure 1, Sheet 2, Item 13).

2. Install six screws (Figure 1, Sheet 1, Item 1), lockwashers (Figure 1, Sheet 1, Item 2), washers (Figure 1,
Sheet 1, Item 3), and nuts (Figure 1, Sheet 1, Item 4).

3. Install engine generator compartment ceiling (WP 0032).

4. Install front roof section housing (WP 0030).

5. Install battery disconnect switch (WP 0051).

6. Install slave receptacle (WP 0054).

7. Install batteries (WP 0050).

8. Install right front door assembly (latch) (WP 0025).

9. Install left front door assembly (latch) (WP 0021).

10. Install left battery access door assembly (WP 0019).

11. Install right battery access door assembly (WP 0018).

END OF TASK

END OF WORK PACKAGE

0034-5/6 blank
 TM 9-6115-730-24 0035

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
REAR SECTION HOUSING ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Equipment Condition

Tool Kit, General Mechanic’s (WP 0123, Item 1) Control box assembly removed (WP 0042)
Generator access cover assembly removed
Materials/Parts (WP 0033)
Left rear door assembly (latch) removed
Foam damping sheet (WP 0124, Item 11) (WP 0023)
Right rear door assembly (latch) removed
Personnel Required (WP 0028)
Winterization heater control box assembly
One removed, if applicable (WP 0089)
Rear roof section housing assembly removed
References (WP 0031)
Potential transformers PT2 and PT3 removed
TM 9-6115-730-24P (WP 0052)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the u nit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

1. Remove three screws (Figure 1, Item 1), lockwashers (Figure 1, Item 2), and washers (Figure 1, Item 3).

2. Remove two screws (Figure 1, Item 4), lockwashers (Figure 1, Item 5), and washers (Figure 1, Item 6).

3. Remove six screws (Figure 1, Item 7), lockwashers (Figure 1, Item 8), and washers (Figure 1, Item 9).

0035-1
 TM 9-6115-730-24 0035

REMOVAL - Continued

4. Remove four screws (Figure 1, Item 10), lockwashers (Figure 1, Item 11), and washers (Figure 1, Item 12)
and rear section housing assembly (Figure 1, Item 21).

Figure 1. Rear Section Housing Assembly.

END OF TASK

0035-2
 TM 9-6115-730-24 0035

DISASSEMBLY

1. Remove four nuts (Figure 1, Item 13), washers (Figure 1, Item 14), screws (Figure 1, Item 15), locking ring
(Figure 1, Item 16), bushing (Figure 1, Item 17), retainer plate (Figure 1, Item 18), spacer (Figure 1, Item 19),
and sleeve (Figure 1, Item 20).

2. Remove eight foam damping sheets as required.

END OF TASK

ASSEMBLY

1. If necessary, use old foam damping sheets as templates to cut new foam damping sheets. Install eight foam
damping sheets.

2. Install sleeve (Figure 1, Item 20), spacer (Figure 1, Item 19), retainer plate (Figure 1, Item 18), bushing
(Figure 1, Item 17), locking ring (Figure 1, Item 16), four screws (Figure 1, Item 15), washers (Figure 1, Item
14), and nuts (Figure 1, Item 13).

END OF TASK

INSTALLATION

1. Install rear section housing assembly (Figure 1, Item 21) and secure with the following

a. Four screws (Figure 1, Item 10), lockwashers (Figure 1, Item 11), and washers (Figure 1, Item 12).

b. Six screws (Figure 1, Item 1), lockwashers (Figure 1, Item 2), and washers (Figure 1, Item 3).

c. Two screws (Figure 1, Item 4), lockwashers (Figure 1, Item 5), and washers (Figure 1, Item 6).

d. Three screws (Figure 1, Item 7), lockwashers (Figure 1, Item 8), and washers (Figure 1, Item 9).

2. If removed, install winterization kit control box assembly (WP 0089).

3. Install generator access cover assembly (WP 0033).

4. Install control box assembly (WP 0041).

5. Install right rear door assembly (latch) (WP 0028).

6. Install left rear door assembly (latch) (WP 0023).

7. Install control box door panel assembly (WP 0020).

8. Install rear roof section housing assembly (WP 0031).

END OF TASK

END OF WORK PACKAGE

0035-3/4 blank
 TM 9-6115-730-24 0036

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
LEFT CENTER PANEL ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Tool Kit, General Mechanic’s (WP 0123, Item 1) TM 9-6115-730-24P

Materials/Parts Equipment Condition

Foam damping sheet (WP 0124, Item 11) Left rear door assembly removed (WP 0022)
Fuel filler neck pocket disconnected from left
Personnel Required center panel assembly (WP 0057)

One

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

Remove three lockwashers (Figure 1, Item 2), washers (Figure 1, Item 3), screws (Figure 1, Item 4), and left center
panel assembly (Figure 1, Item 1).

END OF TASK

DISASSEMBLY

Remove foam damping sheet, if required.

0036-1
 TM 9-6115-730-24 0036

DISASSEMBLY - Continued

Figure 1. Left Center Panel Assembly.

END OF TASK

0036-2
 TM 9-6115-730-24 0036

ASSEMBLY

If necessary, use old foam damping sheet as template to cut new foam damping sheet. Install foam damping sheet.

END OF TASK

INSTALLATION

1. Install left center panel assembly (Figure 1, Item 1) and secure with three screws (Figure 1, Item 4), washers
(Figure 1, Item 3), and lockwashers (Figure 1, Item 2).

2. Connect fuel filler neck pocket to left center panel assembly (Figure 1, Item 1) (WP 0057).

3. Install left rear door assembly (WP 0022).

END OF TASK

END OF WORK PACKAGE

0036-3/4 blank
 TM 9-6115-730-24 0037

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
RIGHT CENTER PANEL ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Tool Kit, General Mechanic’s (WP 0123, Item 1) TM 9-6115-730-24P

Materials/Parts Equipment Condition

Foam damping sheet (WP 0124, Item 11) Right rear door assembly removed (WP 0027)
Right front door assembly removed (WP 0026)
Personnel Required

One

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

Remove seven screws (Figure 1, Item 1), screws (Figure 1, Item 2), washers (Figure 1, Item 3), lockwashers
(Figure 1, Item 4), and right center panel assembly (Figure 1, Item 5).

END OF TASK

DISASSEMBLY

Remove foam damping sheet, if required.

0037-1
 TM 9-6115-730-24 0037

DISASSEMBLY - Continued

Figure 1. Right Center Panel Assembly.

END OF TASK

0037-2
 TM 9-6115-730-24 0037

ASSEMBLY

If necessary, use old foam damping sheet as template to cut new foam damping sheet. Install new foam damping
sheet.

END OF TASK

INSTALLATION

1. Install right center panel assembly (Figure 1, Item 5) and secure with seven lockwashers (Figure 1, Item 4),
washers (Figure 1, Item 3), screws (Figure 1, Item 2), and screws (Figure 1, Item 1).

2. Install right front door assembly (WP 0026).

3. Install right rear door assembly (WP 0027).

END OF TASK

END OF WORK PACKAGE

0037-3/4 blank
 TM 9-6115-730-24 0038

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
RIGHT REAR PANEL ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Foam damping sheet (WP 0124, Item 11) TM 9-6115-730-24P

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

Remove eight locknuts (Figure 1, Item 1), washers (Figure 1, Item 2), lockwashers (Figure 1, Item 3), screws
(Figure 1, Item 4), and right rear panel assembly (Figure 1, Item 5).

END OF TASK

DISASSEMBLY

Remove two foam damping sheets as required.

END OF TASK

ASSEMBLY

If necessary, use old foam damping sheets as templates to cut new foam damping sheets. Install two foam
damping sheets.

END OF TASK

0038-1
 TM 9-6115-730-24 0038

INSTALLATION

Install right rear panel assembly (Figure 1, Item 5) and secure with eight screws (Figure 1, Item 4), lockwashers
(Figure 1, Item 3), washers (Figure 1, Item 2), and locknuts (Figure 1, Item 1).

0038-2
 TM 9-6115-730-24 0038

INSTALLATION - Continued

Figure 1. Right Rear Panel Assembly.

END OF TASK

END OF WORK PACKAGE

0038-3/4 blank
 TM 9-6115-730-24 0039

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
LEFT REAR PANEL ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Foam damping sheet (WP 0124, Item 11) TM 9-6115-730-24P

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

Remove seven screws (Figure 1, Item 1), six screws (Figure 1, Item 2), 13 washers (Figure 1, Item 3), 13
lockwashers (Figure 1, Item 4), and left rear panel assembly (Figure 1, Item 5).

END OF TASK

DISASSEMBLY

Remove three foam damping sheets as required.

END OF TASK

ASSEMBLY

If necessary, use old foam damping sheets as templates to cut new foam damping sheets. Install foam damping
sheets.

END OF TASK

0039-1
 TM 9-6115-730-24 0039

INSTALLATION

Install left rear panel assembly (Figure 1, Item 5), and secure with 13 washers (Figure 1, Item 4), 13 lockwashers
(Figure 1, Item 3), six screws (Figure 1, Item 2), and seven screws (Figure 1, Item 1).

Figure 1. Left Rear Panel Assembly.

END OF TASK

END OF WORK PACKAGE

0039-2
 TM 9-6115-730-24 0040

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
DOOR SUPPORT ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

References

TM 9-6115-730-24P

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

1. Open load board door (Figure 1, Item 1).

2. Remove two screws (Figure 1, Item 2), washers (Figure 1, Item 3), and lockwashers (Figure 1, Item 4).

3. Remove locknut (Figure 1, Item 5), spacer (Figure 1, Item 6), two washers (Figure 1, Item 7), screw (Figure 1,
Item 8), screw (Figure 1, Item 9), lockwasher (Figure 1, Item 10), washer (Figure 1, Item 11), and door
support bracket (Figure 1, Item 12).

4. Remove locknut (Figure 1, Item 13), spacer (Figure 1, Item 14), two washers (Figure 1, Item 15), screw
(Figure 1, Item 16), and link (Figure 1, Item 17).

5. Remove screw (Figure 1, Item 18), washer (Figure 1, Item 19), lockwasher (Figure 1, Item 20), and door
support bracket (Figure 1, Item 21).

0040-1
 TM 9-6115-730-24 0040

REMOVAL - Continued

Figure 1. Door Support Assembly.

END OF TASK

0040-2
 TM 9-6115-730-24 0040

INSTALLATION

1. Install door support bracket (Figure 1, Item 21), and secure with lockwasher (Figure 1, Item 20), washer
(Figure 1, Item 19), and screw (Figure 1, Item 18).

2. Install link (Figure 1, Item 17), screw (Figure 1, Item 16), two washers (Figure 1, Item 15), spacer (Figure 1,
Item 14), and locknut (Figure 1, Item 13).

3. Install door support bracket (Figure 1, Item 12), and secure with washer (Figure 1, Item 11), lockwasher
(Figure 1, Item 10), screw (Figure 1, Item 9), screw (Figure 1, Item 8), two washers (Figure 1, Item 7), spacer
(Figure 1, Item 6), and locknut (Figure 1, Item 5).

4. Install door support bracket (Figure 1, Item 9) on load board door (Figure 1, Item 1) with two lockwashers
(Figure 1, Item 4), washers (Figure 1, Item 3), and screws (Figure 1, Item 2).

5. Close load board door (Figure 1, Item 1).

END OF TASK

END OF WORK PACKAGE

0040-3/4 blank
 TM 9-6115-730-24 0041

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
CONTROL BOX PANEL ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Multimeter 146-4080
References
Materials/Parts
TM 9-6115-730-24P
Sealing compound (WP 0124, Item 40)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

0041-1 Change 1
 TM 9-6115-730-24 0041

NOTE
Table 1 lists removal/installation steps for significant components.

Table 1. WP 0041 Guide.

FIGURE REMOVAL DISASSEMBLY ASSEMBLY INSTALLATION TESTING

NAME ITEM STEPS STEPS STEPS STEPS

Generator Set 12 1 thru 3 1 and 2 20 and 21 1 thru 5 -

Control (GSC)

Alarm Module A2 55 1 thru 3 12 10 1 thru 4 -

VOLTAGE Adjust 73 16 - - 6 1 thru 7

Potentiometer

FREQUENCY Adjust 75 16 - - 6 1 thru 10

Potentiometer

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is set to OFF/RESET, Battery Disconnect
Switch is set to OFF, and DEAD CRANK SWITCH is set to OFF before proceeding.

2. Turn two latches (Figure 1, Sheet 1, Item 1) and open control box door (Figure 1, Sheet 1, Item 2). Refer to
Table 1 for removal/installation steps for specific control box panel assembly items. Tag and disconnect
wiring to components before removing them.

3. Release three studs (Figure 1, Sheet 1, Item 3) and lower control box panel assembly (Figure 1, Sheet 1,
Item 4).

NOTE
Control box panel assembly components can be removed without removing control box panel
assembly.

4. Remove three nuts (Figure 1, Sheet 2, Item 5) to remove control box panel assembly (Figure 1, Sheet 1,
Item 4) from hinges (Figure 1, Sheet 3, Item 6).

5. Unhook holder (Figure 1, Sheet 1, Item 7) from control box (Figure 1, Sheet 1, Item 8) and remove control box
panel assembly (Figure 1, Sheet 1, Item 4) from control box.

Change 1 0041-2
 TM 9-6115-730-24 0041

REMOVAL - Continued

Figure 1. Control Box Panel Assembly (Sheet 1 of 4).

0041-3 Change 1
 TM 9-6115-730-24 0041

CAUTION
ENSURE SYNC MODE SWITCH
IS IN “OFF” POSITION
PRIOR TO STARTING SET

VIEW B

SEE VIEW B

22

Change 1 0041-4
 TMM9-6115-730-24
T 4 2 - 9 2 7 - 5 1 1 6 - 9 00410 4 0

REMOVAL - Continued

CAUTION

Figure 1. Control Box Panel Assembly (Sheet 3 of 4).

00040-5
041-5 Change 1
 TM 9-6115-730-24 0041

Change 1 0041-6
 TM 9-6115-730-24 0041

DISASSEMBLY

1. Loosen screw on front of mating connector using 4mm Allen wrench to disconnect connector P7 and remove
six locknuts (Figure 1, Sheet 2, Item 9) six washers (Figure 1, Sheet 2, Item 10), film (Figure 1, Sheet 2, Item
11), generator set control (GSC) (Figure 1, Sheet 2, Item 12), and seal (Figure 1, Sheet 2, Item 13).

2. Remove 10 fuses (Figure 1, Sheet 2, Item 14), two screws (Figure 1, Sheet 2, Item 15), two washers
(Figure 1, Sheet 2, Item 16), and two loop clamps (Figure 1, Sheet 2, Item 17).

3. Remove screw (Figure 1, Sheet 2, Item 18), nut (Figure 1, Sheet 2, Item 19), and holder (Figure 1, Sheet 1,
Item 7).

4. Remove three retainers (Figure 1, Sheet 2, Item 20), washers (Figure 1, Sheet 2, Item 21), and studs
(Figure 1, Sheet 1, Item 3).

5. Remove nut (Figure 1, Sheet 3, Item 22), washer (Figure 1, Sheet 3, Item 23), panel light (Figure 1, Sheet 3,
Item 24), lens (Figure 1, Sheet 3, Item 25), and lamp (Figure 1, Sheet 3, Item 26). Repeat for other two panel
lights.

6. Remove nut (Figure 1, Sheet 3, Item 27) and screw (Figure 1, Sheet 3, Item 28).

7. Remove nut (Figure 1, Sheet 3, Item 29), washer (Figure 1, Sheet 3, Item 30), anti-rotation washer (Figure 1,
Sheet 3, Item 31), PANEL LIGHT switch (Figure 1, Sheet 3, Item 32), and seal (Figure 1, Sheet 3, Item 33).

8. Remove three nuts (Figure 1, Sheet 3, Item 34), lockwashers (Figure 1, Sheet 3, Item 35), screws (Figure 1,
Sheet 3, Item 36), and DC ammeter (Figure 1, Sheet 3, Item 37).

9. Remove screw (Figure 1, Sheet 3, Item 38), knob (Figure 1, Sheet 3, Item 39), four screws (Figure 1, Sheet 3,
Item 40), SYNC MODE switch (Figure 1, Sheet 3, Item 41), and seal (Figure 1, Sheet 3, Item 42).

10. Remove nut (Figure 1, Sheet 3, Item 43), washer (Figure 1, Sheet 3, Item 44), anti-rotation washer (Figure 1,
Sheet 3, Item 45), PARALLEL/UNIT switch (Figure 1, Sheet 3, Item 46), and seal washer (Figure 1, Sheet 3,
Item 47).

11. Remove lens (Figure 1, Sheet 3, Item 48), lamp (Figure 1, Sheet 3, Item 49), nut (Figure 1, Sheet 3, Item 50),
washer (Figure 1, Sheet 3, Item 51), and indicator light (Figure 1, Sheet 3, Item 52).

12. Remove four locknuts (Figure 1, Sheet 3, Item 53), washers (Figure 1, Sheet 3, Item 54), custom alarm
module (Figure 1, Sheet 3, Item 55), and gasket (Figure 1, Sheet 3, Item 56). If necessary, remove film
(Figure 1, Sheet 3, Item 57).

13. Remove ten locknuts (Figure 1, Sheet 3, Item 58), washers (Figure 1, Sheet 3, Item 59), screws (Figure 1,
Sheet 3, Item 60), and DVR adapter (Figure 1, Sheet 3, Item 61).

14. Remove two nuts (Figure 1, Sheet 4, Item 62), lockwashers (Figure 1, Sheet 4, Item 63), bracket (Figure 1,
Sheet 4, Item 64), and fuel level indicator (Figure 1, Sheet 4, Item 65).

15. Remove nut (Figure 1, Sheet 4, Item 66), washer (Figure 1, Sheet 4, Item 67), anti-rotation washer (Figure 1,
Sheet 4, Item 68), AUX FUEL switch (Figure 1, Sheet 4, Item 69), and seal (Figure 1, Sheet 4, Item 70).

0041-7 Change 1
 TM 9-6115-730-24 0041

DISASSEMBLY - Continued

NOTE
VOLTAGE and FREQUENCY adjust potentiometers should be tested prior to removal.

16. Remove knob (Figure 1, Sheet 4, Item 71) using Allen wrench to unscrew setscrew, nut (Figure 1, Sheet 4,
Item 72), VOLTAGE adjust potentiometer (Figure 1, Sheet 4, Item 73), and seal (Figure 1, Sheet 4, Item 74).
Repeat for FREQUENCY adjust potentiometer (Figure 1, Sheet 4, Item 75).

17. Remove nut (Figure 1, Sheet 4, Item 76), washer (Figure 1, Sheet 4, Item 77), anti-rotation washer (Figure 1,
Sheet 4, Item 78), switch guard (Figure 1, Sheet 4, Item 79), BATTLE SHORT switch (Figure 1, Sheet 4, Item
80), and seal (Figure 1, Sheet 4, Item 81).

18. Remove screw (Figure 1, Sheet 4, Item 82), knob (Figure 1, Sheet 4, Item 83), four screws (Figure 1, Sheet 4,
Item 84), ENGINE CONTROL switch (Figure 1, Sheet 4, Item 85), and seal (Figure 1, Sheet 4, Item 86).

19. Remove nut (Figure 1, Sheet 4, Item 87), washer (Figure 1, Sheet 4, Item 88), four screws (Figure 1, Sheet 4,
Item 89), AC CIRCUIT INTERRUPTER switch (Figure 1, Sheet 4, Item 90), and seal washer (Figure 1, Sheet
4, Item 91).

20. Remove lens (Figure 1, Sheet 4, Item 92), nut (Figure 1, Sheet 4, Item 93), seal (Figure 1, Sheet 4, Item 94),
two block contacts (Figure 1, Sheet 4, Item 95) and (Figure 1, Sheet 4, Item 96), and PUSH TO STOP
EMERGENCY STOP switch (Figure 1, Sheet 4, Item 97).

21. If necessary, remove label (Figure 1, Sheet 4, Item 98).

END OF TASK

TESTING

VOLTAGE Adjust Potentiometer Test

1. Disconnect wires from terminals 7 and 45 of DVR A3.

2. Set multimeter to measure 10,000 ohms and connect multimeter leads to wires removed from terminals 7 and
45 of DVR A3.

3. Rotate potentiometer shaft counterclockwise as far as it will go.

4. Slowly and smoothly rotate VOLTAGE adjust potentiometer shaft clockwise as far as it will go while observing
multimeter.

5. Multimeter indication shall increase at an even rate from 0 - 10,000 ohms. Maximum resistance may vary +
or – 1000 ohms.

6. If multimeter indication changes erratically or is not at maximum ohms when rotation is complete, the
potentiometer is defective and must be replaced.

7. If there is no continuity at any position of potentiometer, troubleshoot wiring between potentiometer and DVR
A3 or replace potentiometer.

Change 1 0041-8
 TM 9-6115-730-24 0041

TESTING - Continued

FREQUENCY Adjust Potentiometer Test

1. Disconnect wires from terminals 26, 27, and 28 of LSM A4.

2. Set multimeter to measure 10,000 ohms and connect multimeter leads to wires removed from terminals
27and 28 of LSM A4.

3. Rotate potentiometer shaft counterclockwise as far as it will go.

4. Slowly and smoothly rotate FREQUENCY adjust potentiometer shaft clockwise as far as it will go while
observing multimeter and note indication.

5. Connect multimeter leads to wires removed from terminals 26 and 27 of LSM A4.

6. Rotate potentiometer shaft clockwise as far as it will go.

7. Slowly and smoothly rotate FREQUENCY adjust potentiometer shaft counterclockwise as far as it will go
while observing multimeter.

8. Multimeter indication shall increase at an even rate from 0-10,000 ohms for each setup. Maximum resistance
may vary + or – 1000 ohms.

9. If multimeter indication changes erratically or is not at maximum ohms when rotation is complete, the
potentiometer is defective and must be replaced.

10. If there is no continuity at any position of potentiometer, troubleshoot wiring between potentiometer and LSM
A4 or replace potentiometer.

END OF TASK

ASSEMBLY

1. If removed, remove label (Figure 1, Sheet 4, Item 98).

2. Install PUSH TO STOP EMERGENCY STOP switch (Figure 1, Sheet 4, Item 97), two block contacts (Figure
1, Sheet 4, Item 96) and (Figure 1, Sheet 4, Item 95), seal (Figure 1, Sheet 4, Item 94), nut (Figure 1, Sheet
4, Item 93), and lens (Figure 1, Sheet 4, Item 92).

3. Install seal washer (Figure 1, Sheet 4, Item 91), AC CIRCUIT INTERRUPTER switch (Figure 1, Sheet 4,
Item 90), four screws (Figure 1, Sheet 4, Item 89), washer (Figure 1, Sheet 4, Item 88), and nut (Figure 1,
Sheet 4, Item 87).

4. Install seal (Figure 1, Sheet 4, Item 86), ENGINE CONTROL switch (Figure 1, Sheet 4, Item 85), four screws
(Figure 1, Sheet 4, Item 84), knob (Figure 1, Sheet 4, Item 83), and screw (Figure 1, Sheet 4, Item 82).

5. Install seal (Figure 1, Sheet 4, Item 81), BATTLE SHORT switch (Figure 1, Sheet 4, Item 80), switch guard
(Figure 1, Sheet 4, Item 79), anti-rotation washer (Figure 1, Sheet 4, Item 78), washer (Figure 1, Sheet 4,
Item 77), and nut (Figure 1, Sheet 4, Item 76).

6. Install FREQUENCY adjust potentiometer (Figure 1, Sheet 4, Item 75), seal (Figure 1, Sheet 4, Item 74), nut
(Figure 1, Sheet 4, Item 72), and knob (Figure 1, Sheet 4, Item 71). Repeat for VOLTAGE adjust
potentiometer (Figure 1, Sheet 4, Item 73).

0041-9 Change 1
 TM 9-6115-730-24 0041

ASSEMBLY - Continued

7. Install seal (Figure 1, Sheet 4, Item 70), AUX FUEL switch (Figure 1, Sheet 4, Item 69), anti-rotation washer
(Figure 1, Sheet 4, Item 68), washer (Figure 1, Sheet 4, Item 67), and nut (Figure 1, Sheet 4, Item 66).

8. Install fuel level indicator (Figure 1, Sheet 4, Item 65), bracket (Figure 1, Sheet 4, Item 64), two lockwashers
(Figure 1, Sheet 4, Item 63), and nuts (Figure 1, Sheet 4, Item 62).

9. Install DVR adapter (Figure 1, Sheet 3, Item 61), ten screws (Figure 1, Sheet 3, Item 60), washers (Figure 1,
Sheet 3, Item 59), and locknuts (Figure 1, Sheet 3, Item 58).

10. If removed, install film (Figure 1, Sheet 3, Item 57) on custom alarm module (Figure 1, Sheet 3, Item 55).
Install gasket (Figure 1, Sheet 3, Item 56), custom alarm module (Figure 1, Sheet 3, Item 55), four washers
(Figure 1, Sheet 3, Item 54), and locknuts (Figure 1, Sheet 3, Item 53).

11. Install indicator light (Figure 1, Sheet 3, Item 52), washer (Figure 1, Sheet 3, Item 51), nut (Figure 1, Sheet 3,
Item 50), lamp (Figure 1, Sheet 3, Item 49), and lens (Figure 1, Sheet 3, Item 48).

12. Install seal washer (Figure 1, Sheet 3, Item 47), PARALLEL/UNIT switch (Figure 1, Sheet 3, Item 46), anti-
rotation washer (Figure 1, Sheet 3, Item 45), washer (Figure 1, Sheet 3, Item 44), and nut (Figure 1, Sheet 3,
Item 43).
13. Install seal (Figure 1, Sheet 3, Item 42), SYNC MODE switch (Figure 1, Sheet 3, Item 41), SYNC MODE
switch caution label (Figure1, Sheet 2, Item 22, if not installed), four screws (Figure 1, Sheet 3, Item 40),
knob (Figure 1, Sheet 3, Item 39), and screw (Figure 1, Sheet 3, Item 38).

14. Install DC ammeter (Figure 1, Sheet 3, Item 37), three screws (Figure 1, Sheet 3, Item 36), lockwashers
(Figure 1, Sheet 3, Item 35), and nuts (Figure 1, Sheet 3, Item 34).

15. Install seal (Figure 1, Sheet 3, Item 33), PANEL LIGHT switch (Figure 1, Sheet 3, Item 32), anti-rotation
washer (Figure 1, Sheet 3, Item 31), washer (Figure 1, Sheet 3, Item 30), and nut (Figure 1, Sheet 3, Item
29).

16. Install screw (Figure 1, Sheet 3, Item 28) and nut (Figure 1, Sheet 3, Item 27).

17. Install lamp (Figure 1, Sheet 3, Item 26), lens (Figure 1, Sheet 3, Item 25), panel light (Figure 1, Sheet 3,
Item 24), washer (Figure 1, Sheet 3, Item 23), and nut (Figure 1, Sheet 3, Item 22). Repeat for other two
panel lights.

18. Install three studs (Figure 1, Sheet 1, Item 3), washers (Figure 1, Sheet 2, Item 21), and retainers (Figure 1,
Sheet 2, Item 20).

19. Install holder (Figure 1, Sheet 1, Item 7), nut (Figure 1, Sheet 2, Item 19), and screw (Figure 1, Sheet 2,
Item 18).

20. Install two loop clamps (Figure 1, Sheet 2, Item 17), two washers (Figure 1, Sheet 2, Item 16), two screws
(Figure 1, Sheet 2, Item 15), and ten fuses (Figure 1, Sheet 2, Item 14).

21. Install seal (Figure 1, Sheet 2, Item 13), generator set control (GSC) (Figure 1, Sheet 2, Item 12), film
(Figure 1, Sheet 2, Item 11), six washers (Figure 1, Sheet 2, Item 10) and six locknuts (Figure 1, Sheet 1,
Item 9).

22. Install connector P7 and tighten screw on front of mating connector using 4mm Allen wrench.

END OF TASK

Change 1 0041-10
 TM 9-6115-730-24 004 1

INSTALLATION

1. Install control box panel assembly (Figure 1, Sheet 1, Item 4) on control box (Figure 1, Sheet 1, Item 8) and
hook holder (Figure 1, Sheet 3, Item 7) to control box.

NOTE
Remove tags and connect wiring as required.

2. Install control panel assembly (Figure 1, Sheet 1, Item 4) onto three hiinges (Figure 1, Sheet 1,
Item 6) and secure with nuts (Figure 1, Sheet 1, Item 5).
3. Raise control box panel assembly (Figure 1, Sheet 1, Item 4) and secure three studs (Figure 1, Sheet 1,
Item 3).

4. Close control box door (Figure 1, Sheet 1, Item 2), and turn two latches (Figure 1, Sheet 1, Item 1) to secure.

5. Restore power by setting DEAD CRANK SWITCH to NORMAL, Battery Disconnect Switch ON, and ENGINE
CONTROL switch to OFF/RESET.

6. If GSC has been removed and installed, reprogram to restore required generator set values and parameters
(WP 0083).
7. If sync mode switch label (Figure 1, Sheet 2, Item 22) is not present, apply it over the sync mode switch
(Figure 1, Sheet 3, Item 39).

END OF TASK

END OF WORK PACKAGE

0041-11/12 blank Change 1

 TM 9-6115-730-24 0042

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
CONTROL BOX ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Tool Kit, General Mechanic’s (WP 0123, Item 1) TM 9-6115-730-24P

Materials/Parts Equipment Condition

Gasket Front roof section removed (WP 0030)

Personnel Required

One

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is set to OFF/RESET, Battery Disconnect
Switch is set to OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Tag and disconnect harness connector P30 from Control Box connector J30.

3. Tag and disconnect harness connector P31 from Control Box connector J31.

4. Tag and disconnect ECM to EMCP harness connector ENG-P37 from Control Box connector J37.

5. Remove ground wire (Figure 1, Item 1), washer (Figure 1, Item 2) and locknut (Figure 1, Item 3) from back of
control box terminal (Figure 1, Item 4).

6. Remove seven screws (Figure 1, Item 5), lockwashers (Figure 1, Item 6), and washers (Figure 1, Item 7).

0042-1 Change 1
 TM 9-6115-730-24 0042

22 23
24

Change 1
 TM 9-6115-730-24 0042

REMOVAL - Continued

7. Remove three screws (Figure 1, Item 8), lockwashers (Figure 1, Item 9), and washers (Figure 1, Item 10).

8. Remove two screws (Figure 1, Item 11), lockwashers (Figure 1, Item 12), and washers (Figure 1, Item 13).

9. Remove five screws (Figure 1, Item 14), lockwashers (Figure 1, Item 15), and washers (Figure 1, Item 16).
10. Remove seven screws (Figure 1, Item 22), lockw ash ers (Figure 1, Item 23), and washers (Figure 1, Item 24).
11. Slide Control Box (Figure 1, Item 17) out of generator set and place on suitable work surface.

12. If necessary, remove two screws (Figure 1, Item 18), lockwashers (Figure 1, Item 19), washers
(Figure 1, Item 20), and brace (Figure 1, Item 21).

END OF TASK

DISASSEMBLY
NOTE
Disassembly of the control panel can be accomplished on or off the generator set, however
access to some components may be improved if control box is removed. Table 1 lists specific
steps for disassembly and assembly of significant control box components.

Table 1. WP 0042 Guide.

FIGURE 2 DISASSEMBLY ASSEMBLY RELATED

NAME ITEM STEPS STEPS STEPS
AC Transformer Box (ATB) A5 45 1, 2, and 14 16
Alarm Reset (AR) 73 1, 2, and 20 10
Auxiliary Fuel Pump Relay (AFPR) 72 1, 2, and 20 10
Bus Transformer Box (BTB) A6 19 1, 2, and 7 23
Cool Down Relay (CDR) 71 1, 2, and 20 10
Dead Bus Relay, High Voltage 79 1, 2, and 21 9
Sensing (DBHI)
Dead Bus Relay, Low Voltage 78 1, 2, and 21 9
Sensing (DBLO)
Digital Voltage Regulator (DVR) A3 98 1, 2, and 26 4
Relay Field Flash (KFF) 75 1, 2, and 20 10
Generator Fault Relay (GFR) 74 1, 2, and 20 10
Ground Fault Circuit Interrupter 42 1, 2, and 13 17
(GFCI)
Load Sharing Module (LSM) A4 28 1, 2, and 9 21 Adjustment
1 thru 4

0042-3 Change 1
 TM 9-6115-730-24 0042

DISASSEMBLY - Continued

Table 1. WP 0042 Guide - Continued.

FIGURE 2 DISASSEMBLY ASSEMBLY RELATED

NAME ITEM STEPS STEPS STEPS
Main Contactor Relay (KR) 70 1, 2, and 20 10
Overload/Short Circuit Module 24 1, 2, and 8 22
Paralleling Relay (PAR) 81 1, 2, and 22 8
Resistor Assembly A7 112 1, 2, and 28 2

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is set to OFF/RESET, Battery Disconnect
Switch is set to OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open control box door and control box panel assembly. Control box panel assembly may be removed for
access if necessary (WP 0041).

3. Remove three receptacles (Figure 2, Sheet 1, Item 1).

4. To remove terminal block TB4 (Figure 2, Sheet 1, Item 2), remove two nuts (Figure 2, Sheet 1, Item 3),
screws (Figure 2, Sheet 1, Item 4), terminal block, and strip (Figure 2, Sheet 1, Item 5). Remove ten screws
(Figure 2, Sheet 1, Item 6) and jumpers (Figure 2, Sheet 1, Item 7). Repeat for terminal block TB3. On TB4
only, remove two screws (Figure 2, Sheet 1, Item 8), diode (Figure 2, Sheet 1, Item 9), and two spade
terminals (Figure 2, Sheet 1, Item 10).

5. To remove fuse block (Figure 2, Sheet 1, Item 11), remove three fuses (Figure 2, Sheet 1, Item 12), two nuts
(Figure 2, Sheet 1, Item 13), two screws (Figure 2, Sheet 1, Item 14), and fuse block.

6. To remove fuse block (Figure 2, Sheet 2, Item 15), remove four fuses (Figure 2, Sheet 2, Item 16), two nuts
(Figure 2, Sheet 2, Item 17), two screws (Figure 2, Sheet 2, Item 18), and fuse block.

7. To remove bus transformer box A6 (Figure 2, Sheet 2, Item 19), remove two fuses (Figure 2, Sheet 2,
Item 20), four screws (Figure 2, Sheet 2, Item 21), four lockwashers (Figure 2, Sheet 2, Item 22), four
washers (Figure 2, Sheet 2, Item 23), and transformer box.

8. To remove overload/short circuit relay (Figure 2, Sheet 2, Item 24), remove four screws (Figure 2, Sheet 2,
Item 25), lockwashers (Figure 2, Sheet 2, Item 26), washers (Figure 2, Sheet 2, Item 27), and relay.

9. To remove load sharing module (LSM) A4 (Figure 2, Sheet 2, Item 28), remove four screws (Figure 2,
Sheet 2, Item 29), washers (Figure 2, Sheet 2, Item 30), and load sharing module.

10. To remove duplex receptacle (Figure 2, Sheet 2, Item 31), remove four screws (Figure 2, Sheet 2, Item 32),
cover (Figure 2, Sheet 2, Item 33), and receptacle.

11. To remove paralleling receptacle (Figure 2, Sheet 2, Item 34), remove four nuts (Figure 2, Sheet 2, Item 35),
four screws (Figure 2, Sheet 2, Item 36), cover (Figure 2, Sheet 2, Item 37), and receptacle. Repeat for other
paralleling receptacle.

12. To remove nameplate (Figure 2, Sheet 2, Item 38), (Figure 2, Sheet 2, Item 39), or (Figure 2, Sheet 2,
Item 40), remove two rivets (Figure 2, Sheet 2, Item 41) and nameplate.

Change 1 0042-4
 TM 9-6115-730-24 0042

DISASSEMBLY - Continued

Figure 2. Control Box Assembly (Sheet 1 of 5).

0042-5 Change 1
 TM 9-6115-730-24 0042

DISASSEMBLY - Continued

Figure 2. Control Box Assembly (Sheet 2 of 5).

Change 1 0042-6
 TM 9-6115-730-24 0042

DISASSEMBLY - Continued

Figure 2. Control Box Assembly (Sheet 3 of 5).

0042-7 Change 1
 TM 9-6115-730-24 0042

DISASSEMBLY - Continued

Figure 2. Control Box Assembly (Sheet 4 of 5).

Change 1 0042-8
 TM 9-6115-730-24 0042

DISASSEMBLY - Continued

Figure 2. Control Box Assembly (Sheet 5 of 5).

0042-9 Change 1
 TM 9-6115-730-24 0042

DISASSEMBLY - Continued

13. To remove ground fault circuit interrupter GFCI (Figure 2, Sheet 3, Item 42), remove two nuts (Figure 2,
Sheet 3, Item 43), screws (Figure 2, Sheet 3, Item 44), and circuit interrupter.

14. To remove AC transformer box A5 (Figure 2, Sheet 3, Item 45), remove three fuses (Figure 2, Sheet 3,
Item 46), four screws (Figure 2, Sheet 3, Item 47), four lockwashers (Figure 2, Sheet 3, Item 48), four
washers (Figure 2, Sheet 3, Item 49), and AC transformer box.

15. To remove upper transformer mounting bracket (Figure 2, Sheet 3, Item 50), remove nut (Figure 2, Sheet 3,
Item 51), two screws (Figure 2, Sheet 3, Item 52), two lockwashers (Figure 2, Sheet 3, Item 53), two washers
(Figure 2, Sheet 3, Item 54), and bracket.

16. To remove lower transformer mounting bracket (Figure 2, Sheet 3, Item 55), remove nut (Figure 2, Sheet 3,
Item 56), two screws (Figure 2, Sheet 3, Item 57), two lockwashers (Figure 2, Sheet 3, Item 58), two washers
(Figure 2, Sheet 3, Item 59), and bracket.

17. To remove loop clamp (Figure 2, Sheet 3, Item 60), remove nut (Figure 2, Sheet 3, Item 61), loop clamp, nut
(Figure 2, Sheet 3, Item 61), and screw (Figure 2, Sheet 3, Item 62).

18. To remove component mounting channel (Figure 2, Sheet 3, Item 63), remove five screws (Figure 2, Sheet 3,
Item 64), lockwashers (Figure 2, Sheet 3, Item 65), washers (Figure 2, Sheet 3, Item 66), and channel.

19. Remove nut (Figure 2, Sheet 3, Item 67), two washers (Figure 2, Sheet 3, Item 68), nut (Figure 2, Sheet 3,
Item 67), and screw (Figure 2, Sheet 3, Item 69).

20. To remove relay KR (Figure 2, Sheet 4, Item 70), CDR (Figure 2, Sheet 4, Item 71), AFPR (Figure 2, Sheet 4,
Item 72), AR (Figure 2, Sheet 4, Item 73), GFR (Figure 2, Sheet 4, Item 74), or KFF (Figure 2, Sheet 4,
Item 75), remove spring (Figure 2, Sheet 4, Item 76), relay, and socket (Figure 2, Sheet 4, Item 77).

21. To remove relay DBLO (Figure 2, Sheet 4, Item 78) or DBHI (Figure 2, Sheet 4, Item 79), remove spring
(Figure 2, Sheet 4, Item 76), relay, and socket (Figure 2, Sheet 4, Item 80).

22. To remove relay PAR (Figure 2, Sheet 4, Item 81), remove spring (Figure 2, Sheet 4, Item 76), relay, and
socket (Figure 2, Sheet 4, Item 82).

23. To remove track (Figure 2, Sheet 4, Item 83), remove two screws (Figure 2, Sheet 4, Item 84), two washers
(Figure 2, Sheet 4, Item 85), two insulator blocks (Figure 2, Sheet 4, Item 86), two clips (Figure 2, Sheet 4,
Item 87), three nuts (Figure 2, Sheet 4, Item 88), three screws (Figure 2, Sheet 4, Item 89), three washers
(Figure 2, Sheet 4, Item 90), and track.

24. To remove connector J30 (Figure 2, Sheet 4, Item 91), remove four nuts (Figure 2, Sheet 4, Item 92), screws
(Figure 2, Sheet 4, Item 93), and connector. Repeat for connector J31 (Figure 2, Sheet 4, Item 94).

25. To remove connector J37 (Figure 2, Sheet 4, Item 95), remove four nuts (Figure 2, Sheet 4, Item 96), screws
(Figure 2, Sheet 4, Item 97), and connector.

26. To remove digital voltage regulator (DVR) A3 (Figure 2, Sheet 4, Item 98), remove four nuts (Figure 2,
Sheet 4, Item 99), screws (Figure 2, Sheet 4, Item 100), digital voltage regulator, and gasket (Figure 2,
Sheet 4, Item 101). Remove two screws (Figure 2, Sheet 4, Item 102) and capacitor (Figure 2, Sheet 4,
Item 103).

Change 1 0042-10
 TM 9-6115-730-24 0042

DISASSEMBLY - Continued

27. To remove DVR bracket (Figure 2, Sheet 4, Item 104), remove two screws (Figure 2, Sheet 4, Item 105),
lockwashers (Figure 2, Sheet 4, Item 106), washers (Figure 2, Sheet 4, Item 107), and bracket. To remove
DVR bracket (Figure 2, Sheet 4, Item 108), remove three screws (Figure 2, Sheet 4, Item 109), lockwashers
(Figure 2, Sheet 4, Item 110), washers (Figure 2, Sheet 4, Item 111), and bracket.

28. To remove resistor assembly A7 (Figure 2, Sheet 5, Item 112), remove two screws, remove two lockwashers,
113A and two flat washers, 113B (Figure 2, Sheet 5, Item 113) and resistor assembly.

29. To remove ground stud (Figure 2, Sheet 5, Item 114), remove two locknuts (Figure 2, Sheet 5, Item 115), two
jam nuts (Figure 2, Sheet 5, Item 116), two lockwashers (Figure 2, Sheet 5, Item 117), external tooth
lockwasher (Figure 2, Sheet 5, Item 118), two washers (Figure 2, Sheet 5, Item 119), and ground stud.

END OF TASK

ASSEMBLY

1. Install ground stud (Figure 2, Sheet 5, Item 114), two washers (Figure 2, Sheet 5, Item 119), external tooth
lockwasher (Figure 2, Sheet 5, Item 118), two lockwashers (Figure 2, Sheet 5, Item 117), two jam nuts
(Figure 2, Sheet 5, Item 116), and two locknuts (Figure 2, Sheet 5, Item 115).

2. Install resistor assembly A7 (Figure 2, Sheet 5, Item 112) and two screws (Figure 2, Sheet 5, Item 113).

3. Install DVR bracket (Figure 2, Sheet 4, Item 108), three washers (Figure 2, Sheet 4, Item 111), lockwashers
(Figure 2, Sheet 4, Item 110), and screws (Figure 2, Sheet 4, Item 109). Install DVR bracket (Figure 2,
Sheet 4, Item 104), three washers (Figure 2, Sheet 4, Item 107), lockwashers (Figure 2, Sheet 4, Item 106),
and screws (Figure 2, Sheet 4, Item 105).

4. Install capacitor (Figure 2, Sheet 4, Item 103) and two screws (Figure 2, Sheet 4, Item 102) on digital voltage
regulator (DVR) A3 (Figure 2, Sheet 4, Item 98). Install gasket (Figure 2, Sheet 4, Item 101), digital voltage
regulator (Figure 2, Sheet 4, Item 98), four screws (Figure 2, Sheet 4, Item 100), and nuts (Figure 2, Sheet 4,
Item 99).

5. Install connector J37 (Figure 2, Sheet 4, Item 95), four screws (Figure 2, Sheet 4, Item 97), and nuts
(Figure 2, Sheet 4, Item 96).

6. Install connector J30 (Figure 2, Sheet 4, Item 91), four screws (Figure 2, Sheet 4, Item 93), and nuts
(Figure 2, Sheet 4, Item 92). Repeat for connector J31 (Figure 2, Sheet 4, Item 94).

7. Install track (Figure 2, Sheet 4, Item 83), three washers (Figure 2, Sheet 4, Item 90), three screws (Figure 2,
Sheet 4, Item 89), three nuts (Figure 2, Sheet 4, Item 88), two clips (Figure 2, Sheet 4, Item 87), two insulator
blocks (Figure 2, Sheet 4, Item 86), two washers (Figure 2, Sheet 4, Item 85), and two screws (Figure 2,
Sheet 4, Item 84).

8. Install socket (Figure 2, Sheet 4, Item 82), relay PAR (Figure 2, Sheet 4, Item 81), and spring (Figure 2,
Sheet 4, Item 76).

9. Install socket (Figure 2, Sheet 4, Item 80), relay DBLO (Figure 2, Sheet 4, Item 78), and spring (Figure 2,
Sheet 4, Item 76).

10. Install socket (Figure 2, Sheet 4, Item 77), relay KFF (Figure 2, Sheet 4, Item 75), GFR (Figure 2, Sheet 4,
Item 74), AR (Figure 2, Sheet 4, Item 73), AFPR (Figure 2, Sheet 4, Item 72), CDR (Figure 2, Sheet 4,
Item 71), KR (Figure 2, Sheet 4, Item 70), and spring (Figure 2, Sheet 4, Item 76).

0042-11 Change 1
 TM 9-6115-730-24 0042

ASSEMBLY - Continued

11. Install screw (Figure 2, Sheet 3, Item 69), nut (Figure 2, Sheet 3, Item 67), two washers (Figure 2, Sheet 3,
Item 68), and nut (Figure 2, Sheet 3, Item 67)

12. Install component mounting channel (Figure 2, Sheet 3, Item 63), five washers (Figure 2, Sheet 3, Item 66),
lockwashers (Figure 2, Sheet 3, Item 65), and screws (Figure 2, Sheet 3, Item 64).

13. Install screw (Figure 2, Sheet 3, Item 62), nut (Figure 2, Sheet 3, Item 61), loop clamp (Figure 2, Sheet 3,
Item 60), and nut (Figure 2, Sheet 3, Item 61).

14. Install lower transformer mounting bracket (Figure 2, Sheet 3, Item 55), two washers (Figure 2, Sheet 3,
Item 59), two lockwashers (Figure 2, Sheet 3, Item 58), two screws (Figure 2, Sheet 3, Item 57), and nut
(Figure 2, Sheet 3, Item 56).

15. Install upper transformer mounting bracket (Figure 2, Sheet 3, Item 50), two washers (Figure 2, Sheet 3, Item
54), two lockwashers (Figure 2, Sheet 3, Item 53), two screws (Figure 2, Sheet 3, Item 52), and nut (Figure 2,
Sheet 3, Item 51).

16. Install AC transformer box A5 (Figure 2, Sheet 3, Item 45), four washers (Figure 2, Sheet 3, Item 49), four
lockwashers (Figure 2, Sheet 3, Item 48), four screws (Figure 2, Sheet 3, Item 47), and three fuses (Figure 2,
Sheet 3, Item 46). Record barcode values for VA, VB, VC, IA, IB, IC (setpoints AC01 thru AC06) for
reprogramming. GSC setpoints must be reprogrammed if AC transformer box A5 is replaced (WP 0081).

17. Install ground fault circuit interrupter GFCI (Figure 2, Sheet 3, Item 42), two screws (Figure 2, Sheet 3,
Item 44), and nuts (Figure 2, Sheet 3, Item 43).

18. Install nameplate (Figure 2, Sheet 2, Item 40), (Figure 2, Sheet 2, Item 39), or (Figure 2, Sheet 2, Item 38)
and two rivets (Figure 2, Sheet 2, Item 41).

19. Install paralleling receptacle (Figure 2, Sheet 2, Item 34), cover (Figure 2, Sheet 2, Item 37), four screws
(Figure 2, Sheet 2, Item 36), and four nuts (Figure 2, Sheet 2, Item 35). Repeat for other paralleling
receptacle.

20. Install duplex receptacle (Figure 2, Sheet 2, Item 31), cover (Figure 2, Sheet 2, Item 33), and four screws
(Figure 2, Sheet 2, Item 32).

21. Install load sharing module (LSM) A4 (Figure 2, Sheet 2, Item 28), four washers (Figure 2, Sheet 2, Item 30),
and screws (Figure 2, Sheet 2, Item 29).

22. Install overload/short circuit relay (Figure 2, Sheet 2, Item 24), four washers (Figure 2, Sheet 2, Item 27),
lockwashers (Figure 2, Sheet 2, Item 26), and screws (Figure 2, Sheet 2, Item 25).

23. Install bus transformer box A6 (Figure 2, Sheet 2, Item 19), four washers (Figure 2, Sheet 2, Item 23), four
lockwashers (Figure 2, Sheet 2, Item 22), four screws (Figure 2, Sheet 2, Item 21), and two fuses (Figure 2,
Sheet 2, Item 20). Record barcode value for VA (setpoint AC07) for reprogramming. GSC setpoints must be
reprogrammed if bus transformer box A6 is replaced (WP 0083).

24. Install fuse block (Figure 2, Sheet 2, Item 15), two screws (Figure 2, Sheet 2, Item 18), two nuts (Figure 2,
Sheet 2, Item 17), and four fuses (Figure 2, Sheet 2, Item 16).

25. Install fuse block (Figure 2, Sheet 1, Item 11), two screws (Figure 2, Sheet 1, Item 14), two nuts (Figure 2,
Sheet 1, Item 13), and three fuses (Figure 2, Sheet 1, Item 12).

Change 1 0042-12
 TM 9-6115-730-24 004 2

ASSEMBLY - Continued

26. On TB4 (Figure 2, Sheet 1, Item 2) only, install two spade terminals (Figure 2, Sheet 1, Item 10), diode
(Figure 2, Sheet 1, Item 9), and two screws (Figure 2, Sheet 1, Item 8). Install ten jumpers (Figure 2, Sheet 1,
Item 7) and ten screws (Figure 2, Sheet 1, Item 6). Install strip (Figure 2, Sheet 1, Item 5), terminal block TB4
(Figure 2, Sheet 1, Item 2), two screws (Figure 2, Sheet 1, Item 4), and two nuts (Figure 2, Sheet 1, Item 3).
Repeat for terminal block TB3.

27. Install three receptacles (Figure 2, Sheet 1, Item 1).

28. Install control box panel assembly (WP 0041).

END OF TASK

INSTALLATION

1. If previously removed, install brace (Figure 1, Item 21) using two screws (Figure 1, Item 18), lockwashers
(Figure 1, Item 19), and washers (Figure 1, Item 20).

2. Slide control box (Figure 1, Item 17) fully into generator set.

3. Install seven screws (Figure 1, Item 22), lockwashers (Figure 1, Item 23), and washers (Figure 1, Item 24).

4. Install five screws (Figure 1, Item 14), lockwashers (Figure 1, Item 15), and washers (Figure 1, Item 16).

5. Install two screws (Figure 1, Item 11), lockwashers (Figure 1, Item 12), and washers (Figure 1, Item 13).

6. Install three screws (Figure 1, Item 8), lockwashers (Figure 1, Item 9), and washers (Figure 1, Item 10).

7. Install seven screws (Figure 1, Item 5), lockwashers (Figure 1, Item 6), and washers (Figure 1, Item 7).

8. Install ground wire (Figure 1, Item 1) to back of control box terminal (Figure 1, Item 4) with washer (Figure 1,
Item 2) and locknut (Figure 1, Item 3)

9. Remove tag and connect ECM to EMCP harness connector ENG-P37 to control box connector J37.

10. Remove tag and connect harness connec tor P31 to control box connector J31.

11. Remove tag and connect harness connector P30 to control box connector J30.

12. Install front roof section (WP 0030).

END OF TASK

0042-13 Change 1
 TM 9-6115-730-24 0042

LSM A4 LOAD GAIN ADJUSTMENT

NOTE
For this procedure the generator set must be running isochronously, not paralleled.

1. Start the generator set and run at full load.

2. Measure the load signal voltage at LSM A4-22 (+) and LSM A4-23 (-).

3. Adjust LSM A4 LOAD GAIN potentiometer for 6.0 Vdc ± 1.0 Vdc.

END OF TASK

END OF WORK PACKAGE

Change 1 0042-14
 TM 9-6115-730-24 0043

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
RESISTOR ASSEMBLY A7 MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Tool Kit, General Mechanic’s (WP 0123, Item 1) TM 9-6115-730-24P

Materials/Parts Equipment Condition

Marker tags (WP 0124, Item 49) Resistor assembly A7 removed from control box
(WP 0042)
Personnel Required

One

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DISASSEMBLY

1. Tag and disconnect wires from resistor assembly A7 components.

2. Remove nut (Figure 1, Item 1), washer (Figure 1, Item 2), and ISOCHRONOUS DROOP switch IDS
(Figure 1, Item 3).

3. Remove nut (Figure 1, Item 4), washer (Figure 1, Item 5), and DC CONTROL POWER circuit breaker CB1
(Figure 1, Item 6).

4. Remove six nuts (Figure 1, Item 7), six screws (Figure 1, Item 8), and resistors R1 (Figure 1, Item 9), R2
(Figure 1, Item 10), and R3 (Figure 1, Item 11).

0043-1
 TM 9-6115-730-24 0043

DISASSEMBLY - Continued

5. Remove diode CRFF (Figure 1, Item 12).

6. Remove two nuts (Figure 1, Item 13), two screws (Figure 1, Item 14), and terminal board (Figure 1, Item 15).

Figure 1. Resistor Assembly A7.

END OF TASK

0043-2
 TM 9-6115-730-24 0043

TEST

1. Using multimeter, measure resistance of the resistors. R1 = 150 ohms +/- 1%, R2 = 10 ohms +/- 1%, and R3
= 15 kohms +/–1%.

2. Using multimeter, check forward and reverse bias on diode CRFF.

3. Replace any components that fail a measurement test.

END OF TASK

ASSEMBLY

1. Install terminal board (Figure 1, Item 15), two screws (Figure 1, Item 14), and two nuts (Figure 1, Item 13).

2. Install diode CRFF (Figure 1, Item 12).

3. Install resistors R3 (Figure 1, Item 11), R2 (Figure 1, Item 10), and R1 (Figure 1, Item 9), with six screws
(Figure 1, Item 8) and nuts (Figure 1, Item 7).

4. Install DC CONTROL POWER circuit breaker CB1 (Figure 1, Item 6), washer (Figure 1, Item 5), and nut
(Figure 1, Item 4).

5. Install ISOCHRONOUS DROOP switch IDS (Figure 1, Item 3), washer (Figure 1, Item 2), and nut (Figure 1,
Item 1).

6. Install resistor assembly A7 (WP 0042).

7. Remove tags and connect wires to resistor assembly A7 components.

END OF TASK

END OF WORK PACKAGE

0043-3/4 blank
 TM 9-6115-730-24 0044

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
CONTROL BOX HARNESS ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Tool Kit, General Mechanic’s (WP 0123, Item 1) WP 0088

FO-4
Materials/Parts TM 55-1500-323-24
TM 9-6115-730-24P
Marker tags (WP 0124, Item 49)

Personnel Required

One

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch
is OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open battery access doors, left front door, left rear doors, load board door, right front doors, right rear doors,
and generator access cover assembly.

3. Using Control Panel Harness Wire List (WP 0088), and Control Box Wiring Diagram, FO-4 as guides, tag and
disconnect control box harness assembly.

END OF TASK

0044-1
 TM 9-6115-730-24 0044

REPAIR OR REPLACEMENT

Repair as required using components identified in Control Panel Harness Wire List and general procedures
identified in Installation Practices for Aircraft Electrical and Electronic Wiring, TM 55-1500-323-24.

END OF TASK

INSTALLATION

1. Using Control Panel Harness Wire List (WP 0088) and Control Box Wiring Diagram, FO-4 as guides, remove
tags and connect control box harness assembly.

2. Close generator access cover assembly, left front door, right rear doors, right front doors, load board door
assembly, left rear doors, and battery access doors.

3. Verify the generator set operates properly.

END OF TASK

END OF WORK PACKAGE

0044-2
 TM 9-6115-730-24 0045

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
RECONNECTION TERMINAL BOARD ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Tiedown straps (WP 0124, Item 47) WP 0083

TM 9-6115-730-24P

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

DISASSEMBLY

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch
is OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open right rear doors.

3. Remove four locknuts (Figure 1, Item 1), four washers (Figure 1, Item 2), and protective cover (Figure 1,
Item 3).

4. Remove two screws (Figure 1, Item 4) and four standoffs (Figure 1, Item 5) and pull reconnection terminal
board assembly (Figure 1, Item 6) away from its lower mounting and two standoffs (Figure 1, Item 7).

0045-1 Chamge 1
 TM 9-6115-730-24 0045

DISASSEMBLY - Continued

Figure 1. Reconnection Terminal Board Assembly.

Change 1 0045-2
 TM 9-6115-730-24 0045

DISASSEMBLY - Continued

NOTE
Cut tiedown straps as required.

5. Remove 13 jam nuts (Figure 1, Item 8), lockwashers (Figure 1, Item 9), and washers (Figure 1, Item 10), and
tag and disconnect wires from rear of reconnection terminal board assembly (Figure 1, Item 6).

6. Remove 13 jam nuts (Figure 1, Item 11), bus bar (Figure 1, Item 12), 13 studs (Figure 1, Item 13), 13 locknuts
(Figure 1, Item 14), and moveable terminal board (Figure 1, Item 15).

END OF TASK

ASSEMBLY

1. Install moveable terminal board (Figure 1, Item 15) on terminal board assembly (Figure 1, Item 6), and secure
with 13 locknuts (Figure 1, Item 14), 13 studs (Figure 1, Item 13), bus bar (Figure 1, Item 12), and 13 jam nuts
(Figure 1, Item 11). Torque locknuts (Figure 1, Item 14) to 20 lb-ft (27 Nm). Torque jam nuts (Figure 1, Item 11)
to 30 lb-ft (41 Nm).
2. Remove tags and connect wires to rear of reconnection terminal board assembly (Figure 1, Item 6), and
secure with 13 washers (Figure 1, Item 10), lockwashers (Figure 1, Item 9) and jam nuts (Figure 1, Item 8).
Torque jam nuts (Figure 1, Item 8) to 30 lb-ft (41 Nm).

NOTE
Install tiedown straps as required.

3. Position reconnection terminal board assembly (Figure 1, Item 6) on its lower mounting and two standoffs
(Figure 1, Item 7), and secure with four standoffs (Figure 1, Item 5) and two screws (Figure 1, Item 4).

4. Install protective cover (Figure 1, Item 3) and secure with four washers (Figure 1, Item 2) and locknuts
(Figure 1, Item 1).

5. Close right rear doors.

6. If required, reprogram GSC and DVR parameters per WP 0083.

END OF TASK

END OF WORK PACKAGE

0045-3/4 blank Change 1

 TM 9-6115-730-24 0046

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
LOAD TERMINAL BOARD ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Tool Kit, General Mechanic’s (WP 0123, Item 1) TM 9-6115-730-24P

Materials/Parts Equipment Condition

Marker tags (WP 0124, Item 49) Load board door removed (WP 0024)
Tiedown straps (WP 0124, Item 48) Door support assembly removed
(WP 0040)
Personnel Required

One

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

DISASSEMBLY

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch
is OFF, and DEAD CRANK SWITCH is OFF before proceeding.

NOTE
Cut tiedown straps as required.

2. Tag and disconnect load cables, if necessary, from front of load board (Figure 1, Sheet 1, Item 1) and pull
cables through opening at rear of generator set.

0046-1
 TM 9-6115-730-24 0046

DISASSEMBLY - Continued

Figure 1. Load Terminal Board Assembly (Sheet 1 of 2).

0046-2
 TM 9-6115-730-24 0046

DISASSEMBLY - Continued

Figure 1. Load Terminal Board Assembly (Sheet 2 of 2).

0046-3
 TM 9-6115-730-24 0046

DISASSEMBLY - Continued

3. Remove two locknuts (Figure 1, Sheet 1, Item 2), six washers (Figure 1, Sheet 1, Item 3), four screws
(Figure 1, Sheet 1, Item 4), and turn load board (Figure 1, Sheet 1, Item 1) partly over.

4. Remove eight locknuts (Figure 1, Sheet 2, Item 5) and 16 washers (Figure 1, Sheet 2, Item 6), and tag and
disconnect wires from the rear of load board (Figure 1,sheet 2, Item6).

5. Tag and disconnect wires from rear of load board (Figure 1, Sheet 2, Item 12) terminals.

6. Tag wires from four varistors, V1 (Figure 1, Sheet 2, Item 7), V2 (Figure 1, Sheet 2, Item 8), V3 (Figure 1,
Sheet 2, Item 9), and V4 (Figure 1, Sheet 2, Item 10).

7. Remove eight jam nuts (Figure 1, Sheet 2, Item 11) and load terminals (Figure 1, Sheet 2, Item 12).

8. Remove four locknuts (Figure 1, Sheet 2, Item 13), four washers (Figure 1, Sheet 2, Item 14), two studs
(Figure 1, Sheet 2, Item 15), bus bar (Figure 1, Sheet 2, Item 16), and ground wire (Figure 1, Sheet 2,
Item 17).

9. Remove four locknuts (Figure 1, Sheet 2, Item 18), four screws (Figure 1, Sheet 2, Item 19), eight washers
(Figure 1, Sheet 2, Item 20), three bus bars (Figure 1, Sheet 2, Item 21), and bus bar (Figure 1, Sheet 2,
Item 22).

CAUTION
Note orientation of EMI filters (Figure 1, Sheet 2, Item 22) before removing.

10. Remove eight nuts (Figure 1, Sheet 2, Item 23), washers (Figure 1, Sheet 2, Item 24), screws (Figure 1,
Sheet 2, Item 25), varistors V1 (Figure 1, Sheet 2, Item 7), V2 (Figure 1, Sheet 2, Item 8), V3 (Figure 1,
Sheet 2, Item 9), and V4 (Figure 1, Sheet 2, Item 10), ground plate (Figure 1, Sheet 2, Item 26), and four
EMI filter assemblies (Figure 1, Sheet 2, Item 27).

END OF TASK

ASSEMBLY

CAUTION
Note orientation of EMI filters (Figure 1, Sheet 2, Item 22) before installing.

1. Install four EMI filter assemblies (Figure 1, Sheet 2, Item 27), ground plate (Figure 1, Sheet 2, Item 26),
varistors V4 (Figure 1, Sheet 2, Item 10), V3 (Figure 1, Sheet 2, Item 9), V2 (Figure 1, Sheet 2, Item 8), and
V1 (Figure 1, Sheet 2, Item 7), eight screws (Figure 1, Sheet 2, Item 25), washers (Figure 1, Sheet 2, Item
24), and nuts (Figure 1, Sheet 2, Item 23).

2. Install bus bar (Figure 1, Sheet 2, Item 22), three bus bars (Figure 1, Sheet 2, Item 21), eight washers
(Figure 1, Sheet 2, Item 20), four screws (Figure 1, Sheet 2, Item 19), and four locknuts (Figure 1, Sheet 2,
Item 18).

3. Install bus bar (Figure 1, Sheet 2, Item 16), two studs (Figure 1, Sheet 2, Item 15), four washers (Figure 1,
Sheet 2, Item 14), ground wire (Figure 1, Sheet 2, Item 17), and four locknuts (Figure 1, Sheet 2, Item 13).

4. Install eight load terminals (Figure 1, Sheet 2, Item 12), and jam nuts (Figure 1, Sheet 2, Item 11).

0046-4
 TM 9-6115-730-24 0046

ASSEMBLY - Continued

NOTE
Install tiedown straps as required.

5. Connect wires from four varistors V4 (Figure 1, Sheet 2, Item 10), V3 (Figure 1, Sheet 2, Item 9), V2 (Figure
1, Sheet 2, Item 8), and V1 (Figure 1, Sheet 2, Item 7), and install eight washers (Figure 1, Sheet 2, Item 6)
and eight locknuts (Figure 1, Sheet 2, Item 5).

6. Position load board (Figure 1, Sheet 1, Item 1) and install four screws (Figure 1, Sheet 1, Item 4), washers
(Figure 1, Sheet 1, Item 3), and two locknuts (Figure 1, Sheet 1, Item 2).

7. Install load board door (WP 0024) and door support assembly (WP 0040) as necessary.

END OF TASK

END OF WORK PACKAGE

0046-5/6 blank
 TM 9-6115-730-24 0047

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
BATTERY CABLE ASSEMBLIES MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic s (WP 0123, Item 1) One

Materials/Parts References

Tiedown straps (WP 0124, Item 48) TM 9-6115-730-24P

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

When disconnecting or removing batteries, disconnect the negative lead that connects directly to
the grounding stud first. Disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply can cause serious injury
to personnel.

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch
is OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Ensure there is no external cable connected to slave receptacle.

3. Open battery access doors.

0047-1 Change 1
 TM 9-6115-730-24 0047

REMOVAL - Continued

NOTE
When looking into battery compartment, batteries are identified from left to right as BT4, BT2,
BT1, and BT3.
Tiedown straps should be cut as required .
4. Tag cables and remove battery terminal knob (Figure 1, Sheet 1, Item 3), lock washer (Figure 1, Sheet 1,
Item 3A), and flat washer (Figure 1, Sheet 1, Item 3B) that secure battery cable 1B40 (Figure 1, Sheet 1, Item
1) and battery cable 1A40 (Figure 1, Sheet 1, Item 2) to battery BT2 negative terminal. Remove battery
cables 1A40 and 1B40.
5. Tag cables and remove battery terminal knob (Figure 1, Sheet 1, Item 5), lock washer (Figure 1, Sheet 1,
Item 5A), and flat washer (Figure 1, Sheet 1, Item 5B) that secure battery cable 1D40 (Figure 1, Sheet 1, Item
4) and battery cable 1B40 (Figure 1, Sheet 1, Item 1) to battery BT4 negative terminal. Remove battery
cables 1B40 and 1D40.
6. Tag cable and remove battery terminal knob (Figure 1, Sheet 1, Item 8), lock washer (Figure 1, Sheet 1, Item
8A), and flat washer (Figure 1, Sheet 1, Item 8B) and battery terminal knob (Figure 1, Sheet 1, Item 9), lock
washer (Figure 1, Sheet 1, Item 9A), and flat washer (Figure 1, Sheet 1, Item 9B) that secure battery cable
12B40 (Figure 1, Sheet 1, Item 6) and battery cable 12A40 (Figure 1, Sheet 1, Item 7) to battery BT1
negative terminal and battery BT3 negative terminal. Remove battery cable 12B40.
7. Tag cable and remove battery terminal knob (Figure 1, Sheet 1, Item 11), lock washer (Figure 1, Sheet 1,
Item 11A), and flat washer (Figure 1, Sheet 1, Item 11B) that secure battery cable 12A40 (Figure 1, Sheet 1,
Item 7) and battery cable 12C40 (Figure 1, Sheet 1, Item 10) to battery BT2 positive terminal. Remove
battery cable 12A40.
8. Tag cable and remove battery terminal knob (Figure 1, Sheet 1, Item 12), lock washer (Figure 1, Sheet 1,
Item 12A), and flat washer (Figure 1, Sheet 1, Item 12B) that secure battery cable 12C40 (Figure 1, Sheet 1,
Item 10) to battery BT4 positive terminal. Remove battery cable 12C40.
9. Tag cable and remove battery terminal knob (Figure 1, Sheet 1, Item 15), lock washer (Figure 1, Sheet 1,
Item 15A), and flat washer (Figure 1, Sheet 1, Item 15B) that secure battery cable 24A40 (Figure 1, Sheet 1,
Item 14) to battery BT1 positive terminal.
10. Tag cable and remove battery terminal knob (Figure 1, Sheet 1, Item 17), lock washer (Figure 1, Sheet 1,
Item 17A), and flat washer (Figure 1, Sheet 1, Item 17B) that secure battery cable 24B40 (Figure 1, Sheet 1,
Item 13) and battery cable 24H40 (Figure 1, Sheet 1, Item 16) to battery BT3 positive terminal. Remove
battery cable 24B40.
11. Remove four nuts (Figure 1, Item 18), screws (Figure 1, Sheet 1, Item 19), and washers (Figure 1, Sheet 1,
Item 20), and push slave receptacle SR (Figure 1, Sheet 1, Item 21) out of TQG.
12. Remove slave receptacle SR (Figure 1, Sheet 1, Item 18) (WP 0054). Disconnect battery cable 1D40
(Figure 1, Sheet 1, Item 4) and battery cable 24H40 (Figure 1, Sheet 1, Item 16) from slave receptacle SR
(Figure 1, Sheet 1, Item 21) and remove battery cables 1D40 and 24H40.
13. Remove four screws (Figure 1, Item 24), lockwashers (Figure 1, Item 25), and washers (Figure 1, Item 26),
and pull battery disconnect switch (BDS) (Figure 1, Item 23) away from wall.
14. At rear of BDS (Figure 1, Item 23), tag and disconnect battery cables 1A40 (Figure 1, Item 2) and 2A40
(Figure 1, Item 22).
15. Remove battery disconnect switch (Figure 1, Item 23). Tag and disconnect sensor cables from BDS.
16. Disconnect battery cable 1A40 (Figure 1, Sheet 1, Item 2) and battery cable 2A40 (Figure 1, Sheet 1, Item 22)
from BDS (Figure 1, Sheet 1, Item 23) and remove battery cable 1A40.
17. Disconnect battery cable 24A40 (Figure 1, Sheet 1, Item 14) from starter solenoid (Figure 1, Sheet 1,
Item 27).

Change 1 0047-2
 TM 9-6115-730-24 0047

REMOVAL - Continued

5 3 15
5A 3A 15A
5B 1 4 3B 22 15B 2 23 14
(1B40) (1D40) (2A40) (1A40) (24A40)

26
25

24

16
(24H40)

17
17A
17B
12 10 11 7 8 6 9 13
12A (12C40) 11A (12A40) 8A (12B40) 9A (24B40)
12B 11B 8B 9B
BT4 BT2 BT1 BT3

22 REF 14 REF
(2A40) 30 (24A40)
18

21

20
33 27
(2C40) 19
200KW-24M-429-1E-C1

Figure 1. Battery Cable Assemblies (Sheet 1 of 2).

0047-3 Change 1
 TM 9-6115-730-24 0047

REMOVAL - Continued

Figure 1. Battery Cable Assemblies (Sheet 2 of 2).

Change 1 0047-4
 TM 9-6115-730-24 0047

REMOVAL - Continued

18. Remove two screws (Figure 1, Sheet 2, Item 28), washers (Figure 1, Sheet 2, Item 29), locknuts (Figure 1,
Sheet 2, Item 30), and clamps (Figure 1, Sheet 2, Item 31) and (Figure 1, Sheet 2, Item 32). Remove battery
cable 24A40 (Figure 1, Sheet 2, Item 14).

19. Disconnect battery cable 2A40 from upper portion of starter (Figure 1, Sheet 2, Item 22) (Figure 1, Sheet 2,
Item 34) and battery cable 2C40 from lower portion of starter (Figure 1, Sheet 1, Item 33) (Figure 1, Sheet 2,
Item 34).

20. Disconnect battery cable 2C40 (Figure 1, Sheet 1, Item 33) from load terminal board GND terminal
(WP 0046).

21. Removed screw (Figure 1, Sheet 2, Item 35), washer (Figure 1, Sheet 2, Item 36), locknut (Figure 1, Sheet 2,
Item 37), and clamp (Figure 1, Sheet 2, Item 38). Remove battery cable 2C40 (Figure 1, Sheet 1, Item 33).

END OF TASK

INSTALLATION

NOTE
Install tiedown straps as required.

1. Install battery cable 2C40 (Figure 1, Sheet 1, Item 33) and secure with screw (Figure 1, Sheet 2, Item 35),
washer (Figure 1, Sheet 2, Item 36), clamp (Figure 1, Sheet 2, Item 38), and locknut (Figure 1, Sheet 2,
Item 37).

2. Connect battery cable 2C40 (Figure 1, Sheet 1, Item 33) to load terminal board terminal GND (WP 0046).

3. Install battery cable 2A40 (Figure 1, Sheet 2, Item 22) and connect battery cable 2A40 (Figure 1, Sheet 2,
Item 22) and battery cable 2C40 (Figure 1, Sheet 1, Item 30) to starter (Figure 1, Sheet 2, Item 34).

4. Install battery cable 24A40 (Figure 1, Sheet 2, Item 14), with two screws (Figure 1, Sheet 2, Item 28), washer
(Figure 1, Sheet 2, Item 29), locknut (Figure 1, Sheet 2, Item 30), and clamps (Figure 1, Sheet 2, Item 31) and
(Figure 1, Sheet 2, Item 32).

5. Connect battery cable 24A40 (Figure 1, Sheet 2, Item 14) to starter solenoid (Figure 1, Sheet 1, Item 27).

6. Position battery disconnect switch (Figure 1, Item 23) near where it is to be installed. Remove tags and
connect battery cable 2A40 (Figure 1, Item 22) and sensor cable 1A40 (Figure 1, Item 2).

7. Install battery disconnect switch (Figure 1, Item 23) with four washers (Figure 1, Item 26), lockwashers
(Figure 1, Item 25), and screws (Figure 1, Item 24).

8. Install battery cables 1D40 (Figure 1, Sheet 1, Item 4) and 24H40 (Figure 1, Sheet 1, Item 16) and connect to
slave receptacle SR (Figure 1, Sheet 1, Item 21).

9. Push slave receptacle SR (Figure 1, Sheet 1, Item 21) into TQG and install four washers (Figure 1, Sheet 1,
Item 20), screws (Figure 1, Sheet 1, Item 19), and nuts (Figure 1, Sheet 1, Item 18).

10. Install battery cable 24H40 (Figure 1, Sheet 1, Item 16) and battery cable 24B40 (Figure 1, Sheet 1, Item 13)
on battery BT3 positive terminal and secure with flat washer (Figure 1, Sheet 1, Item 17B), lock washer
(Figure 1, Sheet 1, Item 17A), and battery terminal knob (Figure 1, Sheet 1, Item 17). Remove tags from
battery cables.

0047-5 Change 1
 TM 9-6115-730-24 0047

INSTALLATION - Continued

11. Install battery cable 24A40 (Figure 1, Sheet 1, Item 14) on battery BT1 positive terminal and secure with flat
washer (Figure 1, Sheet 1, Item 15B), lock washer (Figure 1, Sheet 1, Item 15A), and battery terminal knob
(Figure 1, Sheet 1, Item 15). Remove tag from battery cable.

12. Install battery cable 12C40 (Figure 1, Sheet 1, Item 10) on battery BT4 positive terminal and secure with flat
washer (Figure 1, Sheet 1, Item 12B), lock washer (Figure 1, Sheet 1, Item 12A), and battery terminal knob
(Figure 1, Sheet 1, Item 12). Remove tag from battery cable.

13. Install battery cable 12C40 (Figure 1, Sheet 1, Item 10) and battery cable 12A40 (Figure 1, Sheet 1, Item 7)
on battery BT2 positive terminal and secure with flat washer (Figure 1, Sheet 1, Item 11B), lock washer
(Figure 1, Sheet 1, Item 11A), and battery terminal knob (Figure 1, Sheet 1, Item 11). Remove tags from
battery cables.

14. Install battery cable 12B40 (Figure 1, Sheet 1, Item 6) on battery BT3 negative terminal and secure with flat
washer (Figure 1, Sheet 1, Item 9B), lock washer (Figure 1, Sheet 1, Item 9A), and battery terminal knob
(Figure 1, Sheet 1, Item 9). Remove tag from battery cable.

15. Install battery cable 12A40 (Figure 1, Sheet 1, Item 7) and battery cable 12B40 (Figure 1, Sheet 1, Item 6) on
battery BT1 negative terminal and battery BT3 negative terminal and secure with flat washer (Figure 1, Sheet
1, Item 8B), lock washer (Figure 1, Sheet 1, Item 8A), and battery terminal knob (Figure 1, Sheet 1, Item 8).
Remove tag from battery cable.

16. Install battery cable 1B40 (Figure 1, Sheet 1, Item 1) and battery cable 1D40 (Figure 1, Sheet 1, Item 4) on
battery BT4 negative terminal and secure with flat washer (Figure 1, Sheet 1, Item 5B), lock washer (Figure 1,
Sheet 1, Item 5A), and battery terminal knob (Figure 1, Sheet 1, Item 5). Remove tags from battery cables.

17. Install battery cable 1B40 (Figure 1, Sheet 1, Item 1) and battery cable 1A40 (Figure 1, Sheet 1, Item 2) on
battery BT2 negative terminal and secure with flat washer (Figure 1, Sheet 1, Item 3B), lock washer (Figure 1,
Sheet 1, Item 3A), and battery terminal knob (Figure 1, Sheet 1, Item 3). Remove tags from battery cables.

18. Close battery access doors.

END OF TASK

END OF WORK PACKAGE

Change 1 0047-6
 TM 9-6115-730-24 0048

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
POWER CABLE ASSEMBLIES MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Tool Kit, General Mechanic’s (WP 0123, Item 1) TM 9-6115-730-24P

Materials/Parts Equipment Condition

Marker tags (WP 0124, Item 49) Load terminal board partially removed
Tiedown straps (WP 0124, Item 48) (WP 0046)
Reconnection terminal board partially
Personnel Required removed (WP 0045)
Front plates removed from main load
One contactor (WP 0049)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch
is OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open right rear doors. Open load board door.

0048-1
 TM 9-6115-730-24 0048

REMOVAL - Continued

Figure 1. Power Cable Assemblies.

0048-2
 TM 9-6115-730-24 0048

REMOVAL - Continued

NOTE
Cut tiedown straps as required.

3. Partly remove load terminal board assembly (Figure 1, Item 1) (WP 0046) sufficiently to gain access to rear of
load terminal board assembly.

4. Partly remove reconnection terminal board (Figure 1, Item 2) (WP 0045) sufficiently to gain access to rear of
reconnection terminal board.

5. Remove two plates from front of main load contactor (Figure 1, Item 3) (WP 0049) to gain access to cable
terminals on front of main load contactor.

6. Tag and disconnect cable 110K (Figure 1, Item 4) from terminal 10 on reconnection terminal board (Figure 1,
Item 2) and terminal N on load terminal board assembly (Figure 1, Item 1).

7. Tag and disconnect cable 110L (Figure 1, Item 5) from terminal 12 on reconnection terminal board (Figure 1,
Item 2) and terminal N on load terminal board assembly (Figure 1, Item 1).

NOTE
Except for cables 110K and 110L, all power cables are installed in pairs.

8. Tag and disconnect cables 101A and 101B (Figure 1, Item 6) from terminal 1 on reconnection terminal board
(Figure 1, Item 2) and from two terminals A1 on main load contactor (Figure 1, Item 3).

9. Tag and disconnect cables 102A and 102B (Figure 1, Item 7) from terminal 2 of reconnection terminal board
(Figure 1, Item 2) and from two terminals B1 on main load contactor (Figure 1, Item 3).

10. Tag and disconnect cables 103A and 103B (Figure 1, Item 8) from terminal 3 on reconnection terminal board
(Figure 1, Item 2) and from two terminals C1 on main load contactor (Figure 1, Item 3).

11. Tag and disconnect cables 121A and 121B (Figure 1, Item 9) from two terminals A2 on main load contactor
(Figure 1, Item 3) and from two terminals L1 on load terminal board (Figure 1, Item 1).

12. Tag and disconnect cables 122A and 122B (Figure 1, Item 10) from two terminals B2 on main load contactor
(Figure 1, Item 3) and from two terminals L2 on load terminal board (Figure 1, Item 1).

13. Tag and disconnect cables 123A and 123B (Figure 1, Item 11) from two terminals C2 on main load contactor
(Figure 1, Item 3) and from two terminals L3 on load terminal board (Figure 1, Item 1).

END OF TASK

INSTALLATION

NOTE
Install tiedown straps as required.

1. Remove tags and connect cables 123A and 123B (Figure 1, Item 11) to two terminals L3 on load terminal
board (Figure 1, Item 1) and to two terminals C2 on main load contactor (Figure 1, Item 3).

0048-3
 TM 9-6115-730-24 0048

INSTALLATION - Continued

2. Remove tags and connect cables 122A and 122B (Figure 1, Item 10) to two terminals L2 on load terminal
board (Figure 1, Item 1) and to two terminals B2 on main load contactor (Figure 1, Item 3).

3. Remove tags and connect cables 121A and 121B (Figure 1, Item 9) to two terminals L1 on load terminal
board (Figure 1, Item 1) and to two terminals A2 on main load contactor (Figure 1, Item 3).

4. Remove tags and connect cables 103A and 103B (Figure 1, Item 8) to two terminals C1 on main load
contactor (Figure 1, Item 3) and to two terminals 3 on reconnection terminal board (Figure 1, Item 2).

5. Remove tags and connect cables 102A and 102B (Figure 1, Item 7) to two terminals B1 on main load
contactor (Figure 1, Item 3) and to two terminals 2 on reconnection terminal board (Figure 1, Item 2).

6. Remove tags and connect cables 101A and 101B (Figure 1, Item 6) to two terminals A1 on main load
contactor (Figure 1, Item 3) and to two terminals 1 on reconnection terminal board (Figure 1, Item 2).

7. Remove tags and connect cable 110L (Figure 1, Item 5) to terminal N on load terminal board (Figure 1,
Item 1) and to terminal 12 on reconnection terminal board (Figure 1, Item 2).

8. Remove tags and connect cable 110K (Figure 1, Item 4) to terminal N on load terminal board (Figure 1,
Item 1) and to terminal 10 on reconnection terminal board (Figure 1, Item 2).

9. Install plate on front of main load contactor (Figure 1, Item 3) (WP 0049).

10. Install reconnection terminal board (Figure 1, Item 2) (WP 0045).

11. Install load terminal board (Figure 1, Item 1) (WP 0046).

12. Close load board door. Close right rear doors.

END OF TASK

END OF WORK PACKAGE

0048-4
 TM 9-6115-730-24 0049

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
MAIN LOAD CONTACTOR MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Marker tags (WP 0124, Item 49) TM 9-6115-730-24P

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch
is OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open right rear doors.

3. Remove six screws (Figure 1, Item 1), washers (Figure 1, Item 2), and plate (Figure 1, Item 3).

4. Tag and disconnect cables and wires from main load contactor (Figure 1, Item 4).

5. Remove four screws (Figure 1, Item 5), washers (Figure 1, Item 6), lockwashers (Figure 1, Item 7), and main
load contactor (Figure 1, Item 4).

0049-1
 TM 9-6115-730-24 0049

REMOVAL - Continued

Figure 1. Main Load Contactor.

END OF TASK

0049-2
 TM 9-6115-730-24 0049

INSTALLATION

1. Install main load contactor (Figure 1, Item 4) with four lockwashers (Figure 1, Item 7), washers (Figure 1,
Item 6), and screws (Figure 1, Item 5).

2. Remove tags and connect wires and cables to main load contactor (Figure 1, Item 4).

3. Install plate (Figure 1, Item 3), six washers (Figure 1, Item 2), and screws (Figure 1, Item 1).

4. Close right rear doors.

END OF TASK

END OF WORK PACKAGE

0049-3/4 blank
 TM 9-6115-730-24 0050

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
BATTERIES MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, Two

Common No. 1 (WP 0123, Item 2)
Tool Kit, General Mechanic s (WP 0123, Item 1) References

Materials/Parts TM 9-6115-730-24P

Marker tags (WP 0124, Item 49)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

When disconnecting or removing batteries, disconnect the negative lead that connects directly to
the grounding stud first. Disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply can cause serious injury
to personnel.

WARNING
Each battery weighs more than 70 pounds (32 kg) and requires a two-person lift. Lifting batteries
can cause back strain. Ensure proper lifting techniques are used when lifting batteries. Failure to
comply can cause injury to personnel.

0050-1 Change 1
 TM 9-6115-730-24 0050

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch
is OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Ensure there is no external cable connected to slave receptacle.

3. Open battery access doors.

NOTE
When looking into battery compartment, batteries are identified from left to right as BT4, BT2,
BT1, and BT3.

4. Tag cables and remove battery terminal knob (Figure 1, Item 3), lock washer (Figure 1, Item 3A), and flat
washer (Figure 1, Item 3B) that secure battery cable 1B40 (Figure 1, Item 1) and battery cable 1A40 (Figure
1, Item 2) to battery BT2 negative terminal. Remove battery cables 1A40 and 1B40.

5. Tag cable and remove battery terminal knob (Figure 1, Item 5), lock washer (Figure 1, Item 5A), and flat
washer (Figure 1, Item 5B) and battery terminal knob (Figure 1, Item 6), lock washer (Figure 1, Item 6A), and
flat washer (Figure 1, Item 6B) that secure battery cable 12B40 (Figure 1, Item 4) to battery BT3 negative
terminal and BT1 negative terminal. Remove battery cable 12B40.

6. Tag cables and remove battery terminal knob (Figure 1, Item 8), lock washer (Figure 1, Item 8A), and flat
washer (Figure 1, Item 8B) that secure battery cable 1D40 (Figure 1, Item 7) and battery cable 1B40 (Figure
1, Item 1) to battery BT4 negative terminal. Remove battery cables 1D40 and 1B40.

7. Tag cable and remove battery terminal knob (Figure 1, Item 6), lock washer (Figure 1, Item 6A), and flat
washer (Figure 1, Item 6B) and battery terminal knob (Figure 1, Item 10), lock washer (Figure 1, Item 10A),
and flat washer (Figure 1, Item 10B) that secure battery cable 12A40 (Figure 1, Item 9) to battery BT1
negative terminal and battery BT2 positive terminal. Remove battery cable 12A40.

8. Tag cable and remove battery terminal knob (Figure 1, Item 12), lock washer (Figure 1, Item 12A), and flat
washer (Figure 1, Item 12B) that secure battery cable 12C40 (Figure 1, Item 11) to battery BT4 positive
terminal. Remove battery cable 12C40.

9. Tag cables and remove battery terminal knob (Figure 1, Item 15), lock washer (Figure 1, Item 15A), and flat
washer (Figure 1, Item 15B) that secure battery cable 24A40 (Figure 1, Item 13) and battery cable 24B40
(Figure 1, Item 14) to battery BT1 positive terminal.

10. Tag cables and remove battery terminal knob (Figure 1, Item 17), lock washer (Figure 1, Item 17A), and flat
washer (Figure 1, Item 17B) that secure battery cable 24B40 (Figure 1, Item 14) and battery cable 24H40
(Figure 1, Item 16) to battery BT3 positive terminal. Remove battery cable 24B40.

11. Remove five nuts (Figure 1, Item 18), lockwashers (Figure 1, Item 19), washers (Figure 1, Item 20), and pull
battery hold down angle (Figure 1, Item 21) off five threaded rods (Figure 1, Item 22).

12. Remove battery BT4 (Figure 1, Item 23), battery BT2 (Figure 1, Item 24), BT1 (Figure 1, Item 25), and BT3
(Figure 1, Item 26).

Change 1 0050-2
 TM 9-6115-730-24 0050

REMOVAL - Continued

8 3 15 17
8A 3A 15A 17A
8B 1 (1B40) 7 (1D40) 3B 2 (1A40) 15B 13 (24A40) 14 (24B40) 17B 16 (24H40)

18

19

20

22

12 21 11 10 9 6 4 5
12A (12C40) 10A (12A40) 6A (12B40) 5A
12B 10B 6B 5B
23 24 25 26
(BT4) (BT2) (BT1) (BT3)

_ _ + +

BT4 BT2 BT1 BT3

_ _
+ +

BATTERY ORIENTATION
200KW-24M-432B-C1

Figure 1. Batteries.

END OF TASK

0050-3 Change 1
 TM 9-6115-730-24 0050

TEST AND INSPECTION

NOTE
The testing and charging procedures apply only to the absorbed glass mat (AGM) type batteries
supplied with the TQG.

Do not mix AGM batteries with conventional flooded lead acid batteries, or reduced capacity,
shorter battery life, and possible undercharge problems may occur.

1. Allow battery to sit for at least 3 hours, preferably 8 hours. The battery must be disconnected from any load or
any other battery, and the ambient temperature should be approximately 70 degrees F (21 degrees C). Use
the battery load tester to measure the open circuit voltage across the terminals for 12.8 to 13 Vdc, indicating a
fully charged battery.

2. If battery is not fully charged, charge the battery, using the SEALED or GEL setting on the battery charger,
before proceeding.

3. If battery is fully charged, apply a load of 550 amps for 15 seconds. Check the open circuit voltage again for a
minimum or 9.6 Vdc.

4. If open circuit voltage is 9.6 Vdc or above, recharge the battery using the SEALED or GEL setting on the
battery charger.

5. If the open circuit voltage is less than 9.6 Vdc, battery is defective and must be replaced.

END OF TASK

INSTALLATION

NOTE
Make sure batteries are oriented so that BT4 and BT2 have positive terminals toward battery
access doors, and BT1 and BT3 have negative terminals toward battery access doors.

1. Install battery BT3 (Figure 1, Item 26), BT1 (Figure 1, Item 25), BT2 (Figure 1, Item 24), and BT4 (Figure 1,
Item 23).

2. Position battery hold down angle (Figure 1, Item 21) on five threaded rods (Figure 1, Item 22) and install five
washers (Figure 1, Item 20), lockwashers (Figure 1, Item 19), and nuts (Figure 1, Item 18).

3. Install battery cable 24H40 (Figure 1, Item 16) and battery cable 24B40 (Figure 1, Item 14) on battery BT3
positive terminal and secure with flat washer (Figure 1, Item 17B), lock washer (Figure 1, Item 17A), and
battery terminal knob (Figure 1, Item 17). Remove tags from battery cables.

4. Install battery cable 24B40 (Figure 1, Item 14) and battery cable 24A40 (Figure 1, Item 13) on battery BT1
positive terminal and secure with flat washer (Figure 1, Item 15B), lock washer (Figure 1, Item 15A), and
battery terminal knob (Figure 1, Item 15). Remove tags from battery cables.

Change 1 0050-4
 TM 9-6115-730-24 0050

INSTALLATION - Continued

5. Install battery cable 12C40 (Figure 1, Item 11) on battery BT2 positive terminal and battery BT4 positive
terminal and secure with flat washer (Figure 1, Item 10B), lock washer (Figure 1, Item 10A), and battery
terminal knob (Figure 1, Item 10) and flat washer (Figure 1, Item 12B), lock washer (Figure 1, Item 12A), and
battery terminal knob (Figure 1, Item 12). Remove tags from battery cables.

6. Install battery cable 12A40 (Figure 1, Item 9) on battery BT1 negative terminal and battery BT2 positive
terminal and secure with flat washer (Figure 1, Item 6B), lock washer (Figure 1, Item 6A), and battery terminal
knob (Figure 1, Item 6) and flat washer (Figure 1, Item 10B), lock washer (Figure 1, Item 10A), and battery
terminal knob (Figure 1, Item 10). Remove tags from battery cables.

7. Install battery cable 1B40 (Figure 1, Item 1) and battery cable 1D40 (Figure 1, Item 7) on battery BT4
negative terminal and secure with flat washer (Figure 1, Item 8B), lock washer (Figure 1, Item 8A), and
battery terminal knob (Figure 1, Item 8). Remove tags from battery cables.

8. Install battery cable 12B40 (Figure 1, Item 4) on battery BT3 negative terminal and battery BT1 negative
terminal and secure with flat washer (Figure 1, Item 5B), lock washer (Figure 1, Item 5A), and battery terminal
knob (Figure 1, Item 5) and flat washer (Figure 1, Item 6B), lock washer (Figure 1, Item 6A), and battery
terminal knob (Figure 1, Item 6). Remove tag from battery cable.

9. Install battery cable 1B40 (Figure 1, Item 1) and battery cable 1A40 (Figure 1, Item 2) on battery BT2 negative
terminal and secure with flat washer (Figure 1, Item 3B), lock washer (Figure 1, Item 3A), and battery terminal
knob (Figure 1, Item 3). Remove tags from battery cables.

10. Close battery access doors.

END OF TASK

END OF WORK PACKAGE

0050-5/6 blank Change 1

 TM 9-6115-730-24 0051

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
BATTERY DISCONNECT SWITCH MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic s (WP 0123, Item 1) One

Materials/Parts References

Marker tags (WP 0124, Item 49) TM 9-6115-730-24P

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

When disconnecting or removing batteries, disconnect the negative lead that connects directly to
the grounding stud first. Disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply can cause serious injury
to personnel.

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch
is OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Ensure there is no external cable connected to slave receptacle.

3. Open battery access doors.

0051-1 Change 1
 TM 9-6115-730-24 0051

REMOVAL - Continued

NOTE
When looking into battery compartment, batteries are identified from left to right as BT4, BT2,
BT1, and BT3.

4. Tag cables and remove battery terminal knob (Figure 1, Item 3), lock washer (Figure 1, Item 3A), and flat
washer (Figure 1, Item 3B) that secure battery cable 1B40 (Figure 1, Item 2) and battery cable 1A40 (Figure
1, Item 1) to battery BT2 negative terminal. Remove battery cables 1A40 and 1B40.

5. Tag cable and remove battery terminal knob (Figure 1, Item 5), lock washer (Figure 1, Item 5A), and flat
washer (Figure 1, Item 5B) that secure battery cable 1B40 (Figure 1, Item 2) and battery cable 1D40 (Figure
1, Item 4) to battery BT4 negative terminal. Remove battery cable 1B40.

6. Tag cables and remove battery terminal knob (Figure 1, Item 8), lock washer (Figure 1, Item 8A), and flat
washer (Figure 1, Item 8B) that secure battery cable 12B40 (Figure 1, Item 6) and battery cable 12A40
(Figure 1, Item 7) to battery BT1 negative terminal.

7. Tag cable and remove battery terminal knob (Figure 1, Item 9), lock washer (Figure 1, Item 9A), and flat
washer (Figure 1, Item 9B) that secure battery cable 12B40 (Figure 1, Item 6) to battery BT3 negative
terminal. Remove battery cable 12B40.

8. Remove four screws (Figure 1, Item 10), lockwashers (Figure 1, Item 11), and washers (Figure 1, Item 12),
and pull battery disconnect switch (Figure 1, Item 13) away from wall.

9. At rear of battery disconnect switch (Figure 1, Item 13), tag and disconnect battery cables 1A40 (Figure 1,
Item 1) and 2A40 (Figure 1, Item 14).

10. Remove battery disconnect switch (Figure 1, Item 13). Tag and disconnect wires from BDS.

END OF TASK

INSTALLATION

1. Connect battery 2A40 (Figure 1, Item 14) and 1A40 and sensor cables (Figure 1, Item 1).

2. Install battery disconnect switch (Figure 1, Item 13) with four washers (Figure 1, Item 12), lockwashers
(Figure 1, Item 11), and screws (Figure 1, Item 10).

3. Install battery cable 12B40 (Figure 1, Item 6) on battery BT3 negative terminal and secure with flat washer
(Figure 1, Item 9B), lock washer (Figure 1, Item 9A), and battery terminal knob (Figure 1, Item 9). Remove
tag from battery cable.

4. Install battery cable 12A40 (Figure 1, Item 7) and battery cable 12B40 (Figure 1, Item 6) on battery BT1
negative terminal and secure with flat washer (Figure 1, Item 8B), lock washer (Figure 1, Item 8A), and
battery terminal knob (Figure 1, Item 8). Remove tags from battery cables.

5. Install battery cable 1B40 (Figure 1, Item 2) and battery cable 1D40 (Figure 1, Item 4) on battery BT4
negative terminal and secure with flat washer (Figure 1, Item 5B), lock washer (Figure 1, Item 5A), and
battery terminal knob (Figure 1, Item 5). Remove tags from battery cables.

6. Install battery cable 1B40 (Figure 1, Item 2) and battery cable 1A40 (Figure 1, Item 1) on battery BT2 negative
terminal and secure with flat washer (Figure 1, Item 3B), lock washer (Figure 1, Item 3A), and battery terminal
knob (Figure 1, Item 3). Remove tags from battery cables.

7. Close battery access doors.

Change 1 0051-2
 TM 9-6115-730-24 0051

INSTALLATION - Continued

11

5 3 12
5A 2 4 3A 1 14
5B (1B40) (1D40) 3B (1A40) (2A40)
10

13

BT4 BT2 7 8 BT1 6 9 BT3

(12A40) 8A (12B40) 9A
8B 9B
200KW-24M-433B-C1

Figure 1. Battery Disconnect Switch.

END OF TASK

END OF WORK PACKAGE

0051-3/4 blank Change 1

 TM 9-6115-730-24 0052

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
CURRENT TRANSFORMERS MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Marker tags (WP 0124, Item 49) TM 9-6115-730-24P

Tiedown straps (WP 0124, Item 47)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

Dangerously high voltage can exist across current transformer (CT) output with engine running.
CT could explode if disconnected from load with engine running. Do not disconnect CT with
generator rotating. Failure to comply can cause serious injury or death to personnel.

0052-1
 TM 9-6115-730-24 0052

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch
is OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open right rear doors.

3. Open left rear doors.

NOTE
Each current transformer has two cables running through it. These cables must be disconnected
at one end in order to remove the current transformer.

Cut tiedown straps as required.

4. Tag and disconnect cables running through three current transformers (Figure 1, Sheet 1, Item 1. Tag and
remove sensor wires located on top of current transformers.

5. Remove twelve screws (Figure 1, Sheet 1, Item 2), washers (Figure 1, Sheet 1, Item 3), lockwashers
(Figure 1, Sheet 1, Item 4), and three current transformers (Figure 1, Sheet 1, Item 1).

6. If necessary, remove four screws (Figure 1, Sheet 1, Item 5), washers (Figure 1, Sheet 1, Item 6),
lockwashers (Figure 1, Sheet 1, Item 7), and current transformer bracket (Figure 1, Sheet 1, Item 8).

7. Tag and disconnect cables running through three current transformers (Figure 1, Sheet 2, Item 9). Tag and
remove sensor wires located on top of current transformers.

8. Remove twelve screws (Figure 1, Sheet 2, Item 10), washers (Figure 1, Sheet 2, Item 11), lockwashers
(Figure 1, Sheet 2, Item 12), and three current transformers (Figure 1, Sheet 2, Item 9).

9. Tag and disconnect cable running through current transformer (Figure 1, Sheet 2, Item 13. Tag and remove
sensor wires located on top of current transformers.

10. Remove four screws (Figure 1, Sheet 2, Item 14), washers (Figure 1, Sheet 2, Item 15), lockwashers
(Figure 1, Sheet 2, Item 16), and current transformer (Figure 1, Sheet 2, Item 13).

END OF TASK

INSTALLATION

1. Put one end of cables through current transformer (Figure 1, Sheet 2, Item 13) to be installed above two
power transformers, remove tag, and connect end of cable.

2. Install current transformer (Figure 1, Sheet 2, Item 13), four lockwashers (Figure 1, Sheet 2, Item 16),
washers (Figure 1, Sheet 2, Item 15), and screws (Figure 1, Sheet 2, Item 16). Connect sensor wires to
current transformer (Figure 1, Sheet 2, Item 13).

3. Put one end of cables through each of three current transformers (Figure 1, Sheet 2, Item 9) to be installed
above the generator, remove tags, and connect end of each cable.

4. Install three current transformers (Figure 1, Sheet 2, Item 9), six lockwashers (Figure 1, Sheet 2, Item 12),
washers (Figure 1, Sheet 2, Item 11), and screws (Figure 1, Sheet 2, Item 10). Remove tags and connect
sensor wires located on top of current transformers.

0052-2
 TM 9-6115-730-24 0052

INSTALLATION - Continued

Figure 1. Current Transformers (Sheet 1 of 2).

0052-3
 TM 9-6115-730-24 0052

INSTALLATION - Continued

Figure 1. Current Transformers (Sheet 2 of 2).

0052-4
 TM 9-6115-730-24 0052

INSTALLATION - Continued

5. Install current transformer bracket (Figure 1, Sheet 1, Item 8), four lockwashers (Figure 1, Sheet 1, Item 7),
washers (Figure 1, Sheet 1, Item 6), and screws (Figure 1, Sheet 1, Item 5).

6. Put one end of cables through each of three current transformers (Figure 1, Sheet 1, Item 1) to be installed
adjacent to main load contactor, remove tags, and connect end of each cable.

7. Install three current transformers (Figure 1, Sheet 1, Item 1), six lockwashers (Figure 1, Sheet 1, Item 4),
washers (Figure 1, Sheet 1, Item 3), and screws (Figure 1, Sheet 1, Item 2). Remove tags and connect
sensor wires located on top of current transformers.

8. Close left rear doors.

9. Close right rear doors.

END OF TASK

END OF WORK PACKAGE

0052-5/6 blank
 TM 9-6115-730-24 0053

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
POTENTIAL TRANSFORMER MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Tool Kit, General Mechanic’s (WP 0123, Item 1) TM 9-6115-730-24P

Materials/Parts Equipment Condition

Marker tags (WP 0124, Item 49) Generator access panel assembly removed
Tiedown straps (WP 0124, Item 48) (WP 0033)

Personnel Required

One

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch
is OFF, and DEAD CRANK SWITCH is OFF before proceeding.

NOTE
Cut tiedown straps as required.

2. Tag and disconnect wire harness from potential transformers PT3 (Figure 1, Item 1) and PT2 (Figure 1,
Item 2).

0053-1
 TM 9-6115-730-24 0053

REMOVAL - Continued

Figure 1. Potential Transformer.

3. Remove four screws (Figure 1, Item 3), lockwashers (Figure 1, Item 4), washers (Figure 1, Item 5), and
transformer PT3 (Figure 1, Item 1). Repeat for transformer PT2 (Figure 1, Item 2).

4. If removing bracket, remove two screws (Figure 1, Item 6), lockwashers (Figure 1, Item 7), and washers
(Figure 1, Item 8).

5. If removing bracket, remove two screws (Figure 1, Item 9), lockwashers (Figure 1, Item 10), washers
(Figure 1, Item 11), and potential transformer bracket (Figure 1, Item 12).

END OF TASK

0053-2
 TM 9-6115-730-24 0053

INSTALLATION

NOTE
Install tiedown straps as required.

1. If bracket was removed, install potential transformer bracket (Figure 1, Item 12), two washers (Figure 1,
Item 11), lockwashers (Figure 1, Item 10), and screws (Figure 1, Item 8).

2. If bracket was removed, install two washers (Figure 1, Item 8), lockwashers (Figure 1, Item 7), and screws
(Figure 1, Item 6).

3. Install potential transformer PT2 (Figure 1, Item 2), four washers (Figure 1, Item 5), lockwashers (Figure 1,
Item 4), and screws (Figure 1, Item 3). Repeat for potential transformer PT3 (Figure 1, Item 1).

4. Remove tags and connect wire harness to potential transformers PT2 (Figure 1, Item 2) and PT3 (Figure 1,
Item 1).

5. Install generator access panel (WP 0033).

END OF TASK

END OF WORK PACKAGE

0053-3/4 blank
 TM 9-6115-730-24 0054

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
SLAVE RECEPTACLE MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic s (WP 0123, Item 1) One

Materials/Parts References

Marker tags (WP 0124, Item 49) TM 9-6115-730-24P

Tiedown straps (WP 0124, Item 46)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

When disconnecting or removing batteries, disconnect the negative lead that connects directly to
the grounding stud first. Disconnect the negative end of the interconnection cable next. When
installing batteries, reverse the connection sequence. Failure to comply can cause serious injury
to personnel.

Slave receptacle (NATO connector) is electrically live at all times and is unfused. The Battery
Disconnect Switch does not remove power from the slave receptacle. NATO slave receptacle has
24 VDC even when Battery Disconnect Switch is set of OFF. This circuit is only dead when the
batteries are fully disconnected. Disconnect batteries before performing maintenance on the
slave receptacle. Failure to comply can cause injury or death to personnel.

0054-1 Change 1
 TM 9-6115-730-24 0054

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch
is OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Ensure there is no external cable connected to slave receptacle.

3. Open battery access doors. Open left front door.

NOTE
When looking into battery compartment, batteries are identified from left to right as BT4, BT2,
BT1, and BT3.

Cut tiedown straps as required.

4. Tag cables and remove battery terminal knob (Figure 1, Item 2), lock washer (Figure 1, Item 2A), and flat
washer (Figure 1, Item 2B) that secure battery cable 1A40 (Figure 1, Item 1) to battery BT2 negative terminal.
Remove battery cable 1A40.

5. Tag cable and remove battery terminal knob (Figure 1, Item 4), lock washer (Figure 1, Item 4A), and flat
washer (Figure 1, Item 4B) that secure battery cable 1D40 (Figure 1, Item 3) to battery BT4 negative terminal.
Remove battery cable 1D40.

6. Tag cable and remove battery terminal knob (Figure 1, Item 6), lock washer (Figure 1, Item 6A), and flat
washer (Figure 1, Item 6B) that secure battery cable 24H40 (Figure 1, Item 5) to battery BT3 positive terminal.

7. Remove four nuts (Figure 1, Item 7), screws (Figure 1, Item 8), washers (Figure 1, Item 9), and slave
receptacle (Figure 1, Item 10) out of TQG.

8. Tag and disconnect battery cables 1D40 (Figure 1, Item 3) and 24H40 (Figure 1, Item 5) from slave
receptacle (Figure 1, Item 10).

9. Remove eight locknuts (Figure 1, Item 11), washers (Figure 1, Item 12), screws (Figure 1, Item 13) and
pocket (Figure 1, Item 14).

INSTALLATION

NOTE
Install tiedown straps as required.

1. Install pocket (Figure 1, Item 14), eight screws (Figure 1, Item 13), washers (Figure 1, Item 12), and locknuts
(Figure 1, Item 11).

2. Remove tags and connect battery cables 1D40 (Figure 1, Item 3) and 24H40 (Figure 1, Item 5) to slave
receptacle (Figure 1, Item 10).

3. Install slave receptacle (Figure 1, Item 10) with four washers (Figure 1, Item 9), screws (Figure 1, Item 8), and
nuts (Figure 1, Item 7).

Change 1 0054-2
 TM 9-6115-730-24 0054

INSTALLATION - Continued
4 2 6
4A 2A 6A
4B 3 (1D40) 2B 1 (1A40) 6B 5 (24H40)

BT4 BT2 BT1 BT3

11
14

10

9 13
12
8

200KW-24M-436B-C1

Figure 1. Slave Receptacle.

0054-3 Change 1
 TM 9-6115-730-24 0054

INSTALLATION - Continued

4. Install battery cable 24H40 (Figure 1, Item 5) on battery BT3 positive terminal and secure with flat washer
(Figure 1, Item 6B), lock washer (Figure 1, Item 6A), and battery terminal knob (Figure 1, Item 6). Remove
tag from battery cable.

5. Install battery cable 1D40 (Figure 1, Item 3) on battery BT4 negative terminal and secure with flat washer
(Figure 1, Item 4B), lock washer (Figure 1, Item 4A), and battery terminal knob (Figure 1, Item 4). Remove
tag from battery cable.

6. Install battery cable 1A40 (Figure 1, Item 1) on battery BT2 negative terminal and secure with flat washer
(Figure 1, Item 2B), lock washer (Figure 1, Item 2A), and battery terminal knob (Figure 1, Item 2). Remove
tag from battery cable.

7. Close left front door. Close battery access doors.

END OF TASK

END OF WORK PACKAGE

Change 1 0054-4
 TM 9-6115-730-24 0055

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
ELECTRICAL INSTALLATION MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Marker tags (WP 0124, Item 49) TM 9-6115-730-24P

Tiedown straps (WP 0124, Item 46)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

0055-1
 TM 9-6115-730-24 0055

REMOVAL

NOTE
Table 1 identifies removal and installation steps for maintenance significant components of the
electrical installation. Cut tiedown straps as required.

Table 1. WP 0055 Guide.

FIGURE 1 REMOVAL INSTALLATION

NAME ITEM STEPS STEPS

DEAD CRANK SWITCH 1 1 thru 3 13

CATSW1 (RESET SW FUEL) 15 1, 2 and 6 10

CATSW2 (RESET SW OIL) 16 1, 2 and 6 10

Slave relay SRY 19 1, 2 and 7 9

Starter motor magnetic switch 23 1, 2 and 8 8

(SMMS) relay

Circuit breaker CB2 47 1, 2 and 13 3

Circuit breaker CB4 46 1, 2 and 13 3

Circuit breaker CB5 45 1, 2 and 13 3

Ammeter shunt R4 37 1, 2 and 11 5

Diode D1 39 1, 2 and 12 4

Fuses F1, F2, and F3 55 1, 2 and 15 1

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch
is OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open right rear doors and left rear doors.

3. To remove DEAD CRANK SWITCH (Figure 1, Sheet 1, Item 1), tag and disconnect wires from switch, remove
nut (Figure 1, Sheet 1, Item 2), lockwasher (Figure 1, Sheet 1, Item 3), and switch.

0055-2
 TM 9-6115-730-24 0055

REMOVAL - Continued

Figure 1. Electrical Installation (Sheet 1 of 2).

0055-3
 TM 9-6115-730-24 0055

REMOVAL - Continued

Figure 1. Electrical Installation (Sheet 2 of 2).

0055-4
 TM 9-6115-730-24 0055

REMOVAL - Continued

4. Drill out two rivets (Figure 1, Sheet 1, Item 4), if necessary and remove dead crank plate (Figure 1, Sheet 1,
Item 5). Remove two screws (Figure 1, Sheet 1, Item 6), lockwashers (Figure 1, Sheet 1, Item 7), washers
(Figure 1, Sheet 1, Item 8), and switch plate (Figure 1, Sheet 1, Item 9) from air cleaner bracket (Figure 1,
Sheet 1, Item 10).

5. To remove terminal board TB5 (Figure 1, Sheet 1, Item 11), tag and disconnect wires from terminal board,
remove two nuts (Figure 1, Sheet 1, Item 12), screws (Figure 1, Sheet 1, Item 13), terminal board, and marker
strip (Figure 1, Sheet 1, Item 14).

6. To remove either switch CATSW1 (Figure 1, Sheet 1, Item 15) or switch CATSW2 (Figure 1, Sheet 1,
Item 16), tag and disconnect wires from switch, remove nut (Figure 1, Sheet 1, Item 17), lockwasher
(Figure 1, Sheet 1, Item 18), and switch.

7. To remove slave relay (SRY) (Figure 1, Sheet 1, Item 19), tag and disconnect wires from relay SRY, remove
screw (Figure 1, Sheet 1, Item 20), washer (Figure 1, Sheet 1, Item 21), lockwasher (Figure 1, Sheet 1, Item
22), and relay.

8. To remove starter motor magnetic switch (SMMS) relay (Figure 1, Sheet 1, Item 23), tag and disconnect wires
from SMMS relay, remove two screws (Figure 1, Sheet 1, Item 24), washers (Figure 1, Sheet 1, Item 25),
lockwashers (Figure 1, Sheet 1, Item 26), and SMMS relay.

9. To remove any of three spare fuses (Figure 1, Sheet 1, Item 27), pull fuse out of fuseholder (Figure 1, Sheet
1, Item 28). To remove spare fuseholder (Figure 1, Sheet 1, Item 28), remove two screws (Figure 1, Sheet 1,
Item 29), washers (Figure 1, Sheet 1, Item 30), insulators (Figure 1, Sheet 1, Item 31), and clips (Figure 1,
Sheet 1, Item 32).

10. To remove relay mounting track (Figure 1, Sheet 1, Item 33), remove two screws (Figure 1, Sheet 1, Item 34),
lockwashers (Figure 1, Sheet 1, Item 35), washers (Figure 1, Sheet 1, Item 36), and relay mounting track.

11. Two remove ammeter shunt R4 (Figure 1, Sheet 2, Item 37), tag and disconnect wires from shunt, remove
two screws (Figure 1, Sheet 2, Item 38) and shunt.

12. To remove diode D1 (Figure 1, Sheet 2, Item 39), tag and disconnect wires from diode, remove two screws
(Figure 1, Sheet 2, Item 40), lockwashers (Figure 1, Sheet 2, Item 41), washers (Figure 1, Sheet 2, Item 42),
insulator (Figure 1, Sheet 2, Item 43), and diode D1. Remove nut (Figure 1, Sheet 2, Item 44) and diode D1
(Figure 1, Sheet 2, Item 39) from insulator (Figure 1, Sheet 2, Item 43).

13. To remove any of three circuit breakers CB5 (Figure 1, Sheet 2, Item 45), CB4 (Figure 1, Sheet 2, Item 46), or
CB2 (Figure 1, Sheet 2, Item 47), remove two screws (Figure 1, Sheet 2, Item 48), lockwashers (Figure 1,
Sheet 2, Item 49), washers (Figure 1, Sheet 2, Item 50), and circuit breaker.

14. To remove CB5 CB4, or CB2 brackets (Figure 1, Sheet 2, Item 51), remove two screws (Figure 1, Sheet 2,
Item 52), lockwashers (Figure 1, Sheet 2, Item 53), washers (Figure 1, Sheet 2, Item 54), and bracket.

15. Remove three fuses F1, F2, or F3 (Figure 1, Sheet 1, Item 55), two nuts (Figure 1, Sheet 1, Item 56), two
screws (Figure 1, Sheet 1, Item 57), and fuseholder (Figure 1, Sheet 1, Item 58).

END OF TASK

0055-5
 TM 9-6115-730-24 0055

INSTALLATION

NOTE
Install tiedown straps as required.

1. Install fuseholder (Figure 1, Sheet 1, Item 58), two screws (Figure 1, Sheet 1, Item 57), two nuts (Figure 1,
Sheet 1, Item 56), and three fuses F1, F2, and F3 (Figure 1, Sheet 1, Item 55).

2. To install CB5, CB4, and CB2 circuit breaker brackets (Figure 1, Sheet 2, Item 51), install bracket, two
washers (Figure 1, Sheet 2, Item 54), lockwashers (Figure 1, Sheet 2, Item 53), and screws (Figure 1, Sheet
2, Item 52).

3. To install any of three circuit breakers CB2 (Figure 1, Sheet 2, Item 47), CB4 (Figure 1, Sheet 2, Item 46), or
CB5 (Figure 1, Sheet 2, Item 45), install circuit breaker, two washers (Figure 1, Sheet 2, Item 50),
lockwashers (Figure 1, Sheet 2, Item 49), and screws (Figure 1, Sheet 2, Item 48). Connect wires as tagged.

4. To install diode D1 (Figure 1, Sheet 2, Item 39), install diode, nut (Figure 1, Sheet 2, Item 44), insulator
(Figure 1, Sheet 2, Item 43). Install diode and insulator with two washers (Figure 1, Sheet 2, Item 42),
lockwashers (Figure 1, Sheet 2, Item 41), and screws (Figure 1, Sheet 2, Item 40). Connect wires as tagged.

5. To install ammeter shunt R4 (Figure 1, Sheet 2, Item 37), install shunt and two screws (Figure 1, Sheet 2,
Item 38). Connect wires as tagged.

6. To install relay mounting track (Figure 1, Sheet 1, Item 33), install track, two screws (Figure 1, Sheet 1,
Item 34), lockwashers (Figure 1, Sheet 1, Item 35), and washers (Figure 1, Sheet 1, Item 36).

7. To install any spare fuseholder (Figure 1, Sheet 1, Item 28), install fuseholder (Figure 1, Sheet 1, Item 28),
two insulators (Figure 1, Sheet 1, Item 31), clips (Figure 1, Sheet 1, Item 32), washers (Figure 1, Sheet 1,
Item 30), and two screws (Figure 1, Sheet 1, Item 29). Connect wires as tagged. To install any of three spare
fuses (Figure 1, Sheet 1, Item 27), push fuse into fuseholder (Figure 1, Sheet 1, Item 28).

8. To install starter motor magnetic switch (SMMS) relay (Figure 1, Sheet 1, Item 23), install SMMS relay, two
lockwashers (Figure 1, Sheet 1, Item 26), washers (Figure 1, Sheet 1, Item 25), and two screws (Figure 1,
Sheet 1, Item 24). Connect wires as tagged.

9. To install relay SRY (Figure 1, Sheet 1, Item 19), install relay, lockwasher (Figure 1, Sheet 1, Item 22),
washer (Figure 1, Sheet 1, Item 21), and screw (Figure 1, Sheet 1, Item 20). Connect wires as tagged.

10. To install either switch CATSW2 (Figure 1, Sheet 1, Item 16), or CATSW1 (Figure 1, Sheet 1, Item 15), install
switch, lockwasher (Figure 1, Sheet 1, Item 18), and nut (Figure 1, Sheet 1, Item 17). Connect wires as
tagged.

11. To install terminal board TB5 (Figure 1, Sheet 1, Item 11), install marker strip (Figure 1, Sheet 1, Item 14),
terminal board, two screws (Figure 1, Sheet 1, Item 13) and nuts (Figure 1, Sheet 1, Item 12). Connect wires
as tagged.

12. Install switch plate (Figure 1, Sheet 1, Item 9) on air cleaner bracket (Figure 1, Sheet 1, Item 10) and secure
with two screws (Figure 1, Sheet 1, Item 8), washers (Figure 1, Sheet 1, Item 7), and lockwashers (Figure 1,
Sheet 1, Item 6). Install dead crank plate (Figure 1, Sheet 1, Item 5) and secure with two rivets (Figure 1,
Sheet 1, Item 4).

0055-6
 TM 9-6115-730-24 0055

INSTALLATION - Continued

13. To install DEAD CRANK SWITCH (Figure 1, Sheet 1, Item 1), install switch, lockwasher (Figure 1, Sheet 1,
Item 3), and nut (Figure 1, Sheet 1, Item 2).

14. Close left rear doors and right rear doors.

END OF TASK

END OF WORK PACKAGE

0055-7/8 blank
 TM 9-6115-730-24 0056

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
FUEL LEVEL SWITCH ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) Two

Materials/Parts References

Gasket TM 9-6115-730-24P
Sealing compound (WP 0124, Item 40)
Tiedown straps (WP 0124, Item 47)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Failure to comply can cause injury or death to personnel.

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch
is OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open right rear doors.

NOTE
Cut tiedown straps as required.

3. Tag and disconnect wires from fuel level switch (Figure 1, Item 1).

0056-1
 TM 9-6115-730-24 0056

REMOVAL - Continued

CAUTION
Cover hole in fuel tank to prevent contamination.

4. Remove five screws (Figure 1, Item 2), lockwashers (Figure 1, Item 3), washers (Figure 1, Item 4), fuel level
switch assembly (Figure 1, Item 1), and gasket (Figure 1, Item 5).

Figure 1. Fuel Level Switch Assembly.

END OF TASK

0056-2
 TM 9-6115-730-24 0056

INSTALLATION

1. Apply sealing compound to both sides of gasket (Figure 1, Item 5) and install gasket, fuel level switch
assembly (Figure 1, Item 1), five washers (Figure 1, Item 4), lockwashers (Figure 1, Item 3), and screws
(Figure 1, Item 2).

NOTE
Install tiedown straps as required.

2. Remove tags and connect wires to fuel level switch (Figure 1, Item 1).

3. Close right rear doors.

END OF TASK

END OF WORK PACKAGE

0056-3/4 blank
 TM 9-6115-730-24 0057

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
FUEL HOSES MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Tool Kit, General Mechanic s (WP 0123, Item 1) TM 9-6115-730-24P

Materials/Parts Equipment Condition

Sealant (WP 0124, Item 37) As necessary, radiator removed (WP 0068)
Tiedown straps (WP 0124, Item 46)

Personnel Required

One

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Failure to comply can cause injury or death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the fuel system. Ensure fuel pan is available to drain excess fuel in hose
assemblies.

0057-1 Change 1
 TM 9-6115-730-24 0057

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch
is OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open left front door, left rear doors, and right rear doors.

NOTE
Cut tiedown straps as required.

3. Remove water separator filter drain (Figure 1, Sheet 1, Item 1) from water separator filter (Figure 1, Sheet 1,
Item 3).

4. Place drain pan under the water separator filter (Figure 1, Sheet 1, Item 3). Turn plug (Figure 1, Sheet 1,
Item 2) counterclockwise to open the self ventilated drain. Drain the fuel from the water separator filter, then
retighten plug (Figure 1, Sheet 1, Item 2).

5. Disconnect hose assembly (Figure 1, Sheet 1, Item 4) from fuel pickup tube assembly (Figure 1, Sheet 1,
Item 5) and from water separator filter drain (Figure 1, Sheet 1, Item 1).

6. Disconnect swivel ball fitting (Figure 1, Sheet 1, Item 6) from hose (Figure 1, Sheet 1, Item 8) by removing
clamp (Figure 1, Sheet 1, Item 7).

7. Disconnect hose (Figure 1, Sheet 1, Item 10) from female connector (Figure 1, Sheet 1, Item 9) by removing
clamp (Figure 1, Sheet 1, Item 7).

8. Disconnect female connector (Figure 1, Sheet 1, Item 9) from swivel ball fitting (Figure 1, Sheet 1, Item 6).

9. Disconnect hose (Figure 1, Sheet 1, Item 8) from water separator filter (Figure 1, Sheet 1, Item 3) by
removing clamp (Figure 1, Sheet 1, Item 7).

10. Remove two hose clamps and disconnect hose (Figure 1, Sheet 1, Item 11) from elbow (Figure 1, Sheet 1,
Item 12) on right side of fuel tank (Figure 1, Sheet 1, Item 13) and from 90 degree male fitting (Figure 1,
Sheet 2, Item 14) at rear of fuel tank filler neck (Figure 1, Sheet 2, Item 15).

11. Remove 90 degree male fitting (Figure 1, Sheet 2, Item 14), elbow fitting (Figure 1, Sheet 2, Item 16), nipple
(Figure 1, Sheet 2, Item 17), seal nut (Figure 1, Sheet 2, Item 18), and washer (Figure 1, Sheet 2, Item 19).

12. Disconnect hose (Figure 1, Sheet 1, Item 20) from 90 degree bulkhead elbow (Figure 1, Sheet 1, Item 21) on
fuel fill pocket (Figure 1, Sheet 1, Item 22). If necessary, remove 90 degree elbow (Figure 1, Sheet 2,
Item 21).

13. Disconnect hose (Figure 1, Sheet 2, Item 20) from 90 degree elbow (Figure 1, Sheet 2, Item 23) on auxiliary
fuel pump (Figure 1, Sheet 2, Item 24).

Change 1 0057-2
 TM 9-6115-730-24 0057

REMOVAL - Continued

Figure 1. Fuel Hoses (Sheet 1 of 4).

0057-3 Change 1
 TM 9-6115-730-24 0057

REMOVAL - Continued
26 24 27 28

30

23

29 REF

25

20 REF
VIEW B 25 REF
(PART NO. 0116-1320 ONLY) 26

24

14 11 REF
SEE VIEW B

16
15 23
REF 17
54 19 20 REF
29 5 REF 32
18
TO FUEL
VIEW B
31
COOLER (PART NO. 0116-1333-02 ONLY)

13 REF

200KW-24M-438-2E-C1

Figure 1. Fuel Hoses (Sheet 2 of 4).

Change 1 0057-4
 TM 9-6115-730-24 0057

REMOVAL - Continued

Figure 1. Fuel Hoses (Sheet 3 of 4).

0057-5 Change 1
 TM 9-6115-730-24 0057

REMOVAL - Continued

Figure 1. Fuel Hoses (Sheet 4 of 4).

Change 1 0057-6
 TM 9-6115-730-24 0057

REMOVAL - Continued

14. Disconnect hose (Figure 1, Sheet 2, Item 25) from 90 degree elbow (Figure 1, Sheet 2, Item 26) on auxiliary
fuel pump (Figure 1, Sheet 2, Item 24) and from 90 degree elbow (Figure 1, Sheet 2, Item 27) on fuel solenoid
valve (Figure 1, Sheet 2, Item 28). Disconnect hose (Figure 1, Sheet 2, Item 29) from 90 degree elbow
(Figure 1, Sheet 2, Item 30) on fuel solenoid valve (Figure 1, Sheet 2, Item 28) and adapter (Figure 1, Sheet
2, Item 31) on fuel tank (Figure 1, Sheet 1, Item 13). If necessary, remove 90 degree elbow (Figure 1, Sheet
2, Item 30), 90 degree elbow (Figure 1, Sheet 2, Item 32), and adapter (Figure 1, Sheet 2, Item 31).

15. If necessary, remove 13 bolts (Figure 1, Sheet 3, Item 33), lockwashers (Figure 1, Sheet 3, Item 34), and
washers (Figure 1, Sheet 3, Item 35) on left side of upper front panel (Figure 1, Sheet 3, Item 36).

16. If necessary, remove 7 bolts (Figure 1, Sheet 3, Item 37), lockwashers (Figure 1, Sheet 3, Item 38), and
washers (Figure 1, Sheet 3, Item 39) on lower front panel (Figure 1, Sheet 3, Item 40) to access fuel cooler
fuel lines.

17. Disconnect hose (Figure 1, Sheet 4, Item 41) from 45 degree adapter (Figure 1, Sheet 4, Item 42) on fuel
cooler (Figure 1, Sheet 4, Item 43) and from 90 degree elbow (Figure 1, Sheet 4, Item 44) on fuel filter
(Figure 1, Sheet 4, Item 45). If necessary, remove 45 degree adapter (Figure 1, Sheet 4, Item 42), 90 degree
elbow (Figure 1, Sheet 4, Item 44), and adapter (Figure 1, Sheet 4, Item 46).

18. At two locations on left side of engine, remove two screws (Figure 1, Sheet 4, Item 47), washers (Figure 1,
Sheet 4, Item 48), nuts (Figure 1, Sheet 4, Item 49), and loop clamp (Figure 1, Sheet 4, Item 50). Remove
two screws (Figure 1, Sheet 4, Item 51), lockwashers (Figure 1, Sheet 4, Item 52), and bracket (Figure 1,
Sheet 4, Item 53). Remove hose (Figure 1, Sheet 4, Item 41).

19. Disconnect hose (Figure 1, Sheet 4, Item 54) from fuel cooler (Figure 1, Sheet 4, Item 43) and from elbow
(Figure 1, Sheet 4, Item 55) on fuel tank (Figure 1, Sheet 1, Item 13). If necessary, remove elbow (Figure 1,
Sheet 4, Item 55).

END OF TASK

INSTALLATION

NOTE
Apply sealing compound to all male pipe threads before connecting.

Install tiedown straps as required.

1. If removed, install elbow (Figure 1, Sheet 4, Item 55) on fuel tank (Figure 1, Sheet 1, Item 13). Connect hose
(Figure 1, Sheet 4, Item 54) to elbow (Figure 1, Sheet 4, Item 55) and to fuel cooler (Figure 1, Sheet 4,
Item 43).

2. Position two loop clamps (Figure 1, Sheet 4, Item 50) on hose (Figure 1, Sheet 4, Item 41). At two places on
left side of engine, install bracket (Figure 1, Sheet 4, Item 53), two lockwashers (Figure 1, Sheet 4, Item 52),
and two screws (Figure 1, Sheet 4, Item 51). On each bracket, install loop clamp (Figure 1, Sheet 4, Item 50),
two washers (Figure 1, Sheet 4, Item 48), screws (Figure 1, Sheet 4, Item 47), and nuts (Figure 1, Sheet 4,
Item 49).

3. If removed, install adapter (Figure 1, Sheet 4, Item 46), 90 degree elbow (Figure 1, Sheet 4, Item 44) on fuel
filter (Figure 1, Sheet 4, Item 45) and 45 degree adapter (Figure 1, Sheet 4, Item 42) on fuel cooler (Figure 1,
Sheet 4, Item 43). Connect hose (Figure 1, Sheet 4, Item 41) to 90 degree elbow (Figure 1, Sheet 4, Item 44)
and to 45 degree adapter (Figure 1, Sheet 4, Item 42).

0057-7 Change 1
 TM 9-6115-730-24 0057

INSTALLATION - Continued

4. If necessary, install lower front panel (Figure 1, Sheet 3, Item 40) using 7 washers(Figure 1, Sheet 3, Item
39), lockwashers (Figure 1, Sheet 3, Item 38), and bolts (Figure 1, Sheet 3, Item 37).

5. If necessary, install upper front panel (Figure 1, Sheet 3, Item 36) using 13 washers (Figure 1, Sheet 3, Item
35, lockwashers (Figure 1, Sheet 3, Item 34, and bolts (Figure 1, Sheet 3, Item 33).

6. If removed, install adapter (Figure 1, Sheet 2, Item 31) and 90 degree elbow (Figure 1, Sheet 2, Item 32) on
fuel tank (Figure 1, Sheet 1, Item 13). If removed, install 90 degree elbow (Figure 1, Sheet 2, Item 30) on fuel
solenoid valve (Figure 1, Sheet 2, Item 28). If removed, install 90 degree elbow (Figure 1, Sheet 2, Item 27)
and 90 degree elbow (Figure 1, Sheet 2, Item 26). Connect hose (Figure 1, Sheet 2, Item 25) to 90 degree
elbow (Figure 1, Sheet 2, Item 27) on fuel solenoid valve (Figure 1, Sheet 2, Item 28) and 90 degree elbow
(Figure 1, Sheet 2, Item 26) on auxiliary fuel pump (Figure 1, Sheet 2, Item 24).

7. If removed, install 90 degree elbow (Figure 1, Sheet 2, Item 23) on auxiliary fuel pump (Figure 1, Sheet 2,
Item 24). Connect hose (Figure 1, Sheet 1, Item 20) to 90 degree elbow (Figure 1, Sheet 2, Item 23) and to
90 degree bulkhead elbow (Figure 1, Sheet 1, Item 21) on fuel fill pocket (Figure 1, Sheet 1, Item 22).

8. If removed, install radiator (WP 0068).

9. Install washer (Figure 1, Sheet 2, Item 19), seal nut (Figure 1, Sheet 2, Item 18), nipple (Figure 1, Sheet 2,
Item 17), elbow fitting (Figure 1, Sheet 2, Item 16), and 90 degree male fitting (Figure 1, Sheet 2, Item 14) on
rear of fuel tank filler neck (Figure 1, Sheet 2, Item 15).

10. If removed, install elbow (Figure 1, Sheet 1, Item 12) to right side of fuel tank (Figure 1, Sheet 1, Item 13).
Connect hose (Figure 1, Sheet 1, Item 11) to 90 degree male fitting (Figure 1, Sheet 2, Item 14) at rear of fuel
tank filler neck (Figure 1, Sheet 2, Item 15) and to elbow (Figure 1, Sheet 1, Item 12). Install two hose clamps.

11. Install water separator filter drain (Figure 1, Sheet 1, Item 1) onto water separator filter (Figure 1, Sheet 1,
Item 3).

12. Install hose (Figure 1, Sheet 1, Item 8) onto water separator filter drain (Figure 1, Sheet 1, Item 1) using
clamp (Figure 1, Sheet 1, Item 7).

13. Install swivel ball fitting (Figure 1, Sheet 1, Item 6) onto hose (Figure 1, Sheet 1, Item 8) using clamp (Figure
1, Sheet 1, Item 7).

14. Install female connector (Figure 1, Sheet 1, Item 9) onto swivel ball fitting (Figure 1, Sheet 1, Item 6).

15. Install hose (Figure 1, Sheet 1, Item 10) onto female connector (Figure 1, Sheet 1, Item 9) using clamp
(Figure 1, Sheet 1, Item 7).

16. Install hose assembly (Figure 1, Sheet 1, Item 4) onto fuel pickup tube assembly (Figure 1, Sheet 1, Item 5)
and water separator filter (Figure 1, Sheet 1, Item 3).

END OF TASK

END OF WORK PACKAGE

Change 1 0057-8
 TM 9-6115-730-24 0058

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
FUEL PICKUP TUBE ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Cap and plug set (WP 0124, Item 6) TM 9-6115-730-24P

Gasket
Sealing compound (WP 0124, Item 40)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Failure to comply can cause injury or death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the fuel system.

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch
is OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open left rear doors.

3. Disconnect hose (Figure 1, Item 1) from fuel pickup tube (Figure 1, Item 2).

0058-1
 TM 9-6115-730-24 0058

REMOVAL - Continued

4. Remove five screws (Figure 1, Item 3), lockwashers (Figure 1, Item 4), washers (Figure 1, Item 5), fuel pickup
tube (Figure 1, Item 2), and gasket (Figure 1, Item 6).

Figure 1. Fuel Pickup Tube Assembly.

END OF TASK

0058-2
 TM 9-6115-730-24 0058

INSTALLATION

1. Clean area on fuel tank where gasket (Figure 1, Item 6) will be installed.

2. Apply sealing compound to both sides of gasket (Figure 1, Item 6), and install gasket, fuel pickup tube
(Figure 1, Item 2), five washers (Figure 1, Item 5), lockwashers (Figure 1, Item 4), and screws (Figure 1,
Item 3).

3. Connect hose (Figure 1, Item 1) to fuel pickup tube (Figure 1, Item 2).

4. Close left rear doors.

END OF TASK

END OF WORK PACKAGE

0058-3/4 blank
 TM 9-6115-730-24 0059

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
AUXILIARY FUEL PUMP ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic s (WP 0123, Item 1) Two

Materials/Parts References

Cap and plug set (WP 0124, Item 6) TM 9-6115-730-24P

Fuel (WP 0124, Item 16, 17, 51, or 52)
Gasket
Marker tags (WP 0124, Item 49)
Sealing compound (WP 0124, Item 37)
Tiedown straps (WP 0124, Item 47)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Failure to comply can cause injury or death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the fuel system.

0059-1 Change 1
 TM 9-6115-730-24 0059

SERVICING (Part No. 0116-1320 Only)

NOTE
Servicing can be performed without removing auxiliary fuel pump.

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch
is OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open left front doors and left rear doors.

3. Remove three screws (Figure 1, Item 1), cover (Figure 1, Item 2), gasket (Figure 1, Item 3), and strainer
(Figure 1, Item 4) from auxiliary fuel pump (Figure 1, Item 5).

4. Clean strainer (Figure 1, Item 4) with clean fuel. Replace strainer if damaged.

5. Install strainer (Figure 1, Item 4), gasket (Figure 1, Item 3), cover (Figure 1, Item 2), and three screws
(Figure 1, Item 1).

END OF TASK

SERVICING (Part No. 0116-1333 Only)

NOTE
Servicing can be performed without removing auxiliary fuel pump.

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect
Switch is OFF, and DEAD CRANK SWITCH is OFF before proceeding

2. Open left front doors, and left rear doors.

3. Remove bowl screw (Figure 1, Item 1) that secures fuel bowl (Figure 1, Item 2) to auxiliary fuel pump
(Figure 1, Item 5).

4. Remove fuel bowl (Figure 1, Item 2), O-ring (Figure 1, Item 3), and strainer (Figure 1, Item 4) from
auxiliary fuel pump (Figure 1, Item 5).

5. Clean strainer (Figure 1, Item 4) with clean fuel. Replace strainer if damaged.

6. Install strainer (Figure 1, Item 4), O-ring (Figure 1, Item 3), and fuel bowl (Figure 1, Item 2) on auxiliary
fuel pump (Figure 1, Item 5) and secure with bowl screw (Figure 1, Item 1).

END OF TASK

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch is
OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open left front doors and left rear doors.

Change 1 0059-2
 TM 9-6115-730-24 0059

11 12 5 18 17 8 16

10
9
6

17

13

15
7

14

PART NO.
0116-1320 ONLY

PART NO.
0116-1333-02 ONLY
3 1

3
2
1
200KW-24M-440B-C1

Figure 1. Auxiliary Fuel Pump Assembly.

0059-3 Change 1
 TM 9-6115-730-24 0059

REMOVAL - Continued
NOTE
Cut tiedown straps as required.

3. Disconnect hose (Figure 1, Item 6) and hose (Figure 1, Item 7) from auxiliary fuel pump (Figure 1, Item 5).

4. Tag and disconnect wires coming from solenoid valve (Figure 1, Item 8).

5. Remove two locknuts (Figure 1, Item 9), washers (Figure 1, Item 10), screws (Figure 1, Item 11), and auxiliary
fuel pump (Figure 1, Item 5).

6. If necessary, remove elbow (Figure 1, Item 12) and elbow (Figure 1, Item 13).

7. Disconnect two hoses (Figure 1, Item 14) and (Figure 1, Item 15) from solenoid valve (Figure 1, Item 8).

8. Remove two screws (Figure 1, Item 16) and solenoid valve (Figure 1, Item 8).

9. If necessary, remove two elbows (Figure 1, Item 17).

END OF TASK

INSTALLATION

NOTE
Apply sealing compound to all male pipe threads before connecting.

1. If removed, install two elbows (Figure 1, Item 17).

2. Install solenoid valve (Figure 1, Item 8) and two screws (Figure 1, Item 16).

3. Connect two hoses (Figure 1, Item 15) and (Figure 1, Item 14) to solenoid valve (Figure 1, Item 8).

4. If removed, install two elbows (Figure 1, Item 13) and (Figure 1, Item 12) to auxiliary fuel pump (Figure 1,
Item 5).

5. Making sure ground lug (Figure 1, Item 18) is positioned between screw (Figure 1, Item 11) and washer
(Figure 1, Item 10), install auxiliary fuel pump (Figure 1, Item 5), two screws (Figure 1, Item 11), washers
(Figure 1, Item 10), and locknuts (Figure 1, Item 9).

NOTE
Install tiedown straps as required.

6. Remove tags and connect wires to solenoid valve (Figure 1, Item 8).

7. Connect hose (Figure 1, Item 7) and hose (Figure 1, Item 6).

8. Close left rear doors and left front door.

END OF TASK

END OF WORK PACKAGE

Change 1 0059-4
 TM 9-6115-730-24 0060

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
FUEL COOLER MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Tool Kit, General Mechanic’s (WP 0123, Item 1) TM 9-6115-730-24P

Materials/Parts

Cap and plug set (WP 0124, Item 6)

Personnel Required

One

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

WARNING
Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Failure to comply can cause injury or death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the fuel system.

0060-1
 TM 9-6115-730-24 0060

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch is
OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open left rear door assemblies.

3. Open right rear door assemblies.

4. Remove twenty screws (Figure 1, Sheet 1, Item 1), lockwashers (Figure 1, Sheet 1, Item 2), washers (Figure
1, Sheet 1, Item 3), and horizontal upper front base baffles (Figure 1, Sheet 1, Item 4 and Item 5).

5. Remove twelve screws (Figure 1, Sheet 2, Item 6), lockwashers (Figure 1, Sheet 2, Item 7), washers
(Figure 1, Sheet 1, Item 8), and horizontal lower front base baffles (Figure 1, Sheet 2, Item 9 and Item 10).

NOTE
Fuel will drain from fuel hoses when hoses are disconnected. Keep hoses elevated to minimize
fuel drainage.

6. Disconnect fuel hoses (Figure 1, Sheet 2, Item 11 and Item 12), from fuel cooler (Figure 1, Sheet 2, Item 13)

7. Remove four screws (Figure 1, Sheet 2, Item 14), eight washers (Figure 1, Sheet 2, Item 15), and four
bushings (Figure 1, Sheet 2, Item 16).

8. Remove fuel cooler (Figure 1, Sheet 2, Item 13).

END OF TASK

INSTALLATION

1. Install fuel cooler (Figure 1, Sheet 2, Item 13) with four bushings (Figure 1, Sheet 2, Item 16), eight washers
(Figure 1, Sheet 2, Item 15), and four screws (Figure 1, Sheet 2, Item 14).

2. Connect fuel hoses (Figure 1, Sheet 2, Item 12 and Item 11) onto fuel cooler (Figure 1, Sheet 2, Item 13).

3. Install horizontal lower front base baffles (Figure 1, Sheet 2, Item 10 and Item 9) with twelve washers (Figure
1, Sheet 2, Item 8), lockwashers (Figure 1, Sheet 2, Item 7), and screws (Figure 1, Sheet 2, Item 6).

4. Install horizontal upper front base baffles (Figure 1, Sheet 1, Item 5 and Item 4) with twenty washers (Figure
1, Sheet 1, Item 3), lockwashers (Figure 1, Sheet 1, Item 2), and screws (Figure 1, Sheet 1, Item 1).

5. Close right rear door assemblies.

6. Close left rear door assemblies.

0060-2
 TM 9-6115-730-24 0060

INSTALLATION - Continued

Figure 1. Fuel Cooler (Sheet 1 of 2).

0060-3
 TM 9-6115-730-24 0060

INSTALLATION - Continued

Figure 1. Fuel Cooler (Sheet 2 of 2).

END OF TASK

END OF WORK PACKAGE

0060-4
 TM 9-6115-730-24 0061

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
WATER SEPARATOR FILTER AND BRACKET MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References
Cap and plug set (WP 0124, Item 6) TM 9-6115-730-24P
Filter
Gasket
Sealant (WP 0124, Item 37)
Tiedown strap (WP 0124, Item 46)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Failure to comply can cause injury or death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the fuel system. Ensure fuel pan is available to drain excess fuel from hose and
water separator assembly.

0061-1
 TM 9-6115-730-24 0061

DRAINING

1. Open left front door.

2. Rotate valve (Figure 1, Item 1) and air vent (Figure 1, Item 2) to allow water to drain from bowl (Figure 1,
Item 3).

3. Rotate valve (Figure 1, Item 1) and air vent (Figure 1, Item 2) to close.

4. Close left front door.

END OF TASK

WATER SEPARATOR FILTER ASSEMBLY REPLACEMENT

1. Open left front door.

2. Remove clamp (Figure 1, Item 4) and disconnect hose (Figure 1, Item 5) from drain port on bottom of water
separator filter bowl (Figure 1, Item 3).

3. Remove water separator filter assembly (Figure 1, Item 7)

4. Install new filter element (Figure 1, Item 8) into water separator assembly (Figure 1, Item 7). Install new water
separator filter assembly.

5. Connect hose (Figure 1, Item 5) to bottom of bowl (Figure 1, Item 3) and install clamp (Figure 1, Item 4).

6. Close left front doors.

END OF TASK

WATER SEPARATOR FILTER REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF, Battery Disconnect Switch is OFF,
and DEAD CRANK SWITCH is OFF before proceeding.

2. Open left front doors.

NOTE
Cut tiedown straps as required.

3. Remove clamp (Figure 1, Item 4) and disconnect hose (Figure 1, Item 5) from drain port on bottom of water
separator filter bowl (Figure 1, Item 3).

4. Disconnect hose (Figure 1, Item 9) and hose (Figure 1, Item 10) from water separator filter assembly
(Figure 1, Item 7).

0061-2
 TM 9-6115-730-24 0061

WATER SEPARATOR FILTER REMOVAL - Continued

Figure 1. Water Separator Filter and Bracket.

0061-3
 TM 9-6115-730-24 0061

WATER SEPARATOR FILTER REMOVAL - Continued

5. Remove two screws (Figure 1, Item 11), lockwashers (Figure 1, Item 12), spacers (Figure 1, Item 13), and
water separator filter assembly (Figure 1, Item 7) with bracket (Figure 1, Item 14).

6. Remove two screws (Figure 1, Item 15), washers (Figure 1, Item 16), lockwashers (Figure 1, Item 17), nuts
(Figure 1, Item 18), and bracket (Figure 1, Item 14).

7. Remove clamp (Figure 1, Item 19), swivel (Figure 1, Item 20), clamp (Figure 1, Item 21), and hose barb
(Figure 1, Item 22) from hose (Figure 1, Item 23).

8. If necessary, remove two elbows (Figure 1, Item 24).

END OF TASK

WATER SEPARATOR FILTER INSTALLATION

NOTE
Install tiedown straps as required.

1. Apply sealant to male threads and install two elbows (Figure 1, Item 24) on water separator filter assembly
(Figure 1, Item 7).

2. Install hose barb (Figure 1, Item 22) on hose (Figure 1, Item 23) with clamp (Figure 1, Item 21), swivel
(Figure 1, Item 20), and clamp (Figure 1, Item 19).

3. Install water separator filter assembly (Figure 1, Item 7) onto bracket (Figure 1, Item 14), and secure with two
nuts (Figure 1, Item 18), lockwashers (Figure 1, Item 17), washers (Figure 1, Item 16), and screws (Figure 1,
Item 15).

4. Install bracket (Figure 1, Item 14) with water separator filter assembly (Figure 1, Item 7), two spacers
(Figure 1, Item 13), lockwashers (Figure 1, Item 12), and screws (Figure 1, Item 11).

5. Connect hose (Figure 1, Item 10) and hose (Figure 1, Item 9) to water separator filter assembly (Figure 1,
Item 7).

6. Connect hose (Figure 1, Item 5) to drain port on bottom of water separator filter bowl (Figure 1, Item 3) and
install clamp (Figure 1, Item 4).

7. Close left front door.

END OF TASK

END OF WORK PACKAGE

0061-4
 TM 9-6115-730-24 0062

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
FUEL LEVEL SENDER MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) Two

Multimeter
References
Materials/Parts
TM 9-6115-730-24P
Cap and plug set (WP 0124, Item 6)
Gasket
Sealant (WP 0124, Item 40)
Tiedown straps (WP 0124, Item 48)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Failure to comply can cause injury or death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the fuel system.

0062-1
 TM 9-6115-730-24 0062

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch is
OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open left rear doors.

NOTE
Cut tiedown straps as required.

3. Tag and disconnect wires from fuel level sender (Figure 1, Sheet 1, Item 1).

Figure 1. Fuel Level Sender (Sheet 1 of 2).

0062-2
 TM 9-6115-730-24 0062

REMOVAL - Continued

Figure 1. Fuel Level Sender (Sheet 2 of 2).

0062-3
 TM 9-6115-730-24 0062

REMOVAL - Continued

CAUTION
Note orientation of sender assembly to ensure correct installation.

4. Remove five screws (Figure 1, Sheet 1, Item 2), lockwashers (Figure 1, Sheet 1, Item 3), washers (Figure 1,
Sheet 1, Item 4), fuel level sender assembly (Figure 1, Sheet 1, Item 1), and gasket (Figure 1, Sheet 1,
Item 5).

END OF TASK

TEST AND INSPECTION

1. Remove five screws, lockwashers and fuel level sender assembly from fuel tank.

2. Set Battery Disconnect Switch to ON.

3. Set DEAD CRANK SWITCH to NORMAL.

4. Set Engine Control Switch to COOL DOWN/STOP.

5. Hold fuel level sender (Figure 1, Sheet 1, Item 1) in vertical position with armature (Figure 1, Sheet 2, Item 6)
hanging down. Fuel level indicator should read “E” +/- 1/8 inch.

6. Raise armature (Figure 1, Sheet 2, Item 6) to full up position. Fuel level indicator should read “F” +/- 1/8 inch.

7. Check resistance in “Full” and “Empty” positions according to Figure 1, Sheet 2.

8. If resistance measurements are incorrect, replace fuel level sender.

9. If resistance measurements are correct, verify the wiring per FO-1, Sheet 2 and FO-3, Sheet 1.

10. If the wiring is correct, replace fuel indicator.

END OF TASK

0062-4
 TM 9-6115-730-24 0062

INSTALLATION

1. Clean area on fuel tank where gasket (Figure 1, Sheet 1, Item 5) is to be installed.

CAUTION
Install sender as marked or incorrect fuel level indications will result.

2. Apply sealing compound to both sides of gasket (Figure 1, Sheet 1, Item 5) and install gasket, fuel level sender
assembly (Figure 1, Sheet 1, Item 1), five washers (Figure 1, Sheet 1, Item 4), lockwashers (Figure 1,
Sheet 1, Item 3), and screws (Figure 1, Sheet 1, Item 2).

NOTE
Install tiedown straps as required.

3. Remove tags and connect wires from fuel level sender (Figure 1, Sheet 1, Item 1).

4. Close left rear doors.

END OF TASK

END OF WORK PACKAGE

0062-5/6 blank
 TM 9-6115-730-24 0063

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
FUEL TANK MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Equipment Condition (cont.)

Tool Kit, General Mechanic’s (WP 0123, Item 1) Engine-generator compartment ceiling
assembly removed (WP 0032)
Materials/Parts Front section housing assembly removed
(WP 0034)
Repair kit, adhesive (WP 0124, Item 36) Rear Section Housing assembly removed
(WP 0035)
References Left center panel assembly removed
(WP 0036)
TM 9-6115-730-10 Right center panel assembly removed
TM 9-6115-730-24P (WP 0037)
Fuel drain valve and piping removed
Personnel Required (WP 0057)
Auxiliary fuel pump removed (WP 0059)
One Engine removed (WP 0096)
Fuel level switch assembly removed
Equipment Condition (WP 0056)
Fuel pickup tube assembly removed
Front roof housing assembly removed (WP 0058)
(WP 0030) Fuel level sender removed (WP 0062)
Rear roof housing assembly removed Fuel filler inlet disconnected (WP 0057)
(WP 0031) Fuel hoses and fittings removed (WP 0057)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the u nit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

0063-1
 TM 9-6115-730-24 0063

WARNING
DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Failure to comply can cause injury or death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the fuel system.

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch is
OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Remove four screws (Figure 1, item 1), four nuts (Figure 1, item 2), washers (Figure 1, item 3) two hold down
assemblies (Figure 1, item 4), and fuel tank (Figure 1, item 5).

END OF TASK

REPAIR

Repair damage to fuel tank with adhesive repair kit, following directions provided with the kit.

END OF TASK

INSTALLATION

1. Install fuel tank (Figure 1, item 5), two hold down assemblies (Figure 1, item 4), four screws (Figure 1, item 1),
washers (Figure 1, item 3), and nuts (Figure 1, item 2).

2. Install fuel drain valve and piping (WP 0057).

3. Install fuel hoses and fittings (WP 0057).

4. Connect fuel filler inlet (WP 0057).

5. Install fuel level sender (WP 0062).

6. Install fuel pickup tube (WP 0058).

7. Install fuel level switch assembly (WP 0056).

8. Install engine (WP 0096).

0063-2
 TM 9-6115-730-24 0063

INSTALLATION - Continued

Figure 1. Fuel Tank Maintenance.

0063-3
 TM 9-6115-730-24 0063

INSTALLATION - Continued

9. Install auxiliary fuel pump (WP 0059).

10. Install Engine-generator Compartment Ceiling Assembly (WP 0032).

11. Install Front Section Housing Assembly (WP 0034).

12. Install Front Roof Housing Assembly (WP 0030).

13. Install Rear Section Housing Assembly (WP 0035).

14. Install Rear Roof Housing Assembly (WP 0031).

15. Install Left Center Panel Assembly (WP 0036).

16. Install Right Center Panel Assembly (WP 0037).

17. Service fuel tank (TM 9-6115-730-10).

END OF TASK

END OF WORK PACKAGE

0063-4
 TM 9-6115-730-24 0064

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
COOLANT RECOVERY SYSTEM MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, One

Common No. 1 (WP 0123, Item 2)
Tool Kit, General Mechanic’s (WP 0123, Item 1) References

Materials/Parts TM 9-6115-730-24P

Antifreeze (WP 0124, Item 5)

Cap and plug set (WP 0124, Item 6)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/ or liquids can result in burns and scalding. Shut down generator set, and allow system to
cool before performing checks, services, and maintenance. Failure to comply can cause injury or
death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the coolant system.

0064-1
 TM 9-6115-730-24 0064

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch is
OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open right rear doors.

3. Place container under coolant recovery system bottle (Figure 1, Item 1).

4. Remove two hose clamps (Figure 1, Item 2) securing hoses (Figure 1, Item 3) and (Figure 1, Item 4) to coolant
recovery system bottle (Figure 1, Item 1) and disconnect two hoses.

5. Drain coolant into suitable container until coolant recovery system is empty. Retain coolant for refilling cooling
system.

6. Remove two screws (Figure 1, Item 5), washers (Figure 1, Item 6), lockwashers (Figure 1, Item 7), and coolant
recovery system bottle (Figure 1, Item 1).

END OF TASK

INSTALLATION

1. Install coolant recovery system bottle (Figure 1, Item 1), two washers (Figure 1, Item 7), lockwashers
(Figure 1, Item 6), and screws (Figure 1, Item 5).

2. Connect two hoses (Figure 1, Item 3) and (Figure 1, Item 4) to coolant recovery system bottle (Figure 1,
Item 1) and secure with two hose clamps (Figure 1, Item 2).

3. Pour coolant into coolant recovery system bottle (Figure 1, Item 1). If necessary, add coolant so level is
between HOT and COLD marks on bottle.

4. Close right rear doors.

0064-2
 TM 9-6115-730-24 0064

INSTALLATION - Continued

Figure 1. Coolant Recovery System.

END OF TASK

END OF WORK PACKAGE

0064-3/4 blank
 TM 9-6115-730-24 0065

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
SURGE TANK MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, One

Common No. 1 (WP 0123, Item 2)
Tool Kit, General Mechanic’s (WP 0123, Item 1) References

Materials/Parts TM 9-6115-730-24P

Cap and plug set (WP 0124, Item 6) Equipment Condition

Marker tags (WP 0124, Item 49)
Sealant (WP 0124, Item 37) Right side access cover removed (WP 0029)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/ or liquids can result in burns and scalding. Shut down generator set, and allow system to
cool before performing checks, services, and maintenance. Failure to comply can cause injury or
death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the coolant system.

0065-1
 TM 9-6115-730-24 0065

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch is
OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open right rear doors and right front doors.

3. Place container under COOLANT DRAIN on right side of TQG.

4. Remove coolant fill cap (Figure 1, Item 1) and open drain valves (Figure 1, Item 2) and (Figure 1, Item 3).

5. Drain approximately two gallons of coolant into suitable container until surge tank (Figure 1, Item 4) is empty.
Retain coolant for refilling cooling system.

6. Remove hose clamp (Figure 1, Item 5) and disconnect hose (Figure 1, Item 6) from bottom of surge tank
(Figure 1, Item 4).

7. Remove coolant level sensor (Figure 1, Item 7) and reducer (Figure 1, Item 8) from surge tank (Figure 1,
Item 4).

8. Loosen two hose clamps (Figure 1, Item 9) and disconnect water hose (Figure 1, Item 10) from top of surge
tank (Figure 1, Item 4).

9. Remove two hose clamps and tag and disconnect two hoses (Figure 1, Item 11) and (Figure 1, Item 12) from
top of surge tank (Figure 1, Item 4).

10. Remove four locknuts (Figure 1, Item 13), washers (Figure 1, Item 14), and screws (Figure 1, Item 15), and
remove two lower surge tank brackets (Figure 1, Item 16) and surge tank (Figure 1, Item 4) from two upper
surge tank brackets (Figure 1, Item 17).

11. Remove two screws (Figure 1, Item 18), lockwashers (Figure 1, Item 19), and washers (Figure 1, Item 20),
and remove two upper surge tank brackets (Figure 1, Item 17).

END OF TASK

INSTALLATION

1. Install two upper surge tank brackets (Figure 1, Item 17) and secure with two washers (Figure 1, Item 20),
lockwashers (Figure 1, Item 19), and screws (Figure 1, Item 18).

2. Install surge tank (Figure 1, Item 4) and two lower surge tank brackets (Figure 1, Item 16) and secure with four
screws (Figure 1, Item 15), washers (Figure 1, Item 14), and locknuts (Figure 1, Item 13).

3. Remove tags and connect two hoses (Figure 1, Item 12) and (Figure 1, Item 11) to top of surge tank
(Figure 1, Item 4).

4. Connect water hose (Figure 1, Item 10) to top of surge tank (Figure 1, Item 4) and tighten two hose clamps
(Figure 1, Item 9).

5. Apply sealing compound to male threads of reducer (Figure 1, Item 8) and coolant level sensor (Figure 1,
Item 7) and install reducer and coolant level sensor on surge tank (Figure 1, Item 4).

0065-2
 TM 9-6115-730-24 0065

INSTALLATION - Continued

Figure 1. Surge Tank.

0065-3
 TM 9-6115-730-24 0065

INSTALLATION - Continued

6. Connect hose (Figure 1, Item 6) to bottom of surge tank (Figure 1, Item 4) and install hose clamp (Figure 1,
Item 5).

7. Pour coolant into COOLANT FILL and install fill cap (Figure 1, Item 1). If necessary, add coolant so level is
between HOT and COLD marks on coolant recovery system bottle.

WARNING
Operating the generator set with any access door open exposes personnel to a high noise level.
Hearing protection must be worn when operating or working near the generator set with any
access door open. Failure to comply can cause hearing damage to personnel.

8. Operate TQG and check for leaks.

9. Install right side access cover (WP 0029).

10. Close right rear doors and right front doors.

END OF TASK

END OF WORK PACKAGE

0065-4
 TM 9-6115-730-24 0066

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
FAN AND FAN GUARDS MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Tool Kit, General Mechanic’s (WP 0123, Item 1) TM 9-6115-730-24P

Material/Parts Equipment Condition

Antifreeze (WP 0124, item 5) Cooling system drained (WP 0068)

Personnel Required

One

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/ or liquids can result in burns and scalding. Shut down generator set, and allow system to
cool before performing checks, services, and maintenance. Failure to comply can cause injury or
death to personnel.

Fan has sharp blades. Use caution and wear gloves when removing or installing belts. Failure to
comply can cause injury to personnel.

0066-1
 TM 9-6115-730-24 0066

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch is
OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open right front doors and left front door.

NOTE
Table 1 lists removal and installation steps for fan and fan guard elements.

Table 1. WP 0066 Guide.

FIGURE 1 REMOVAL INSTALLATION

NAME ITEM STEPS STEPS

Upper right fan guard 4 3 thru 6 19 thru 23

Lower right fan guard 12 5 and 7 thru 9 17 thru 21

Upper left fan guard 36 10 thru 12 14 and 15

Lower left fan guard 37 13 and 14 12, 13 thru 15

Left shroud flange 41 20 thru 22 and 24 2, 4 thru 6

Right shroud flange 16 20 thru 23 3 thru 6

Fan and adapter 86, 87 3 thru 25 1 and 2

3. Remove nut (Figure 1, Sheet 1, Item 1), lockwasher (Figure 1, Sheet 1, Item 2), and screw (Figure 1, Sheet 1,
Item 3) attaching rear of upper right fan guard (Figure 1, Sheet 1, Item 4) to top of engine.

4. If necessary, remove nut (Figure 1, Sheet 1, Item 5), washer (Figure 1, Sheet 1, Item 6), lockwasher (Figure 1,
Sheet 1, Item 7), and bracket (Figure 1, Sheet 1, Item 8).

5. Remove two locknuts (Figure 1, Sheet 1, Item 9), washers (Figure 1, Sheet 1, Item 10), and screws (Figure 1,
Sheet 1, Item 11) attaching upper right fan guard (Figure 1, Sheet 1, Item 4) and lower right fan guard
(Figure 1, Sheet 1, Item 12) together.

6. Remove four screws (Figure 1, Sheet 1, Item 13), washers (Figure 1, Sheet 1, Item 14), lockwashers (Figure 1,
Sheet 1, Item 15), and upper right fan guard (Figure 1, Sheet 1, Item 4) from right shroud flange (Figure 1,
Sheet 1, Item 16).

7. Remove locknut (Figure 1, Sheet 1, Item 17), washer (Figure 1, Sheet 1, Item 18), and screw (Figure 1,
Sheet 1, Item 19) attaching rear of lower right fan guard (Figure 1, Sheet 1, Item 12) to bracket (Figure 1
Sheet 1, Item 20) attached to engine.

0066-2
 TM 9-6115-730-24 0066

REMOVAL - Continued

Figure 1. Fan and Fan Guards (Sheet 1 of 3).

0066-3
 TM 9-6115-730-24 0066

REMOVAL - Continued

Figure 1. Fan and Fan Guards (Sheet 2 of 3).

0066-4
 TM 9-6115-730-24 0066

REMOVAL - Continued

Figure 1. Fan and Fan Guards (Sheet 3 of 3).

0066-5
 TM 9-6115-730-24 0066

REMOVAL - Continued

8. Remove screw (Figure 1, Sheet 1, Item 21) and washer (Figure 1, Sheet 1, Item 22) and remove bracket
(Figure 1, Sheet 1, Item 20) from engine.

9. Remove four screws (Figure 1, Sheet 1, Item 23), lockwashers (Figure 1, Sheet 1, Item 24), washers (Figure 1,
Sheet 1, Item 25) and lower right fan guard (Figure 1, Sheet 1, Item 12) from right shroud flange (Figure 1,
Sheet 1, Item 16).

10. Remove locknut (Figure 1, Sheet 1, Item 26), two washers (Figure 1, Sheet 1, Item 27), and screw (Figure 1,
Sheet 1, Item 28). Remove screw (Figure 1, Sheet 1, Item 29), lockwasher (Figure 1, Sheet 1, Item 30), and
washer (Figure 1, Sheet 1, Item 31) and remove bracket (Figure 1, Sheet 1, Item 32) from engine.

11. Remove two locknuts (Figure 1, Sheet 1, Item 33), washers (Figure 1, Sheet 1, Item 34), and screws (Figure 1,
Sheet 1, Item 35) that attach upper left fan guard (Figure 1, Sheet 1, Item 36) and lower left fan guard
(Figure 1, Sheet 1, Item 37) together.

12. Remove four screws (Figure 1, Sheet 1, Item 38), lockwashers (Figure 1, Sheet 1, Item 39), washers (Figure 1,
Sheet 1, Item 40), and upper left fan guard (Figure 1, Sheet 1, Item 36) from left shroud flange (Figure 1,
Sheet 1, Item 41).

13. Remove locknut (Figure 1, Sheet 1, Item 42), two washers (Figure 1, Sheet 1, Item 43), and screw (Figure 1,
Sheet 1, Item 44) from lower left fan guard (Figure 1, Sheet 1, Item 37).

14. Remove four screws (Figure 1, Sheet 1, Item 45), lockwashers (Figure 1, Sheet 1, Item 46), washers (Figure 1,
Sheet 1, Item 47), and lower left fan guard (Figure 1, Sheet 1, Item 37) from left shroud flange (Figure 1,
Sheet 1, Item 41).

15. Remove eight hose clamps (Figure 1, Sheet 2, Item 48), two hose connectors (Figure 1, Sheet 2, Item 49), and
manifold in hose (Figure 1, Sheet 2, Item 50) from radiator (Figure 1, sheet 2, item 51) and from elbow (Figure
1, sheet 2, item 52).

16. Remove four hose clamps (Figure 1, Sheet 2, Item 53), coolant hose (Figure 1, Sheet 2, Item 54), and upper
radiator hose (Figure 1, Sheet 2, Item 55) from radiator (Figure 1, sheet 2, item 51) and from elbow (Figure 1,
sheet 2, item 56).

17. Remove eight hose clamps (Figure 1, Sheet 2, Item 57), two hose connectors (Figure 1, Sheet 2, Item 58),
manifold out tube (Figure 1, Sheet 2, Item 59), from radiator (Figure 1, Sheet 2, Item 51) and from turbo out
elbow (Figure 1, Sheet 2, Item 60).

18. Remove two hose clamps (Figure 1, Sheet 2, Item 61) and lower radiator hose (Figure 1, Sheet 2, Item 62),
from radiator (Figure 1, Sheet 2, Item 51).

19. Remove four screws (Figure 1, Sheet 2, Item 63) and lockwashers (Figure 1, Sheet 2, Item 64), washers
(Figure 1, Sheet 2, Item 65), and two radiator mounting tie rods (Figure 1, Sheet 2, Item 66).

20. Remove 10 screws (Figure 1, Sheet 3, Item 67), lockwashers (Figure 1, Sheet 3 Item 68), washers (Figure 1,
Sheet 3, Item 69), and upper shroud plate (Figure 1, Sheet 3, Item 70) from right shroud flange (Figure 1,
Sheet 1, Item 16) and left shroud flange (Figure 1, Sheet 1, Item 41).

21. Remove eight screws (Figure 1, Sheet 3, Item 71), lockwashers (Figure 1, Sheet 3, Item 72), washers
(Figure 1, Sheet 3, Item 73), and lower shroud plate (Figure 1, Sheet 3, Item 74) from right shroud flange
(Figure 1, Sheet 1, Item 16) and left shroud flange (Figure 1, Sheet 1, Item 41).

0066-6
 TM 9-6115-730-24 0066

REMOVAL - Continued

22. Remove locknut (Figure 1, Sheet 3, Item 75), washer (Figure 1, Sheet 3, Item 76), and screw (Figure 1,
Sheet 3, Item 77) in two places, top and bottom, that attach right shroud flange (Figure 1, Sheet 1, Item 16)
and left shroud flange (Figure 1, Sheet 1, Item 41) together.

23. Remove 10 screws (Figure 1, Sheet 3, Item 78), lockwashers (Figure 1, Sheet 3, Item 79), washers (Figure 1,
Sheet 3, Item 80), and right shroud flange (Figure 1, Sheet 1, Item 16) from radiator (Figure 1, Sheet 1,
Item 51).

24. Remove 10 screws (Figure 1, Sheet 3, Item 81), lockwashers (Figure 1, Sheet 3, Item 82), washers (Figure 1,
Sheet 3, Item 83), and left shroud flange (Figure 1, Sheet 1, Item 41) from radiator (Figure 1, Sheet 1, Item 51).

25. Remove 6 screws (Figure 1, Sheet 3, Item 84), washers (Figure 1, Sheet 3, Item 85), fan (Figure 1, Sheet 3,
Item 86), fan mounting adapter (Figure 1, Sheet 3, Item 87), and O-ring (Figure 1, Sheet 3, Item 88).

END OF TASK

INSTALLATION

1. Install O-ring (Figure 1, Sheet 3, Item 88), fan mounting adapter (Figure 1, Sheet 3, Item 87), fan (Figure 1,
Sheet 3, Item 86), and secure with six washers (Figure 1, Sheet 3, Item 85) and screws (Figure 1, Sheet 3,
Item 84). Torque screws (Figure 1, Sheet 3, Item 86) to 27-33 lb-ft (37-44 Nm).

2. Install left shroud flange (Figure 1, Sheet 3, Item 41) onto radiator (Figure 1, Sheet 1, Item 51) and secure with
10 washers (Figure 1, Sheet 3, Item 83), lockwashers (Figure 1, Sheet 3, Item 82), and screws (Figure 1,
Sheet 3, Item 81).

3. Install right shroud flange (Figure 1, Sheet 1, Item 16) onto radiator (Figure 1, Sheet 1, Item 51) and secure
with 10 washers (Figure 1, Sheet 3, Item 80), lockwashers (Figure 1, Sheet 3, Item 79), and screws (Figure 1,
Sheet 3, Item 78).

4. Hold right shroud flange (Figure 1, Sheet 1, Item 16) and left shroud flange (Figure 1, Sheet 1, Item 41)
together and secure with screw (Figure 1, Sheet 3, Item 77), washer (Figure 1, Sheet 3, Item 76), and locknut
(Figure 1, Sheet 3, Item 75), in two places, top and bottom.

5. Install lower shroud plate (Figure 1, Sheet 3, Item 74) onto right shroud flange (Figure 1, Sheet 1, Item 16) and
left shroud flange (Figure 1, Sheet 1, Item 41) and secure with eight washers (Figure 1, Sheet 3, Item 73),
lockwashers (Figure 1, Sheet 3, Item 72), and screws (Figure 1, Sheet 3, Item 71).

6. Install upper shroud plate (Figure 1, Sheet 3, Item 70) onto right shroud flange (Figure 1, Sheet 1, Item 16) and
left shroud flange (Figure 1, Sheet 1, Item 41) and secure with 10 washers (Figure 1, Sheet 3, Item 69),
lockwashers (Figure 1, Sheet 3, Item 68), and screws (Figure 1, Sheet 3, Item 67).

7. Install two radiator mounting tie rods (Figure 1, Sheet 2, Item 66) with two washers (Figure 1, Sheet 2, Item
65), lockwashers (Figure 1, Sheet 2, Item 64), and four screws (Figure 1, Sheet 2, Item 63).

8. Install lower radiator hose (Figure 1, Sheet 2, Item 62) onto radiator (Figure 1, Sheet 2, Item 51) and secure
with two hose clamps (Figure 1, Sheet 2, Item 61).

9. Install manifold out tube (Figure 1, Sheet 2, Item 59) and two hose connectors (Figure 1, Sheet 2, Item 58)
onto turbo out elbow (Figure 1, Sheet 2, Item 60) and onto radiator (Figure 1, Sheet 2, Item 51) and secure
with eight hose clamps (Figure 1, Sheet 2, Item 57).

0066-7
 TM 9-6115-730-24 0066

INSTALLATION - Continued

10. Install upper radiator hose (Figure 1, Sheet 2, Item 55) and coolant hose (Figure 1, Sheet 2, Item 54) onto
radiator (Figure 1, Sheet 2, item 51) and onto elbow (Figure 1, Sheet 2, item 56) and secure with four hose
clamps (Figure 1, Sheet 2, Item 53).

11. Install manifold in hose (Figure 1, Sheet 2, Item 50) and two hose connectors (Figure 1, Sheet 2, Item 49) onto
elbow (Figure 1, sheet 2, item 52) and onto radiator (Figure 1, Sheet 2, item 51) and secure with eight hose
clamps (Figure 1, Sheet 2, Item 48).

12. Install lower left fan guard (Figure 1, Sheet 1, Item 37) on left shroud flange (Figure 1, Sheet 1, Item 41) and
secure with four washers (Figure 1, Sheet 1, Item 47), lockwashers (Figure 1, Sheet 1, Item 46), and screws
(Figure 1, Sheet 1, Item 45).

13. Install screw (Figure 1, Sheet 1, Item 44), two washers (Figure 1, Sheet 1, Item 43), and locknut (Figure 1,
Sheet 1, Item 42) on lower fan left guard (Figure 1, Sheet 1, Item 37).

14. Install upper left fan guard (Figure 1, Sheet 1, Item 36) on left shroud flange (Figure 1, Sheet 1, Item 41) and
secure with four washers (Figure 1, Sheet 1, Item 40), lockwashers (Figure 1, Sheet 1, Item 39), and screws
(Figure 1, Sheet 1, Item 38).

15. Hold upper left fan guard (Figure 1, Sheet 1, Item 36) and lower left fan guard (Figure 1, Sheet 1, Item 37)
together and secure with two screws (Figure 1, Sheet 1, Item 35), washers (Figure 1, Sheet 1, Item 34), and
locknuts (Figure 1, Sheet 1, Item 33).

16. Install bracket (Figure 1, Sheet 1, Item 32) on engine and secure with screw (Figure 1, Sheet 1, Item 29),
lockwasher (Figure 1, Sheet 1, Item 30), and washer (Figure 1, Sheet 1, Item 31. Install screw (Figure 1,
Sheet 1, Item 28), two washers (Figure 1, Sheet 1, Item 27), and locknut (Figure 1, Sheet 1, Item 26).

17. Install lower right fan guard (Figure 1, Sheet 1, Item 12) on right shroud flange (Figure 1, Sheet 1, Item 16),
and secure with four washers (Figure 1, Sheet 1, Item 25), lockwashers (Figure 1, Sheet 1, Item 24), and
screws (Figure 1, Sheet 1, Item 23).

18. Install bracket (Figure 1, Sheet 1, Item 20) on engine and secure with washer (Figure 1, Sheet 1, Item 12) and
screw (Figure 1, Sheet 1, Item 21).

19. Attach rear of lower right fan guard (Figure 1, Sheet 1, Item 12) to bracket (Figure 1, Sheet 1, Item 20) and
secure with screw (Figure 1, Sheet 1, Item 19), washer (Figure 1, Sheet 1, Item 18), and locknut (Figure 1,
Sheet 1, Item 17).

20. Install upper right fan guard (Figure 1, Sheet 1, Item 4) on right shroud flange (Figure 1, Sheet 1, Item 16) and
secure with four lockwashers (Figure 1, Sheet 1, Item 15), washers (Figure 1, Sheet 1, Item 14), and screws
(Figure 1, Sheet 1, Item 13).

21. Hold upper right fan guard (Figure 1, Sheet 1, Item 4) and lower right fan guard (Figure 1, Sheet 1, Item 12)
together, and secure with two screws (Figure 1, Sheet 1, Item 11), washers (Figure 1, Sheet 1, Item 10), and
locknuts (Figure 1, Sheet 1, Item 9).

0066-8
 TM 9-6115-730-24 0066

INSTALLATION - Continued

22. If necessary, install bracket (Figure 1, Sheet 1, Item 8) with nut (Figure 1, Sheet 1, Item 5), washer (Figure 1,
Sheet 1, Item 6), and lockwasher (Figure 1, Sheet 1, Item 7).

23. Secure rear of upper right fan guard (Figure 1, Sheet 1, Item 4) to engine with screw (Figure 1, Sheet 1,
Item 3), lockwasher (Figure 1, Sheet 1, Item 2) and nut (Figure 1, Sheet 1, Item 1).

24. Refill cooling system with coolant.

25. Close left front door and right front doors.

END OF TASK

END OF WORK PACKAGE

0066-9/10 blank
 TM 9-6115-730-24 0067

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
COOLANT HOSE ASSEMBLIES MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, One

Common No. 1 (WP 0123, Item 2)
Tool Kit, General Mechanic’s (WP 0123, Item 1) References

Materials/Parts TM 9-6115-730-24P

Antifreeze (WP 0124, Item 5) Equipment Condition

Cap and plug set (WP 0124, Item 6)
Sealant (WP 0124, Item 37) Side access panel removed (WP 0029)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/ or liquids can result in burns and scalding. Shut down generator set, and allow system to
cool before performing checks, services, and maintenance. Failure to comply can cause injury or
death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the coolant system.

0067-1
 TM 9-6115-730-24 0067

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch
is OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open left front door, left rear doors, right front doors, and right rear doors.

NOTE
Coolant system capacity is 42 quarts (39.7 liters).

3. Place suitable container under coolant drain on front right side of TQG. Open drain valve (Figure 1, Sheet 3,
Item 1) on right rear side of engine, and drain valve (Figure 1, Sheet 3, Item 2) on front right side bottom of
engine, and drain coolant. Save coolant for refilling system.

4. On right side, remove two hose clamps (Figure 1, Sheet 3, Item 3) and hose (Figure 1, Sheet 3, Item 4) from
radiator filler neck and from coolant recovery system.

5. Remove two hose clamps (Figure 1, Sheet 3, Item 5) and hose (Figure 1, Sheet 3, Item 6) from coolant
recovery system and from tee fitting (Figure 1, Sheet 3, Item 7).

6. Remove locknut (Figure 1, Sheet 4, Item 8), screw (Figure 1, Sheet 4, Item 9), washer (Figure 1, Sheet 4,
Item 10), and loop clamp (Figure 1, Sheet 4, Item 11). Remove two hose clamps (Figure 1, Sheet 4, Item 12)
and hose (Figure 1, Sheet 3, Item 13) from tee fitting (Figure 1, Sheet 3, Item 7) and tee fitting (Figure 1,
Sheet 4, Item 14).

7. Remove loop clamp (Figure 1, Sheet 4, Item 15) and hose (Figure 1, Sheet 1, Item 16) from bottom of water
separator filter.

8. Remove fitting (Figure 1, Sheet 3, Item 17), 90 degree elbow (Figure 1, Sheet 3, Item 18), drain valve
(Figure 1, Sheet 3, Item 2), nipple (Figure 1, Sheet 3, Item 19), and 90 degree elbow (Figure 1, Sheet 3,
Item 20) from bottom of radiator.

9. At rear of engine, remove two hose clamps (Figure 1, Sheet 3, Item 21), hose (Figure 1, Sheet 3, Item 22),
drain valve (Figure 1, Sheet 3, Item 1), and reducer fitting (Figure 1, Sheet 3, Item 23).

10. At radiator filler neck, remove two hose clamps (Figure 1, Sheet 3, Item 24) and hose (Figure 1, Sheet 3,
Item 25).

11. At top of surge tank, remove two hose clamps (Figure 1, Sheet 2, Item 26) and disconnect hose (Figure 1,
Sheet 2, Item 27) and hose (Figure 1, Sheet 2, Item 28).

12. On top of engine, remove two loop clamps (Figure 1, Sheet 2, Item 29).

13. On right side of engine, remove hose clamp (Figure 1, Sheet 3, Item 30) and remove hose (Figure 1, Sheet 2,
Item 27). On right side of radiator, remove hose clamp (Figure 1, Sheet 3, Item 31) and hose (Figure 1,
Sheet 2, Item 28). Remove two fittings (Figure 1, Sheet 3, Item 32).

14. Remove two hose clamps (Figure 1, Sheet 3, Item 33) and hose (Figure 1, Sheet 3, Item 34). Remove fitting
(Figure 1, Sheet 3, Item 35), 90 degree elbow (Figure 1, Sheet 3, Item 36), and nipple (Figure 1, Sheet 3,
Item 37).

15. On top of engine, remove eight hose clamps (Figure 1, Sheet 2, Item 38), manifold out tube (Figure 1,
Sheet 2, Item 39), and two bellows (Figure 1, Sheet 2, Item 40).

0067-2
 TM 9-6115-730-24 0067

REMOVAL - Continued

Figure 1. Coolant Hose Assemblies (Sheet 1 of 4).

0067-3
 TM 9-6115-730-24 0067

REMOVAL - Continued

Figure 1. Coolant Hose Assemblies (Sheet 2 of 4).

0067-4
 TM 9-6115-730-24 0067

REMOVAL - Continued

Figure 1. Coolant Hose Assemblies (Sheet 3 of 4).

0067-5
 TM 9-6115-730-24 0067

REMOVAL - Continued

Figure 1. Coolant Hose Assemblies (Sheet 4 of 4).

0067-6
 TM 9-6115-730-24 0067

REMOVAL - Continued

16. Remove eight hose clamps (Figure 1, Sheet 2, Item 41), manifold in tube (Figure 1, Sheet 2, Item 42), and
two bellows (Figure 1, Sheet 2, Item 43).

17. Below water separator filter, remove hose barb fitting (Figure 1, Sheet 1, Item 44), swivel fitting (Figure 1,
Sheet 1, Item 45), two hose clamps (Figure 1, Sheet 1, Item 46), and hose (Figure 1, Sheet 1, Item 47).

18. On left side of engine, remove two hose clamps (Figure 1, Sheet 1, Item 48), hose (Figure 1, Sheet 1, Item 49),
hose clamp (Figure 1, Sheet 1, Item 50), upper radiator hose (Figure 1, Sheet 1, Item 51), drain valve
(Figure 1, Sheet 1, Item 52), 90 degree elbow (Figure 1, Sheet 1, Item 53), and hose elbow (Figure 1,
Sheet 1, Item 54).

19. On lower right side of engine, remove two hose clamps (Figure 1, Sheet 3, Item 55) and lower radiator hose
(Figure 1, Sheet 3, Item 56).

END OF TASK

INSTALLATION

NOTE
Apply sealing compound to all male pipe threads before connecting.

1. At lower right side of engine, install lower radiator hose (Figure 1, Sheet 3, Item 56) and two hose clamps
(Figure 1, Sheet 3, Item 55).

2. On left side of engine, install hose elbow (Figure 1, Sheet 1, Item 54), 90 degree elbow (Figure 1, Sheet 1,
Item 53), drain valve (Figure 1, Sheet 1, Item 52), upper radiator hose (Figure 1, Sheet 1, Item 51), hose
clamp (Figure 1, Sheet 1, Item 50), hose (Figure 1, Sheet 1, Item 49), and two hose clamps (Figure 1,
Sheet 1, Item 48).

3. Below water separator filter, install hose (Figure 1, Sheet 1, Item 47), two hose clamps (Figure 1, Sheet 1,
Item 46), swivel fitting (Figure 1, Sheet 1, Item 45), and hose barb fitting (Figure 1, Sheet 1, Item 44).

4. On top of engine, install two bellows (Figure 1, Sheet 2, Item 43), manifold in tube (Figure 1, Sheet 2,
Item 42), and eight hose clamps (Figure 1, Sheet 2, Item 41).

5. Install two bellows (Figure 1, Sheet 2, Item 40), manifold out tube (Figure 1, Sheet 2, Item 39), and eight hose
clamps (Figure 1, Sheet 2, Item 38).

6. On right side of engine, install nipple (Figure 1, Sheet 3, Item 37), 90 degree elbow (Figure 1, Sheet 3,
Item 36), and fitting (Figure 1, Sheet 3, Item 35). Install hose (Figure 1, Sheet 3, Item 34) and two hose clamps
(Figure 1, Sheet 3, Item 33).

7. On right side of radiator, install two fittings (Figure 1, Sheet 3, Item 32), hose (Figure 1, Sheet 2, Item 28), and
hose clamp (Figure 1, Sheet 3, Item 31). On right side of engine, install hose (Figure 1, Sheet 2, Item 27) and
hose clamp (Figure 1, Sheet 3, Item 30).

8. On top of engine, install two loop clamps (Figure 1, Sheet 2, Item 29).

0067-7
 TM 9-6115-730-24 0067

INSTALLATION - Continued

9. At top of surge tank, connect hose (Figure 1, Sheet 2, Item 28) and hose (Figure 1, Sheet 2, Item 27), and
install two hose clamps (Figure 1, Sheet 2, Item 26).

10. At radiator filler neck, install hose (Figure 1, Sheet 3, Item 25) and two hose clamps (Figure 1, Sheet 3,
Item 24).

11. At rear of engine, install reducer fitting (Figure 1, Sheet 3, Item 23), drain valve (Figure 1, Sheet 3, Item 1),
hose (Figure 1, Sheet 3, Item 22), and two hose clamps (Figure 1, Sheet 3, Item 21).

12. At bottom of radiator, install 90 degree elbow (Figure 1, Sheet 3, Item 20), nipple (Figure 1, Sheet 3, Item 19),
drain valve (Figure 1, Sheet 3, Item 2), 90 degree elbow (Figure 1, Sheet 3, Item 18), and fitting (Figure 1,
Sheet 3, Item 17).

13. Install hose (Figure 1, Sheet 1, Item 16) and loop clamp (Figure 1, Sheet 4, Item 15) to bottom of water
separator filter.

14. Install hose (Figure 1, Sheet 3, Item 13) and three hose clamps (Figure 1, Sheet 4, Item 12) on tee fitting
(Figure 1, Sheet 4, Item 14).

15. At lower rear of radiator, install loop clamp (Figure 1, Sheet 4, Item 11), washer (Figure 1, Sheet 4, Item 10),
screw (Figure 1, Sheet 4, Item 9), and locknut (Figure 1, Sheet 4, Item 8).

16. Connect hose (Figure 1, Sheet 3, Item 6) to tee fitting (Figure 1, Sheet 3, Item 7) and to coolant recovery
system, and install two hose clamps (Figure 1, Sheet 3, Item 5).

17. Install hose (Figure 1, Sheet 3, Item 4) to coolant recovery system and radiator filler neck and install two hose
clamps (Figure 1, Sheet 3, Item 3).

18. Close drain valve (Figure 1, Sheet 3, Item 2) on front right side bottom of engine and close drain valve
(Figure 1, Sheet 3, Item 1) on right rear side of engine.

NOTE
Coolant system capacity is 42 quarts (39.7 liters).

19. Refill cooling system with coolant.

20. Install side access cover (WP 0029).

21. Close right rear doors, right front doors, left rear doors, and left front door.

END OF TASK

END OF WORK PACKAGE

0067-8
 TM 9-6115-730-24 0068

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
RADIATOR ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Shop Equipment, Automotive Maintenance, TM 750-254

Common No. 1 (WP 0123, Item 2) TM 9-6115-730-24P
Tool Kit, General Mechanic’s (WP 0123, Item 1)
Equipment Condition
Materials/Parts
Front roof section housing assembly removed
Antifreeze (WP 0124, Item 5) (WP 0030)
Cap and plug set (WP 0124, Item 6) Rear roof section housing assembly removed
Sealing compound (WP 0124, Item 40) (WP 0031)
Exhaust system removed (WP 0069)
Personnel Required Engine generator compartment ceiling assembly
Two removed (WP 0032)
Fan guards, shrouds, and upper and lower
shroud plates removed (WP 0066)
Right front door assembly (latch) removed
(WP 0025)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

0068-1
 TM 9-6115-730-24 0068

WARNING
Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/ or liquids can result in burns and scalding. Shut down generator set, and allow system to
cool before performing checks, services, and maintenance. Failure to comply can cause injury or
death to personnel.

Radiator weighs more than 140 pounds (64 kg) and requires a two-person lift. Lifting radiator can
cause back strain. Ensure proper lifting techniques are used when lifting radiator. Failure to
comply can cause injury to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the coolant system.

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch is
OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open left front door and right front doors.

NOTE
Coolant system capacity is 42 quarts (39.7 liters).

3. Place suitable container under COOLANT DRAIN on front right side of TQG. Open drain valve (Figure 1,
Sheet 1, Item 1) on right side at rear of engine, and drain valve (Figure 1, Sheet 1, Item 2) on lower right front
of engine, and drain coolant. Save coolant for refilling system.

4. Remove sill from upper edge of left front door assembly (latch) opening.

5. Remove document box, located above right front door assembly (latch).

6. On right side of engine, remove hose clamp (Figure 1, Sheet 2, Item 3) and disconnect hose (Figure 1,
Sheet 2, Item 4) from barbed fitting (Figure 1, Sheet 2, Item 5). Remove barbed fitting (Figure 1, Sheet 2,
Item 5) from radiator (Figure 1, Sheet 1, Item 6).

7. Remove eight hose clamps (Figure 1, Sheet 1, Item 7), two bellows (Figure 1, Sheet 1, Item 8), and manifold
out tube (Figure 1, Sheet 1, Item 9) from right side of radiator (Figure 1, Sheet 1, Item 6).

8. Remove two hose clamps (Figure 1, Sheet 2, Item 10) and lower radiator hose (Figure 1, Sheet 2, Item 11).

9. Remove hose clamp (Figure 1, Sheet 1, Item 12) and disconnect coolant hose (Figure 1, Sheet 1, Item 13)
from female connector (Figure 1, Sheet 1, Item 14) on lower right side of radiator (Figure 1, Sheet 1, Item 6).

10. Remove female connector (Figure 1, Sheet 1, Item 14), 90 degree elbow (Figure 1, Sheet 1, Item 15), drain
valve (Figure 1, Sheet 1, Item 2), nipple (Figure 1, Sheet 1, Item 16), and 90 degree elbow (Figure 1, Sheet 1,
Item 17) from radiator (Figure 1, Sheet 1, Item 6).

0068-2
 TM 9-6115-730-24 0068

REMOVAL - Continued

Figure 1. Radiator Assembly (Sheet 1 of 2).

0068-3
 TM 9-6115-730-24 0068

REMOVAL - Continued

Figure 1. Radiator Assembly (Sheet 2 of 2).

0068-4
 TM 9-6115-730-24 0068

REMOVAL - Continued

11. At top of engine, remove eight hose clamps (Figure 1, Sheet 2, Item 18), two bellows (Figure 1, Sheet 2,
Item 19), and manifold in tube (Figure 1, Sheet 2, Item 20).

12. Remove two hose clamps (Figure 1, Sheet 2, Item 21), coolant hose (Figure 1, Sheet 2, Item 22), two hose
clamps (Figure 1, Sheet 2, Item 23), upper radiator hose (Figure 1, Sheet 2, Item 24), and elbow (Figure 1,
Sheet 2, Item 25).

13. Remove two screws (Figure 1, Sheet 2, Item 26), lockwashers (Figure 1, Sheet 2, Item 27), and washers
(Figure 1, Sheet 2, Item 28).

14. Remove two screws (Figure 1, Sheet 2, Item 29), lockwashers (Figure 1, Sheet 2, Item 30), nuts (Figure 1,
Sheet 2, Item 31), and two upper radiator mounting tie rods (Figure 1, Sheet 2, Item 32) from radiator
(Figure 1, Sheet 1, Item 6) and upper radiator support mounting bracket (Figure 1, Sheet 2, Item 33).

WARNING
Radiator weighs more than 140 pounds (64 kg) and requires a two-person lift. Lifting radiator can
cause back strain. Ensure proper lifting techniques are used when lifting radiator. Failure to
comply can cause injury to personnel.

15. Under radiator (Figure 1, Sheet 1, Item 6), remove two screws (Figure 1, Sheet 2, Item 34), lockwashers
(Figure 1, Sheet 2, Item 35), and washers (Figure 1, Sheet 2, Item 36), and remove radiator (Figure 1, Sheet 1,
Item 6) out of housing through left front door assembly (latch).

16. Remove four screws (Figure 1, Sheet 2, Item 37), lockwashers (Figure 1, Sheet 2, Item 38), washers (Figure 1,
Sheet 2, Item 39), radiator air block plate (Figure 1, Sheet 2, Item 40) and foam (Figure 1, Sheet 2, Item 41)
from upper right side of radiator (Figure 1, Sheet 1, Item 6). Repeat for left side of radiator (Figure 1, Sheet 1,
Item 6).

END OF TASK

REPAIR OR REPLACEMENT

1. For repair of the radiator, refer to procedures in TM 750-254, Cooling Systems: Tactical Vehicles.

2. Inspect foam (Figure 1, Sheet 2, Item 41) and repair or replace, as required.

END OF TASK

0068-5
 TM 9-6115-730-24 0068

INSTALLATION

1. Install foam (Figure 1, Sheet 2, Item 41) and radiator air block plate (Figure 1, Sheet 2, Item 40) on upper
right side of radiator (Figure 1, Sheet 1, Item 6), and secure with four washers (Figure 1, Sheet 2, Item 39),
lockwashers (Figure 1, Sheet 2, Item 38), and screws (Figure 1, Sheet 2, Item 37). Repeat for left side of
radiator (Figure 1, Sheet 1, Item 6).

WARNING
Radiator weighs more than 140 pounds (64 kg) and requires a two-person lift. Lifting radiator can
cause back strain. Ensure proper lifting techniques are used when lifting radiator. Failure to
comply can cause injury to personnel.

NOTE
Apply sealing compound to all male pipe threads before connecting.

2. Install radiator (Figure 1, Sheet 1, Item 6) through left front door assembly (latch) and install two washers
(Figure 1, Sheet 2, Item 36), lockwashers (Figure 1, Sheet 2, Item 35) and screws (Figure 1, Sheet 2, Item 34)
under radiator.

3. Install two upper radiator mounting tie rods (Figure 1, Sheet 2, Item 32) and to upper radiator support mounting
bracket (Figure 1, Sheet 2, Item 33) and secure with two screws (Figure 1, Sheet 2, Item 29), lockwashers
(Figure 1, Sheet 2, Item 30), and nuts (Figure 1, Sheet 2, Item 31).

4. Install two screws (Figure 1, Sheet 2, Item 26), lockwashers (Figure 1, Sheet 2, Item 27), and washers
(Figure 1, Sheet 2, Item 28).

5. Install elbow (Figure 1, Sheet 2, Item 25), upper radiator hose (Figure 1, Sheet 2, Item 24), two hose clamps
(Figure 1, Sheet 2, Item 23), coolant hose (Figure 1, Sheet 2, Item 22), and two hose clamps (Figure 1,
Sheet 2, Item 21).

6. At left side of engine, install manifold in tube (Figure 1, Sheet 2, Item 20), two bellows (Figure 1, Sheet 2,
Item 19) and eight hose clamps (Figure 1, Sheet 2, Item 18).

7. At lower right side of radiator (Figure 1, Sheet 1, Item 6), install 90 degree elbow (Figure 1, Sheet 1, Item 17),
nipple (Figure 1, Sheet 1, Item 16), drain valve (Figure 1, Sheet 1, Item 2), 90 degree elbow (Figure 1, Sheet 1,
Item 15), and female connector (Figure 1, Sheet 1, Item 14).

8. Connect coolant hose (Figure 1, Sheet 1, Item 13) to female connector (Figure 1, Sheet 1, Item 14) and install
hose clamp (Figure 1, Sheet 1, Item 12).

9. Install lower radiator hose (Figure 1, Sheet 1, Item 11) and two hose clamps (Figure 1, Sheet 1, Item 10).

10. On right side of engine, install manifold out tube (Figure 1, Sheet 1, Item 9), two bellows (Figure 1, Sheet 1,
Item 8), and eight hose clamps (Figure 1, Sheet 1, Item 7).

11. Install barbed fitting (Figure 1, Sheet 1, Item 5) on radiator (Figure 1, Sheet 1, Item 6), connect hose
(Figure 1, Sheet 1, Item 4), and install hose clamp (Figure 1, Sheet 1, Item 3).

12. Install document box above right front door assembly (latch).

0068-6
 TM 9-6115-730-24 0068

INSTALLATION - Continued

13. Install sill on upper edge of left front door assembly (latch) opening.

14. Close left front door and right front doors.

15. Install fan guards, shrouds, and upper and lower shroud plates (WP 0066).

16. Install engine generator compartment ceiling assembly (WP 0032).

17. Install exhaust system (WP 0069).

18. Install rear roof section housing assembly (WP 0031).

19. Install front roof section housing assembly (WP 0030).

NOTE
Coolant system capacity is 38 quarts (34.5 liters).

20. Close drain valves (Figure 1, Sheet 1, Item 1) and (Figure 1, Sheet 1, Item 2). Refill cooling system with
coolant. Add coolant as required.

21. Set Battery Disconnect Switch to ON and DEAD CRANK SWITCH to ON. On EMCP set ENGINE CONTROL
switch to START.

22. With engine running, check for leaks.

END OF TASK

FLUSHING

For flushing of the cooling system, refer to procedures in TM 750-254, Cooling Systems: Tactical Vehicles.

END OF TASK

END OF WORK PACKAGE

0068-7/8 blank
 TM 9-6115-730-24 0069

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
EXHAUST SYSTEM MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) Two

Materials/Parts References

Wire, nonelectrical (WP 0124, Item 53) TM 9-6115-730-24P

Equipment Condition
Access covers removed (WP 0029)
Front roof section housing assembly removed
(WP 0030)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

Exhaust system can get very hot. Shut down generator set, and allow system to cool before
performing checks, services, and maintenance. Failure to comply can cause severe burns and
injury to personnel.

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch is
OFF, and DEAD CRANK SWITCH is OFF before proceeding.

0069-1
Change 1
 TM 9-6115-730-24 006 9

REMOVAL

2. Open left front door and right front door.

WARNING
The muffler blanket is made of fiberglass fabric which can break down with heat and flexing.
Fiberglass fibers can irritate the flesh and respiratory passages. Wear protective eyewear, mask,
and gloves when removing or installing muffler blanket. Failure to comply can cause injury to
personnel.

3. Remove lacing and elbow blanket (Figure 1, Item 1), inlet pipe turbo end blanket (Figure 1, Item 2), inlet pipe
muffler end blanket (Figure 1, Item 3), and muffler blanket (Figure 1, Item 4).

4. Remove pipe clamp (Figure 1, Item 5) from exhaust in elbow (Figure 1, Item 6).

5. Remove two exhaust pipe clamps (Figure 1, Item 7) and one ceramic strip (Figure 1, Item 8) that attaches flex
exhaust tube assembly (Figure 1, Item 9) to muffler (Figure 1, Item 10) and remove flex exhaust tube assembly
(Figure 1, Item 9) from muffler and exhaust in elbow (Figure 1, Item 6).

6. Remove eight locknuts (Figure 1, Item 11), washers (Figure 1, Item 12), and screws (Figure 1, Item 13), and
remove exhaust flange (Figure 1, Item 14), exhaust in elbow (Figure 1, Item 6), and bellows (Figure 1, Item
15). Remove clamp (Figure 1, Item 16) and insulation strip (Figure 1, Item 17).

7. Remove two locknuts (Figure 1, Item 18) and washers (Figure 1, Item 19) from each of two muffler tie down
strap assemblies (Figure 1, Item 20), and remove straps, clamp (Figure 1, Item 25), and muffler
(Figure 1, Item 10).

8. Remove four locknuts (Figure 1, Item 21), washers (Figure 1, Item 22), and screws (Figure 1, Item 23) from
each of two muffler brackets (Figure 1, Item 24), and remove two brackets (Figure 1, Item 24) from
engine/generator compartment ceiling.

END OF TASK

INSTALLATION

1. Install two brackets (Figure 1, Item 24) to engine/generator compartment ceiling, and secure with four screws
(Figure 1, Item 23), washers (Figure 1, Item 22), and locknuts (Figure 1, Item 21).

2. Install muffler (Figure 1, Item 10), clamp (Figure 1, Item 25), two muffler tiedown strap assemblies
(Figure 1,Item 20), two washers (Figure 1, Item 19),.and locknuts (Figure 1, Item 18)

3. Install exhaust flange (Figure 1, Item 14) and bellows (Figure 1, Item 15) on exhaust in elbow (Figure 1, Item
6). Install insulation strip (Figure 1, Item 17) and clamp (Figure 1, Item 16). Install eight screws (Figure 1, Item
13), washers (Figure 1, Item 12), and locknuts (Figure 1, Item 11).

0069-2
Change 1
Change 1
 TM 9-6115-730-24 0069

INSTALLATION - Continued

4. Install flex exhaust tube assembly (Figure 1, Item 9) on muffler (Figure 1, Item 10) and exhaust in elbow
(Figure 1, Item 6) and install ceramic strip (Figure 1, Item 8) and two exhaust pipe clamps (Figure 1, Item 7).

5. Install pipe clamp (Figure 1, Item 5) on exhaust in elbow (Figure 1, Item 6).

WARNING
The muffler blanket is made of fiberglass fabric which can break down with heat and flexing.
Fiberglass fibers can irritate the flesh and respiratory passages. Wear protective eyewear, mask,
and gloves when removing or installing muffler blanket. Failure to comply can cause injury to
personnel.

6. Install muffler blanket (Figure 1, Item 4), inlet pipe muffler end blanket (Figure 1, Item 3), inlet pipe turbo end
blanket (Figure 1, Item 2), elbow blanket (Figure 1, Item 1), and secure with lacing.

7. Install front roof section housing assembly (WP 0030).

8. Install access covers (WP 0029).

9. Close left front door and right front door.

END OF TASK

END OF WORK PACKAGE

0069-4
Change 1
 TM 9-6115-730-24 0070

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
CRANKCASE VENTILATION FILTER MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Cap and plug set (WP 0124, Item 6) TM 9-6115-730-24P

Wiping rags (WP 0124, Item 35)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set, and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply can
cause injury or death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the air cleaner system.

0070-1
 TM 9-6115-730-24 0070

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch is
OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open left rear doors.

3. Disconnect hose (Figure 1, Item 1) and reducer (Figure 1, Item 2) from bottom of crankcase ventilation filter
(Figure 1, Item 3).

4. Unlatch bowl (Figure 1, Item 4) from crankcase ventilator filter (Figure 1, Item 3) and remove filter element
(Figure 1, Item 5).

END OF TASK

INSTALLATION

1. Install filter element (Figure 1, Item 5) and latch bowl (Figure 1, Item 4) back onto crankcase ventilation filter
(Figure 1, Item 3).

2. Install reducer (Figure 1, Item 2) to bottom of crankcase ventilation filter (Figure 1, Item 3) and install hose
(Figure 1, Item 1).

3. Close left rear doors.

0070-2
 TM 9-6115-730-24 0070

INSTALLATION - Continued

Figure 1. Crankcase Ventilation Filter.

END OF TASK

END OF WORK PACKAGE

0070-3/4 blank
 TM 9-6115-730-24 0071

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
AIR CLEANER FILTER MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References
Cap and plug set (WP 0124, Item 6) TM 9-6115-730-24P
Filter, inner
Filter, outer
Wiping rags (WP 0124, Item 35)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set, and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply can
cause injury or death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the air cleaner system.

0071-1
 TM 9-6115-730-24 0071

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch is
OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open left rear doors.

CAUTION
Do not twist filters or damage may occur.

3. Unfasten wing nut (Figure 1, Item 1) and remove outer filter (Figure 1, Item 2) from air cleaner housing
(Figure 1, Item 3).

4. Remove C-clip (Figure 1, Item 4).

5. Remove cotter pin (Figure 1, Item 5), indicator nut (Figure 1, Item 6), and inner filter element (Figure 1,
Item 7).

6. Reset indicator nut (Figure 1, Item 6) by applying compressed air to rear of the indicator nut while sealing the
front opening of nut.

END OF TASK

CLEANING

WARNING
Cleaning with compressed air can cause flying particles. When using compressed air, wear
protective glasses and use clean, low pressure air, less than 30 psi (208 kPa). Failure to comply
can cause eye injury to personnel.

1. If not excessively dirty, clean filter elements (Figure 1, Item 2) and (Figure 1, Item 7) with low pressure (less
than 30 psi) compressed air.

2. Wipe interior of housing (Figure 1, Item 3) with clean lint-free cloth.

3. Replace filter elements when damaged or when they cannot be cleaned.

END OF TASK

INSTALLATION

1. Install inner filter element (Figure 1, Item 7), indicator nut (Figure 1, Item 6), and cotter pin (Figure 1, Item 5).

2. Install C-clip (Figure 1, Item 4), outer filter element (Figure 1, Item 2), and hand tighten wing nut (Figure 1,
Item 1).

3. Close left rear doors.

0071-2
 TM 9-6115-730-24 0071

INSTALLATION - Continued

Figure 1. Air Cleaner Filter.

END OF TASK

END OF WORK PACKAGE

0071-3/4 blank
 TM 9-6115-730-24 0072

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
AIR CLEANER SYSTEM MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) Two

Materials/Parts References

Cap and plug set (WP 0124, Item 6) TM 9-6115-730-24P

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set, and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply can
cause injury or death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the air cleaner system.

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch is
OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open right front doors and left front door.

0072-1
 TM 9-6115-730-24 0072

REMOVAL - Continued

3. Remove air cleaner indicator (Figure 1, Sheet 1, Item 1) from air cleaner (Figure 1, Sheet 1, Item 2).

4. Remove two clamps (Figure 1, Sheet 1, Item 3) and (Figure 1, Sheet 1, Item 4) and reducing elbow (Figure 1,
Sheet 1, Item 5) from air cleaner (Figure 1, Sheet 1, Item 2) and restricted tap sleeve (Figure 1, Sheet 1,
Item 6).

5. Remove sensor (Figure 1, Sheet 1, Item 7) from restricted tap sleeve (Figure 1, Sheet 1, Item 6).

6. Remove two clamps (Figure 1, Sheet 1, Item 8) and hose (Figure 1, Sheet 1, Item 9) from restricted tap sleeve
(Figure 1, Sheet 1, Item 6) and OUT port fitting on crankcase ventilation filter (Figure 1, Sheet 2, Item 10).

7. Remove clamp (Figure 1, Sheet 1, Item 11) and disconnect restricted tap sleeve (Figure 1, Sheet 1, Item 6)
from air vent hose (Figure 1, Sheet 1, Item 12).

8. Remove clamp (Figure 1, Sheet 1, Item 13) and disconnect air vent hose (Figure 1, Sheet 1, Item 12) from
engine turbo.

9. Remove two clamps (Figure 1, Sheet 2, Item 14) and hose (Figure 1, Sheet 2, Item 15) from IN port fitting on
crankcase ventilation filter (Figure 1, Sheet 2, Item 10) and engine crankcase filter adapter.

10. Remove two clamps (Figure 1, Sheet 2, Item 16) and disconnect hose (Figure 1, Sheet 2, Item 17) from swivel
fitting (Figure 1, Sheet 2, Item 18) on bottom of crankcase ventilation filter (Figure 1, Sheet 2, Item 10) and
from check valve (Figure 1, Sheet 2, Item 19) on left hand rear engine dipstick port.

11. Remove check valve (Figure 1, Sheet 2, Item 19) and elbow (Figure 1, Sheet 2, Item 20) from left hand rear
engine dipstick port.

12. Remove two screws (Figure 1, Sheet 2, Item 21), lockwashers (Figure 1, Sheet 2, Item 22), washers (Figure 1,
Sheet 2, Item 23), and crankcase ventilation filter (Figure 1, Sheet 2, Item 10) from bracket (Figure 1, Sheet 2,
Item 24).

WARNING
Air cleaner weighs 66 pounds (30 kg) and requires a two-person lift. Ensure proper lifting
techniques are used when lifting air cleaner. Failure to comply can cause injury to personnel.

13. Loosen nut (Figure 1, Sheet 1, Item 25) on each air cleaner mounting band (Figure 1, Sheet 1, Item 26).
Remove air cleaner (Figure 1, Sheet 1, Item 2).

14. Loosen captive wing nut (Figure 1, Sheet 1, Item 28) and remove air cleaner cover (Figure 1, Sheet 1,
Item 27), and remove air cleaner (Figure 1, Sheet 1, Item 2) from air cleaner mounting bands (Figure 1,
Sheet 1, Item 26).

15. Remove four locknuts (Figure 1, Sheet 1, Item 29), washers (Figure 1, Sheet 1, Item 30), screws (Figure 1,
Sheet 1, Item 31), and two air cleaner mounting bands (Figure 1, Sheet 1, Item 26).

16. Remove two hose fittings (Figure 1, Sheet 2, Item 32) from crankcase ventilation filter (Figure 1, Sheet 1,
Item 10).

0072-2
 TM 9-6115-730-24 0072

REMOVAL - Continued

Figure 1. Air Cleaner System (Sheet 1 of 2).

0072-3
 TM 9-6115-730-24 0072

REMOVAL - Continued

Figure 1. Air Cleaner System (Sheet 2 of 2).

END OF TASK

0072-4
 TM 9-6115-730-24 0072

INSTALLATION

1. Install two hose fittings (Figure 1, Sheet 1, Item 30) to crankcase ventilation filter (Figure 1, Sheet 2, Item 32).

2. Install two air cleaner mounting bands (Figure 1, Sheet 1, Item 26) and secure with four screws (Figure 1,
Sheet 1, Item 31), washers (Figure 1, Sheet 1, Item 30), and locknuts (Figure 1, Sheet 1, Item 29).

WARNING
Air cleaner weighs 66 pounds (30 kg) and requires a two-person lift. Ensure proper lifting
techniques are used when lifting air cleaner. Failure to comply can cause injury to personnel.

3. Install air cleaner (Figure 1, Sheet 1, Item 2) in two air cleaner mounting bands (Figure 1, Sheet 1, Item 26)
and tighten two nuts (Figure 1, Sheet 1, Item 25).

4. Install air cleaner cover (Figure 1, Sheet 1, Item 27) and tighten wing nut (Figure 1, Sheet 1, Item 28).

5. Install crankcase ventilation filter (Figure 1, Sheet 2, Item 10) on bracket (Figure 1, Sheet 2, Item 24) and
secure with two screws (Figure 1, Sheet 2, Item 21), lockwashers (Figure 1, Sheet 2, Item 22), and washers
(Figure 1, Sheet 2, Item 23).

6. Install elbow (Figure 1, Sheet 2, Item 20) and check valve (Figure 1, Sheet 2, Item 19) in left hand rear engine
dipstick port.

7. Connect hose (Figure 1, Sheet 2, Item 17) from swivel fitting (Figure 1, Sheet 2, Item 18) on bottom of
crankcase ventilation filter (Figure 1, Sheet 2, Item 10) and to check valve (Figure 1, Sheet 2, Item 19) on left
hand rear engine dipstick port, and install two clamps (Figure 1, Sheet 2, Item 16).

8. Connect hose (Figure 1, Sheet 2, Item 15) to IN port fitting on crankcase ventilation filter (Figure 1, Sheet 2,
Item 10) and to engine crankcase filter adapter, and install two clamps (Figure 1, Sheet 2, Item 14).

9. Connect air vent hose (Figure 1, Sheet 1, Item 12) to engine turbo and install clamp (Figure 1, Sheet 1,
Item 13).

10. Connect restricted tap sleeve (Figure 1, Sheet 1, Item 6) to air vent hose (Figure 1, Sheet 1, Item 12) and
install clamp (Figure 1, Sheet 1, Item 11).

11. Connect hose (Figure 1, Sheet 1, Item 9) to restricted tap sleeve (Figure 1, Sheet 1, Item 6) and to OUT port
fitting on crankcase ventilation filter (Figure 1, Sheet 2, Item 10), and install two clamps (Figure 1, Sheet 1,
Item 8).

12. Install sensor (Figure 1, Sheet 1, Item 7) on restricted tap sleeve (Figure 1, Sheet 1, Item 6).

13. Install reducing elbow (Figure 1, Sheet 1, Item 5) on air cleaner (Figure 1, Sheet 1, Item 2) and restricted tap
sleeve (Figure 1, Sheet 1, Item 6) and install two clamps (Figure 1, Sheet 1, Item 4) and (Figure 1, Sheet 1,
Item 3).

14. Install air cleaner indicator (Figure 1, Sheet 1, Item 1) on air cleaner (Figure 1, Sheet 1, Item 2).

15. Close left front door and right front doors.

END OF TASK

END OF WORK PACKAGE

0072-5/6 blank
 TM 9-6115-730-24 0073

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
ETHER INJECTION ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Cap and plug set (WP 0124, Item 6) TM 9-6115-730-24P

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

Breathing ether fumes can cause fainting. Do not manually discharge or deliberately inhale ether.
Failure to comply can cause injury to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the ether injector assembly.

0073-1
 TM 9-6115-730-24 0073

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch is
OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open left front doors.

3. Disconnect wire harness connector ENG-P13 from injector valve (Figure 1, Item 1).

4. Disconnect tubing (Figure 1, Item 2) from injector valve (Figure 1, Item 1).

5. Loosen clamp (Figure 1, Item 3) and remove ether bottle (Figure 1, Item 4) and immediately install cap
(Figure 1, Item 5).

6. If necessary, remove two screws (Figure 1, Item 6), washers (Figure 1, Item 7), and clamp (Figure 1, Item 3).

7. If necessary, remove two screws (Figure 1, Item 12) washers (Figure 1, Item 13), retaining clamp (Figure 1,
Item 10) and injector valve (Figure 1, Item 1).

8. If necessary, remove two screws (Figure 1, Item 8), washers (Figure 1, Item 9), and valve mounting bracket
(Figure 1, Item 11).

INSTALLATION

1. If removed, install valve mounting bracket (Figure 1, Item 11), two washers (Figure 1, Item 9),and screws
(Figure 1, Item 8).

2. If removed, install injector valve (Figure 1, Item 1) and retaining bracket (Figure 1, Item 10) with two washers
(Figure 1, Item 13) and screws (Figure 1, Item 12).

3. If removed, install clamp (Figure 1, Item 3), two washers (Figure 1, Item 7), and screws (Figure 1, Item 6).

4. Remove cap (Figure 1, Item 5), and immediately install ether bottle (Figure 1, Item 4). Tighten clamp
(Figure 1, Item 3).

5. Connect tubing (Figure 1, Item 2) to injector valve (Figure 1, Item 1).

6. Connect wire harness connector ENG-P13 to injector valve (Figure 1, Item 1).

7. Close left front doors.

0073-2
 TM 9-6115-730-24 0073

INSTALLATION - Continued

Figure 1. Ether Injection Assembly.

END OF TASK

END OF WORK PACKAGE

0073-3/4 blank
 TM 9-6115-730-24 0074

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
ALTERNATOR MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Tool Kit, General Mechanic’s (WP 0123, Item 1) TM 9-6115-730-24P

Materials/Parts Equipment Condition

Marker tags (WP 0124, Item 49) MAN OUT tube removed (WP 0067)
Upper right and lower right fan guards removed
Personnel Required (WP 0066)
Remove alternator belts (WP 0075)
One

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set, and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply can
cause injury or death to personnel.

0074-1
 TM 9-6115-730-24 0074

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch is
OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open right front doors.

3. Tag and disconnect wiring from alternator. Note routing of alternator belts (Figure 1, Item 1).

4. Loosen nut (Figure 1, Item 2) and turn nut (Figure 1, Item 2) counterclockwise (CW) to relieve tension on
alternator belts (Figure 1, Item 1) and slip belts off alternator pulley (Figure 1, Item 4).

5. Tag and disconnect wiring from alternator (Figure 1, Item 5).

WARNING
Support alternator when removing attaching hardware or alternator may fall. Failure to comply
can cause injury to personnel and equipment damage.

6. While supporting alternator (Figure 1, Item 5), remove nut (Figure 1, Item 6), two washers (Figure 1, Item 7),
and bolt (Figure 1, Item 8).

7. Remove bolt (Figure 1, Item 9), washer (Figure 1, Item 10), and alternator (Figure 1, Item 5).

END OF TASK

INSTALLATION

WARNING
Support alternator when removing attaching hardware or alternator may fall. Failure to comply
can cause injury to personnel and equipment damage.

1. Install alternator (Figure 1, Item 5) and secure with washer (Figure 1, Item 10) and bolt (Figure 1, Item 9).
Tighten bolt.

2. Install bolt (Figure 1, Item 8), two washers (Figure 1, Item 7), and nut (Figure 1, Item 6). Tighten nut.

3. Position alternator belts (Figure 1, Item 1) onto alternator pulley (Figure 1, Item 4), check positioning of belt and
turn nut (Figure 1, Item 2) clockwise (CW) to increase tension on belts.

4. Connect wiring to alternator (Figure 1, Item 5).

5. Perform belt tension adjustment.

6. Install upper right and lower right fan guards (WP 0066).

7. Install MAN OUT tube (WP 0067).

0074-2
 TM 9-6115-730-24 0074

INSTALLATION - Continued

Figure 1. Alternator.

END OF TASK

BELT TENSION ADJUSTMENT

1. Check belt tension on belt (Figure 1, Item 1) farthest from the engine using tension gauge. Tension for new
belts should be 155-165 lb (690-734 Nm). For belts which have operated more than 30 minutes, the tension
should be 90-110 lb (401-489 Nm).

2. Adjust tension as required by turning nuts (Figure 1, Item 2) and (Figure 1, Item 3) until desired tension is
achieved. Tighten nuts (Figure 1, Item 2) and (Figure 1, Item 3) to lock in adjustment.

END OF TASK

END OF WORK PACKAGE

0074-3/4 blank
 TM 9-6115-730-24 0075

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
ALTERNATOR BELT MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Tool Kit, General Mechanic’s (WP 0123, Item 1) TM 9-6115-730-24P

Materials/Parts Equipment Condition

Belt Upper right fan guard removed (WP 0066)

Personnel Required

One

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set, and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply can
cause injury or death to personnel.

0075-1
 TM 9-6115-730-24 0075

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch is
OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open right front doors.

3. Note routing of alternator belts (Figure 1, Item 1).

WARNING
Fan has sharp blades. Use caution and wear gloves when removing or installing belts. Failure to
comply can cause injury to personnel.

4. Turn nut (Figure 1, Item 2) counterclockwise (CCW) to relieve tension on alternator belts (Figure 1, Item 1) and
slip belts off alternator pulley (Figure 1, Item 3), fan pulley (Figure 1, Item 4), and crankshaft pulley (Figure 1,
Item 5).

5. Carefully thread alternator belts (Figure 1, Item 1) over fan blades and remove belts.

END OF TASK

INSTALLATION

WARNING
Fan has sharp blades. Use caution and wear gloves when removing or installing belts. Failure to
comply can cause injury to personnel.

1. Carefully thread alternator belts (Figure 1, Item 1) over fan blades.

2. Position alternator belts (Figure 1, Item 1) on crankshaft pulley (Figure 1, Item 5), fan pulley (Figure 1, Item 4)
and alternator pulley (Figure 1, Item 3).

3. Turn nut (Figure 1, Item 2) clockwise (CW) to increase belt tension.

4. Perform belt tension adjustment.

0075-2
 TM 9-6115-730-24 0075

INSTALLATION - Continued

Figure 1. Alternator Belt.

END OF TASK

0075-3
 TM 9-6115-730-24 0075

BELT TENSION ADJUSTMENT

1. Use tension gauge to check tension on belt (Figure 1, Item 1) farthest from the engine. Tension for new belts
should be 155-165 lb (690-734 Nm). For belts which have operated more than 30 minutes, the tension should
be 90-110 lb (401-489 Nm).

2. Adjust tension as required by turning nut (Figure 1, Item 2) until desired tension is achieved. Tighten nut
(Figure 1, Item 6) to lock in adjustment.

3. Install upper right fan guard (WP 0066).

4. Close right front doors.

END OF TASK

END OF WORK PACKAGE

0075-4
 TM 9-6115-730-24 0076

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
STARTER MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) Two

Materials/Parts References

Gasket TM 9-6115-730-24P
Marker tags (WP 0124, Item 49)
Equipment Condition

Engine wiring harness connectors ENG-P1 and

ENG-P2 disconnected from ECM (WP 0082)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set, and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply can
cause injury or death to personnel.

0076-1
 TM 9-6115-730-24 0076

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch
is OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open left rear doors.

WARNING
Starter weighs 65 pounds (29 kg) and requires a two-person lift. Ensure proper lifting techniques
are used when lifting starter. Failure to comply can cause injury to personnel.

3. Tag and disconnect wiring from ground terminal and solenoid on starter (Figure 1, Item 1) and remove cover
on starter solenoid.

4. Remove three bolts (Figure 1, Item 2) bottom bolt first, gasket (Figure 1, Item 3), and starter (Figure 1, Item 1).

END OF TASK

INSTALLATION

WARNING
Starter weighs 65 pounds (29 kg) and requires a two-person lift. Ensure proper lifting techniques
are used when lifting starter. Failure to comply can cause injury to personnel.

1. Position gasket (Figure 1, Item 3) and starter (Figure 1, Item 1) into flywheel housing, ensure starter gear teeth
mesh with flywheel gear teeth, and line up mounting holes. Install three bolts (Figure 1, Item 2). Tighten bolts.

2. Install cover on starter solenoid. Connect engine wiring harness connectors ENG-P1 and ENG-P2 to ECM
(WP 0082).

3. Clean electrical contacts if necessary. Connect wiring to starter (Figure 1, Item 1).

4. Close left rear doors.

0076-2
 TM 9-6115-730-24 0076

INSTALLATION - Continued

Figure 1. Starter.

END OF TASK

END OF WORK PACKAGE

0076-3/4 blank
 TM 9-6115-730-24 0077

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
TENSIONER MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Tool Kit, General Mechanic’s (WP 0124, Item 1) TM 9-6115-730-24P

Personnel Required Equipment Condition

One Upper right fan guard removed (WP 0066)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set, and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply can
cause injury or death to personnel.

Fan has sharp blades. Use caution and wear gloves when removing or installing belts. Failure to
comply can cause injury to personnel.

0077-1
 TM 9-6115-730-24 0077

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch is
OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open right front doors.

3. Note routing of alternator belts (Figure 1, Item 1).

4. Turn nut (Figure 1, Item 2) CCW to relieve tension on alternator belts (Figure 1, Item 1) and slip belt (Figure 1,
Item 1) off alternator pulley (Figure 1, Item 3).

WARNING
Support alternator when removing attaching hardware or alternator may fall. Failure to comply
can cause injury to personnel and equipment damage.

5. While supporting alternator (Figure 1, Item 4), remove nut (Figure 1, Item 5), two washers (Figure 1, Item 6),
and bolt (Figure 1, Item 7).

6. Remove bolt (Figure 1, Item 8), washer (Figure 1, Item 9), and rod (Figure 1, Item 10).

7. Remove nut (Figure 1, Item 11), two washers (Figure 1, Item 12), block (Figure 1, Item 13), and nut (Figure 1,
Item 2) from rod (Figure 1, Item 10).

END OF TASK

INSTALLATION

1. Install nut (Figure 1, Item 2), block (Figure 1, Item 13), two washers (Figure 1, Item 12), and nut (Figure 1,
Item 11) on rod (Figure 1, Item 10).

2. Install rod (Figure 1, Item 10) and secure with washer (Figure 1, Item 9) and bolt (Figure 1, Item 8). Tighten
bolt.

WARNING
Support alternator when removing attaching hardware or alternator may fall. Failure to comply
can cause injury to personnel and equipment damage.

3. Support alternator (Figure 1, Item 4) in place and install block (Figure 1, Item 13) over alternator mounting hole
and install bolt (Figure 1, Item 7), two washers (Figure 1, Item 6), and nut (Figure 1, Item 5). Tighten nut.

4. Slip alternator belts (Figure 1, Item 1) over pulleys and tighten nut (Figure 1, Item 2) CW to tighten belt.

5. Perform belt tension adjustment (WP 0075).

6. Install upper right fan guard (WP 0066).

7. Close right front doors.

0077-2
 TM 9-6115-730-24 0077

INSTALLATION - Continued

Figure 1. Tensioner.

END OF TASK

END OF WORK PACKAGE

0077-3/4 blank
 TM 9-6115-730-24 0078

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
FUEL PRIMING PUMP MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Gasket TM 9-6115-730-24P
Wiping rags (WP 0124, Item 35)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Failure to comply can cause injury or death to personnel.

When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set, and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply can
cause injury or death to personnel.

0078-1
 TM 9-6115-730-24 0078

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch
is OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open left rear doors.

3. Remove bolt (Figure 1, Item 1), washer (Figure 1, Item 2), bolt (Figure 1, Item 3), washer (Figure 1, Item 4),
fuel priming pump (Figure 1, Item 5), and gasket (Figure 1, Item 6).

END OF TASK

INSTALLATION

1. Clean area where gasket (Figure 1, Item 6) will mate with engine.

2. Apply a light coat of fuel to gasket and install gasket (Figure 1, Item 6), fuel priming pump (Figure 1, Item 5),
washers (Figure 1, Item 4), bolt (Figure 1, Item 3), washer (Figure 1, Item 2), and bolt (Figure 1, Item 1) .
Tighten bolts.

3. Close left rear doors.

0078-2
 TM 9-6115-730-24 0078

INSTALLATION - Continued

Figure 1. Fuel Priming Pump.

END OF TASK

END OF WORK PACKAGE

0078-3/4 blank
 TM 9-6115-730-24 0079

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
OIL FILTER MAINTENANCE AND OIL CHANGE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, One

Common No. 1 (WP 0123, Item 2)
Tool Kit, General Mechanic’s (WP 0123, Item 1) References

Materials/Parts WP 0016
TM 9-6115-730-24P
Lubricating oil (WP 0124, Items 23-30)
Oil filter
Seal
Wiping rags (WP 0124, Item 35)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set, and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply can
cause injury or death to personnel.

0079-1
 TM 9-6115-730-24 0079

FILTER REMOVAL AND OIL DRAIN

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch
is OFF, and DEAD CRANK SWITCH is OFF before proceeding.

CAUTION
Do not drain oil when engine is cold. When engine is cold, oil contaminants are not suspended in
the oil and will not be removed during the draining process. This will allow contaminants to remain
in oil and will cause equipment damage.

2. Allow engine to cool for approximately 10 minutes.

3. Open right front doors and left front door.

NOTE
Engine oil system capacity is 38 quarts (36 liters).

4. Place suitable container under oil drain on lower front left side of TQG, near slave receptacle.

5. Remove plug (Figure 1, Item 1) from oil drain.

6. Open oil drain valve (Figure 1, Item 2) at lower right side of oil pan and allow oil to drain from system.

7. Remove oil filter (Figure 1, Item 3), using strap wrench if necessary.

8. On right side of engine, opposite drain valve, remove magnetic plug (Figure 1, Item 4) and seal (Figure 1,
Item 5) from oil pan. Check magnetic plug for metal particles. Wipe off magnetic plug.

NOTE
If metal particles are found on the magnetic plug, notify supervisor.

END OF TASK

FILTER INSTALLATION AND OIL FILL

1. Install seal (Figure 1, Item 5) and magnetic plug (Figure 1, Item 4).

2. Clean area where filter mounts.

3. Apply thin coat of oil on rubber seal (Figure 1, Item 6) of new oil filter (Figure 1, Item 3).

4. Install oil filter (Figure 1, Item 3) by hand until seal (Figure 1, Item 6) contacts base, then tighten another ¾
turn.

5. Close drain valve (Figure 1, Item 2) and install plug (Figure 1, Item 1) in oil drain.

NOTE
Engine oil system capacity is 38 quarts (36 liters).

6. Remove oil filler cap (Figure 1, Item 7) on right front of engine. Refill with oil (WP 0016 for proper oil). Install
oil filler cap (Figure 1, Item 7).

0079-2
 TM 9-6115-730-24 0079

FILTER INSTALLATION AND OIL FILL - Continued

Figure 1. Oil Filter Maintenance and Oil Change.

0079-3
 TM 9-6115-730-24 0079

FILTER INSTALLATION AND OIL FILL - Continued

7. Check dipstick (Figure 1, Item 8) for correct oil level.

8. Set Battery Disconnect Switch to ON. Set DEAD CRANK SWITCH to NORMAL. On EMCP set ENGINE
CONTROL switch to COOL DOWN/STOP.

9. Reset CATSW2 (RESET SW OIL) switch inside left rear door.

WARNING
Operating the generator set with any access door open exposes personnel to a high noise level.
Hearing protection must be worn when operating or working near the generator set with any
access door open. Failure to comply can cause hearing damage to personnel.

10. Operate engine and check for leaks.

11. Check dipstick for correct oil level.

12. Close right front doors and left front door.

END OF TASK

OIL SAMPLING

CAUTION
Do not sample oil when engine is cold. When engine is cold, oil contaminants are not suspended
in the oil and a true representative sample of the oil will not be obtained. This may cause
equipment damage.

NOTE
Oil sampling is performed in accordance with AOAP requirements and processes.

1. Allow engine to cool for approximately 10 minutes.

2. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch
is OFF, and DEAD CRANK SWITCH is OFF before proceeding.

3. Open right front door assembly.

4. Open oil drain valve (Figure 1, Item 9) on right side of engine below oil filter, collect oil sample, and close
drain valve.

5. Close right front door assembly (latch).

END OF TASK

END OF WORK PACKAGE

0079-4
 TM 9-6115-730-24 0080

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
FUEL FILTER MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Filter Wrench
References
Materials/Parts
TM 9-6115-730-24P
Diesel fuel (WP 0124, Item 16, 17, 51, or 52)
Wiping rags (WP 0124, Item 35)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye protection are
required when working in contact with diesel fuel. Avoid repeated or prolonged contact. Provide
adequate ventilation. Failure to comply can cause injury or death to personnel.

When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set, and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply can
cause injury or death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the engine.

0080-1
 TM 9-6115-730-24 0080

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch is
OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open left door.

3. Place suitable container under fuel filter (Figure 1, Item 1) to retain spillage.

4. Remove fuel filter (Figure 1, Item 1).

Figure 1. Fuel Filter.

END OF TASK

INSTALLATION

1. Clean area where fuel filter (Figure 1, Item 1) will mate with fuel filter base (Figure 1, Item 3).

2. Apply light coat of fuel to seal (Figure 1, Item 2).

3. Install fuel filter (Figure 1, Item 1) by hand until seal (Figure 1, Item 2) contacts fuel filter base. Turn an
additional 3/4 turn by hand.

4. Reset CAT SW1 FUEL FILTER RESET switch inside left rear door.

0080-2
 TM 9-6115-730-24 0080

INSTALLATION - Continued

5. Operate fuel priming pump (Figure 1, Item 4) until strong pressure is felt.

WARNING
Operating the generator set with any access door open exposes personnel to a high noise level.
Hearing protection must be worn when operating or working near the generator set with any
access door open. Failure to comply can cause hearing damage to personnel.

6. Operate engine and check for leaks.

7. Close left front door.

END OF TASK

END OF WORK PACKAGE

0080-3/4 blank
 TM 9-6115-730-24 0081

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
THERMOSTAT MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, One

Common No. 1 (WP 0123, Item 2)
Tool Kit, General Mechanic’s (WP 0123, Item 1) References

Materials/Parts TM 9-6115-730-24P

Antifreeze (WP 0124 Item 5) Equipment Condition

Cap and plug set (WP 0124, Item 6)
Gasket Remove alternator (WP 0074)
Seal (2)
Thermostat
Wiping rags (WP 0124, Item 35)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

Cooling system operates at high temperature and pressure. Contact with high pressure steam
and/ or liquids can result in burns and scalding. Shut down generator set, and allow system to
cool before performing checks, services, and maintenance. Failure to comply can cause injury or
death to personnel.

0081-1
 TM 9-6115-730-24 0081

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the engine.

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch is
OFF, and DEAD CRANK SWITCH is OFF before proceeding.

2. Open right front doors.

3. Place suitable container under coolant drain on right front side of TQG. Open drain valve (Figure 1, Item 1) on
lower right front of engine, below radiator, and drain approximately 2 gallons (7.5 L) of coolant. Save coolant
for refilling system.

4. For optional winterization kit only, loosen hose clamp (Figure 1, Item 2) and disconnect hose (Figure 1, Item 3)
and remove valve (Figure 1, item 4).

5. If optional winterization kit is not present, remove three plugs (Figure 1, item 5) if necessary.

6. Loosen hose clamp (Figure 1, Item 6) and disconnect hose (Figure 1, Item 7).

7. Remove two bolts (Figure 1, Item 8) and washers (Figure 1, Item 9).

8. Remove four plain studs (Figure 1, Item 10), washers (Figure 1, item 11), and thermostat housing (Figure 1,
Item 12).

9. Remove two thermostats (Figure 1, Item 13), seals (Figure 1, Item 14), and gasket (Figure 1, Item 15).

END OF TASK

INSTALLATION

1. Install two seals (Figure 1, Item 14) into thermostat housing (Figure 1, Item 12) with lips toward inside of
housing. Moisten seals (Figure 1, Item 14) with small amount of coolant mixture.

2. Install two thermostats (Figure 1, Item 13), large side first, into thermostat housing (Figure 1, Item 12).

3. Position gasket (Figure 1, Item 15) onto thermostat housing (Figure 1, item 12) and install thermostat housing
with two washers (Figure 1, item 9) and bolts (Figure 1, item 8). Tighten bolts.

4. Install four washers (Figure 1, Item 11) and plain studs (Figure 1, Item 10). Tighten studs.

5. Connect hose (Figure 1, Item 7) and tighten hose clamp (Figure 1, Item 6).

6. If optional winterization kit is not present, install three plugs (Figure 1, item 5) if required.

7. For optional winterization kit only, install valve (Figure 1, item 4), connect hose (Figure 1, Item 3) and tighten
hose clamp (Figure 1, Item 2).

0081-2
 TM 9-6115-730-24 0081

INSTALLATION - Continued

Figure 1. Thermostat.

8. Close drain valve (Figure 1, Item 1).

9. Refill cooling system with coolant that was drained out.

WARNING
Operating the generator set with any access door open exposes personnel to a high noise level.
Hearing protection must be worn when operating or working near the generator set with any
access door open. Failure to comply can cause hearing damage to personnel.

10. Operate engine and check for leaks.

11. Close right front doors.

END OF TASK

END OF WORK PACKAGE

0081-3/4 blank
 TM 9-6115-730-24 0082

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
ENGINE CONTROL MODULE MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) Two

Materials/Parts References

Tiedown straps (WP 0124, Item 46) TM 9-6115-730-24P

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set, and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply can
cause injury or death to personnel.

0082-1
 TM 9-6115-730-24 0082

REMOVAL

1. Refer to WP 0013, SYMPTOM 13 to copy the configuration data from the old ECM.

2. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF/RESET, Battery Disconnect Switch is
OFF, and DEAD CRANK SWITCH is OFF before proceeding.

3. Open left front door and left rear doors.

NOTE
Cut tiedown straps as required.

4. Tag and disconnect engine harness connector J2/ENG-P2 (Figure 1, Item 1) and vehicle harness connector
J1/ENG-P1 (Figure 1, Item 2) from engine control module (Figure 1, Item 3).

5. Remove two nuts (Figure 1, Item 4), two washers (Figure 1, Item 5), plate (Figure 1, Item 6), three stud bolts
(Figure 1, Item 7), three washers (Figure 1, Item 8), three washers (Figure 1, Item 9), three mounts (Figure 1,
Item 10), and three spacers (Figure 1, Item 11).

6. Remove bolt (Figure 1, Item 12), washer (Figure 1, Item 13), clip (Figure 1, Item 14), washer (Figure 1, Item 9),
mount (Figure 1, Item 10), spacer (Figure 1, Item 11), and engine control module (Figure 1, Item 3).

7. Remove nut (Figure 1, Item 15), washer (Figure 1, Item 16), strap (Figure 1, Item 17), and clip (Figure 1,
Item 18).

END OF TASK

INSTALLATION

1. Install clip (Figure 1, Item 18), strap (Figure 1, Item 17), washer (Figure 1, Item 16), and nut (Figure 1,
Item 15) on plate (Figure 1, Item 6).

2. Install engine control module (Figure 1, Item 3), spacer (Figure 1, Item 11), mount (Figure 1, Item 10), washer
(Figure 1, Item 9), clip (Figure 1, Item 14), washer (Figure 1, Item 13), and bolt (Figure 1, Item 12).

3. Install three spacers (Figure 1, Item 11), three mounts (Figure 1, Item 10), three washers (Figure 1, Item 9),
three washers (Figure 1, Item 8), three studbolts (Figure 1, Item 7), plate (Figure 1, Item 6), two washers
(Figure 1, Item 5), and two nuts (Figure 1, Item 4).

4. Install vehicle harness connector J1/ENG-P1 (Figure 1, Item 2) and engine harness connector J2/ENG-P2
(Figure 1, Item 1). Torque allen head screws on J1/ENG-P1 and J2/ENG-P2 ECM connectors to 55 +13.0 -
4.0 lb. in. (6.0 +1.5 -0.5 Nm)

5. Close left rear doors and left front door.

6. Refer to WP 0013, SYMPTOM 9 to flash program the flash file into the ECM.

7. Refer to WP 0013, SYMPTOM 13 to copy the configuration data into the ECM.

8. Refer to WP 0013, SYMPTOM 8 to calibrate the engine timing sensors.

9. Refer to WP 0013 SYMPTOM 12 to load the injector codes.

0082-2
 TM 9-6115-730-24 0082

INSTALLATION - Continued

Figure 1. Engine Control Module.

END OF TASK

END OF WORK PACKAGE

0082-3/4 blank
 TM 9-6115-730-24 0083

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
REPROGRAMMING

INITIAL SETUP:

Personnel Required Equipment Condition

One TQG is not operating and powered down

References

WP 0014

REPROGRAMMING DVR PARAMETERS FOR VOLTAGE AND FREQUENCY CHANGE

The following procedure is used if the voltage and frequency settings for the generator set must be changed
because of mission requirements. When that occurs, the reconnection board must be repositioned (WP 0014) and
the DVR must be reprogrammed for specified frequency and voltage.

1. Set Battery Disconnect Switch to ON.

2. Set DEAD CRANK SWITCH to NORMAL.

3. On EMCP, set ENGINE CONTROL switch to COOL DOWN/STOP.

4. Select reprogramming data from Table 1 below according to the desired output voltage and desired
frequency. Mission requirements will define requirements. Note: All 6 of the DVR PARAMETERS

Table 1. 200 kW TQG DVR Voltage and Frequency Programming Parameters and Setpoints.

DESIRED OUTPUT DVR PARAMETER NUMBER

VOLTS HERTZ :01 :02 :03 :04 :05 :06

120/208 60 217 1.0 0 694 4.34 58.8

120/208 50 205 1.0 0 578 3.61 49.8

240/416 60 434 2.0 0 347 4.34 58.8

240/416 50 410 2.0 0 289 3.61 49.8

0083-1 Change 1
 TM 9-6115-730-24 008 3

REPROGRAMMING DVR PARAMETERS FOR VOLTAGE AND FREQUENCY CHANGE - Continued

5. Press the up arrow key . DVR display should read :01 (the colon with the number indicates that the
number is a parameter number).

6. Press and hold up arrow key until display shows parameter number :90. Parameter number “90 is a
password that can be used to protect the settings.

7. Press Function key on DVR once to display data for parameter :90.

8. Press and hold up arrow key or down arrow key to set the data for parameter number :90 to 0200.

9. Press Function key on DVR once to display parameter :90.

10. Press and hold up arrow key or down arrow key to change to parameter number :01.

11. Press Function key on DVR once to data for parameter.

12. Press and hold up arrow key or down arrow key to set the data for parameter per Table 1.

13. Press Function key on DVR once to switch back to the parameter number.

14. Press up arrow key once to change to next parameter number per Table 1.

15. Keep repeating from step 9, entering parameter data from Table 1, until all 6 parameter data is entered or
verified to be correct.

16. Press Function key on DVR once to display data for parameter :90.

17. Press and hold up arrow key or down arrow key to set the data for parameter number :90 to any
number but 0009 to lock the DVR. DVR will not stay locked when Engine Control switch is switched from
either COOL DOWN/STOP to OFF/RESET and back to COOL DOWN/STOP or from COOL DOWN/STOP to
MANUAL START.

18. Press Function key on DVR once to switch back to parameter number. Press and hold up arrow key
or down arrow to set the parameter number back to 01.

19. Proceed to REPROGRAMMING GSC SETPOINTS FOR VOLTAGE AND FREQUENCY CHANGE and
reprogram the OP5 parameters for P028 thru P031 (steps 1 thru 25).

20. If the generator set is not to be used, set ENGINE CONTROL Switch(ECS) to OFF/RESET, set DEAD CRANK
SWITCH to OFF, and set Battery Disconnect Switch to OFF.

END OF TASK

Change 1 0083-2
 TM 9-6115-730-24 0083

REPROGRAMMING OR VERIFYING DVR PARAMETERS

The following procedure is used to reprogram the DVR if a DVR is replaced or if there is some reason to verify
DVR parameters. Table 2 describes the parameters and lists values to be programmed or verified.

1. Set Battery Disconnect Switch to ON.

2. Set DEAD CRANK SWITCH to NORMAL.

3. On EMCP, set ENGINE CONTROL switch to COOL DOWN/STOP.

4. Select reprogramming data or parameter to be verified from Table 2.

5. DVR display should read :01 (the colon with the number indicates that the number is a parameter number).

6. Press and hold up arrow key until display shows parameter number :90.

7. Press Function key on DVR once to display data for parameter :90

0083-3 Change 1
 TM 9-6115-730-24 0083

REPROGRAMMING OR VERIFYING DVR PARAMETERS - Continued

Table 2. 200 kW TQG DVR Programming Parameters.

TQG SETPOINTS TQG SETPOINTS

240/216 120/206

DESCRIPTION PARAMETER ACTION UNITS 60 Hz 50 Hz 60 Hz 50 Hz

Generator output :01 Program Volts 434 410 217 205

Voltage

Ratio of output volts :02 Program – 2.0 2.0 1.0 1.0

to sensing volts

Generator type :03 Program – 0 0 0 0

Rated Generator :04 Program Ampere 347 289 694 578

Output Current
CT Voltage at Rated :05 Program Volts 4.34 3.61 4.34 3.61
Output Current
Knee Frequency :06 Program Hz 58.8 49.8 58.8 49.8

Decreasing Volts/Hz :07 Program Volts/Hz 3.0 3.0 3.0 3.0

Slope 1
Decreasing Volts/Hz :08 Program Volts/Hz 2.0 2.0 2.0 2.0
Slope 2

Minimum Voltage :09 Program % 50.0 50.0 50.0 50.0

Under Frequency :10 Program Hz 25.0 25.0 25.0 25.0

Point
Overvoltage Trip :11 Program % 125.0 125.0 125.0 125.0
Point
Overvoltage Trip :12 Program Seconds 2 2 2 2
Time
Under Voltage Trip :13 Program % 75 75 75 75
Point
Under Voltage Trip :14 Program Seconds 30 30 30 30
Time

Voltage Gain (IR :15 Program % 0 0 0 0

Compensation)

Change 1 0083-4
 TM 9-6115-730-24 0083

REPROGRAMMING OR VERIFYING DVR PARAMETERS - Continued

Table 2. 200 kW TQG DVR Programming Parameters - Continued.

TQG SETPOINTS TQG SETPOINTS

240/216 120/206

DESCRIPTION PARAMETER ACTION UNITS 60 Hz 50 Hz 60 Hz 50 Hz

Integral Gain :16 Program – 3.0 3.0 3.0 3.0

Proportional Gain :17 Program – 1.0 1.0 1.0 1.0

Single Phase :18 Program – 0000 0000 0000 0000

Sensing 3ph=0
1ph=1

Diode Monitor Trip :19 Program Ampere 2.0 2.0 2.0 2.0
Point

Reverse VAR Trip :20 Program Seconds .5 .5 .5 .5

Time

Reverse VAR Fault :21 Program – 2 2 2 2

Selection

Droop/CCC Select :22 Program – 0 0 0 0

0+D 1=CCC

Droop Percentage :30 Program % 1.8 1.8 1.8 1.8

Reverse Power :34 Program % 20 20 20 20

Trip Point

Reverse Power :35 Program Seconds 7 7 7 7

Trip Time

Frequency :50 View Hz – – – –

Voltage :51 View Volts – – – –

Current :52 View Ampere – – – –

Reactive Output :53 View Ampere – – – –

Current

Generator Real :54 View Ampere – – – –

Current

0083-5 Change 1
 TM 9-6115-730-24 00 83

REPROGRAMMING OR VERIFYING DVR PARAMETERS - Continued

Table 2. 200 kW TQG DVR Programming Parameters - Continued.

TQG SETPOINTS TQG SETPOINTS

240/216 120/206

DESCRIPTION PARAMETER ACTION UNITS 60 Hz 50 Hz 60 Hz 50 Hz

Exciter Field Current :55 View Ampere – – – –

3-phase kW :56 View kW – – – –

Power factor :57 View – – – – –

3-phase kVAR :58 View – – – – –

Hours :60 View Hours – – – –

Password :90 Program – 0009 0009 0009 0009

Software ID :91 View – 1.05 1.05 1.05 1.05

Latest Fault :92 View – – – – –

Previous Fault :93 View – – – – –

Fault Clear :94 Switch – – – – –

Shutdown Fault :96 Switch – – – – –

Reset

8. Press and hold up arrow key or down arrow key to set the data for parameter number :90 to 0009.
DVR will not stay locked when ENGINE CONTROL switch is switched from either COOL DOWN/STOP to
OFF/RESET and back to COOLDOWN/STOP or from COOL DOWN/STOP to MANUAL START.

9. Press Function key on DVR once to display parameter: 90.

10. Press and hold up arrow key or down arrow key to change to parameter number :01.

11. Press Function key on DVR once to display data for parameter.

12. Press and hold up arrow key or down arrow key to set the data for parameter per Table 2.

Change 1 0083-6
 TM 9-6115-730-24 008 3

REPROGRAMMING OR VERIFYING DVR PARAMETERS - Continued

13. Press Function key on DVR once to switch back to the parameter number.

14. Press up arrow key once to change to next parameter number per Table 2.

15. Keep repeating from step 7, entering or viewing parameter data from Table 2, until all parameter data is
entered or verified to be correct.

16. Press Function key on DVR once to display data for parameter :90.

17. Press and hold up arrow key or down arrow key to set the data for parameter number :90 to any
number but 0009 to lock the DVR. DVR will not stay locked when ENGINE CONTROL switch is switched
from either COOL DOWN/STOP to OFF/RESET and back to COOL DOWN/STOP or from COOL
DOWN/STOP to MANUAL START.

18. If the generator set is not to be used, set ENGINE CONTROL switch to OFF/RESET, set DEAD CRANK
SWITCH to OFF, and set Battery Disconnect Switch to OFF.

END OF TASK

REPROGRAMMING GSC SETPOINTS FOR VOLTAGE AND FREQUENCY CHANGE

1. Set Battery Disconnect Switch to ON.

2. Set DEAD CRANK SWITCH to NORMAL.

3. On EMCP, set ENGINE CONTROL Switch (ECS) to COOL DOWN/STOP.

4. Select programming data for GSC from Table 3 for desired output voltage and desired frequency.

Table 3. 200 kW TQG GSC Programming Setpoints.

DESIRED OUTPUT OP5-0 OP5-1

VOLTS HERTZ P028 P029 P030 P031 P114 P117 P120 P123

120/208 60 208 694 200 60 63 66 57 54

120/208 50 208 576 166 50 53 55 48 45

240/416 60 416 347 200 60 63 66 57 54

240/416 50 416 288 166 50 53 55 48 45

0083-7 Change 1
 TM 9-6115-730-24

REPROGRAMMING GSC SETPOINTS FOR VOLTAGE AND FREQUENCY CHANGE - Continued

NOTE
In SERVICE MODE, the buttons on the GSC keypad perform new functions as follows:

POWER METER is Scroll Right

AC METER is Scroll Up
ENGINE METER is Scroll Down
LAMP TEST is Select
ALARM CODES is Enter

5. Press SERVICE MODE key on GSC. SERV will be displayed on upper display. OP1 will be displayed on lower
display.

6. Press AC METER key five times. OP3 will be displayed.

7. Press the LAMP TEST key. P E ---------- will be displayed. The left-most underline will be flashing. If an error
is made any time during the password entry, P E FAIL will be displayed. Password entry can be restarted by
pressing LAMP TEST key.

8. Press POWER METER key. P E 1 _ _ _ _ will be displayed. The left-most underline will be flashing.

9. Press ENGINE METER key. P E 1 3 _ _ _ will be displayed. The left-most underline will be flashing.

10. Press AC METER key. P E 1 3 2 _ _ will be displayed. The left-most underline will be flashing.

11. Press AC ENGINE key. P E 1 3 2 3 _ will be displayed. The underline will be flashing.

12. Press POWER METER key. P E 1 3 2 3 1 will be displayed.

13. Press ALARM CODES key. P E PASS will be displayed.

14. Press EXIT key. OP4 will be displayed.

15. Press AC METER key. OP5 will be displayed.

NOTE
For input values the OP set and the parameter values will toggle between the upper and lower
displays as each OP set is entered.

16. Press AC METER key or ENGINE METER key until OP5-0 is displayed.

17. Press LAMP TEST key. P001 will be displayed followed by the value of the setpoint.

18. Press ENGINE METER key until P028 is displayed (P028 is first setpoint in table).

19. Press LAMP TEST key. The value of the setpoint will begin to flash.

20. Press AC METER key or ENGINE METER key to change the value, as required, to what is shown in Table 3
corresponding to the desired voltage and frequency.

21. Press ALARM CODES key. The value of the setpoint will stop flashing.

Change 1 0083-8
 TM 9-6115-730-24 008 3

REPROGRAMMING GSC SETPOINTS FOR VOLTAGE AND FREQUENCY CHANGE - Continued

22. Repeat steps 18 through 21 until all setpoint values are checked or changed for OP5-0.

23. Repeat steps 16 through 22 for OP5-1. The first setpoint displayed will be P101. The first setpoint to be
changed/verified is P114, per Table 3.

24. At the completion of the programming, press EXIT key until SERV is no longer displayed on upper display.

25. If the generator set is not to be used, set ENGINE CONTROL Switch (ECS) to OFF/RESET, set DEAD CRANK
SWITCH to OFF, and set Battery Disconnect Switch to OFF.

END OF TASK

REPROGRAMMING OR VERIFYING GSC SETPOINTS

The following procedure is used to reprogram the GSC if a GSC is replaced or if there is some reason to verify
GSC setpoints as part of troubleshooting or analysis. Table 4 describes 200 kW OP5-0 Engine/Generator Setpoint
Programming and lists values to be programmed or verified. Table 5 describes OP5-1 Protective Relaying Setpoint
Programming and lists values to be programmed or verified. Table 6 describes OP5-3 Synchronization Setpoint
Programming and lists values to be programmed or verified. Table 7 describes OP6-0 Spare Input/Output Setpoint
Programming. Table 8 describes OP8 data from ATB and BTB transformers in the control panel that must be
entered if either of those devices is replaced.

1. Set Battery Disconnect Switch to ON.

2. Set DEAD CRANK SWITCH to NORMAL.

3. On EMCP, set ENGINE CONTROL switch to COOL DOWN/STOP.

4. Select programming data for GSC from Tables 4 thru 8 for GSC programming to be verified or completed. If
GSC has been replaced, all setpoints must be verified or reprogrammed. Factory default values must be
verified and TQG custom values must be programmed.

NOTE
In SERVICE MODE, the buttons on the GSC keypad perform new functions as follows:

POWER METER is Scroll Right

AC METER is Scroll Up
ENGINE METER is Scroll Down
LAMP TEST is Select
ALARM CODES is Enter

5. Press SERVICE MODE key on GSC. SERV will be displayed on upper display. OP1 will be displayed on
lower display.

6. Press AC METER key five times. OP3 will be displayed.

7. Press the LAMP TEST key. P E ---------- will be displayed. The left-most underline will be flashing. If an error
is made any time during the password entry, P E FAIL will be displayed. Password entry can be restarted by
pressing LAMP TEST key.

8. Press POWER METER key. P E 1 _ _ _ _ will be displayed. The left-most underline will be flashing.

0083-9 Change 1
 TM 9-6115-730-24 00 83

REPROGRAMMING OR VERIFYING GSC SETPOINTS - Continued

9. Press ENGINE METER key. P E 1 3 _ _ _ will be displayed. The left-most underline will be flashing.

10. Press AC METER key. P E 1 3 2 _ _ will be displayed. The left-most underline will be flashing.

11. Press ENGINE METER key. P E 1 3 2 3 _ will be displayed. The underline will be flashing.

12. Press POWER METER key. P E 1 3 2 3 1 will be displayed.

13. Press ALARM CODES key. P E PASS will be displayed.

14. Press EXIT key. OP4 will be displayed.

15. Press AC METER key. OP5 will be displayed.

NOTE
For input values the OP set and the parameter values will toggle between the upper and lower
displays as each OP set is entered.

16. Press AC METER key or ENGINE METER key until OP5-0 is displayed.

17. Press LAMP TEST key. P001 will be displayed followed by the value of the setpoint.

18. Press ENGINE METER key until next setpoint to be verified or changed is displayed.

19. Press LAMP TEST key. The value of the setpoint will begin to flash.

20. Press AC METER key or ENGINE METER key to change the value, as required, to what is shown in Table 4
corresponding to the desired setpoint value.

21. Press ALARM CODES key. The value of the setpoint will stop flashing.

22. Repeat steps 18 through 21 until all setpoint values are checked or changed for OP5-0.

23. Repeat the process in steps 16 through 22 for OP5-1. The first setpoint displayed for OP5-1 will be P101. The
first setpoint to be changed/verified is P101 per Table 5.

24. Repeat the process in steps 16 through 22 for OP5-3. The first setpoint displayed for OP5-3 will be P301. The
first setpoint to be changed/verified is P301, per Table 6.

25. Repeat the process in steps 16 through 22 for OP6-0. The first setpoint displayed for OP6-0 will be SP01. The
first setpoint to be changed/verified is SP01 per Table 7.

26. At the completion of the programming, press EXIT key until SERV is no longer displayed on upper display.

27. If the generator set is not to be used, set ENGINE CONTROL switch to OFF/RESET, set DEAD CRANK
SWITCH to OFF, and set Battery Disconnect Switch to OFF.

Change 1 0083-10
 TM 9-6115-730-24 0083

REPROGRAMMING OR VERIFYING GSC SETPOINTS - Continued

Table 4. 200 kW OP5-0 Engine/Generator Setpoint Programming.

240/416 120/208
FACTORY 60 Hz 60Hz
DESCRIPTION RANGE OF VALUES DEFAULT (50 Hz) 8 (50 Hz)

P001 – Fuel Solenoid Type: 0 – ETR fuel solenoid 0 0 0

Type of fuel system solenoid 1 – ETS fuel solenoid
used on the TQG.

P002 – Units Shown: Type of 0 – for English units (psi, °F) 0 0 0

measurement units shown on 1 – for metric units (kPa, °C)
the GSC display.

P003 – Shutdown Override for 0 – for engine shutdown 0 0 0

Engine Fault: GSC response 1 – for alarm only (shutdown
to a low engine oil pressure or override, no engine shutdown)
high coolant temperature fault.

P004 – Shutdown Override 0 – for alarm only (shutdown 0 0 0

For Sensor Fault: GSC override, no engine shutdown)
response to a diagnostic fault 1 – for engine shutdown
with the engine oil pressure
sensor, coolant temperature
sensor, oil temperature
sensor, sensor power supply,
or coolant loss sensor.

P005 – Coolant Loss Sensor 0 – for TQGs without a coolant 0 1 1

Installed: Tells whether or not loss sensor
the optional engine coolant 1 – for TQGs with coolant loss
loss sensor is installed on the sensor
TQG.

P006 – Shutdown Override for 0 – for engine shutdown 0 1 1

Coolant Loss Fault: GSC 1 – for alarm only (shutdown
response to an engine coolant override, no engine shutdown)
loss fault.

P007 – System Voltage, 24 or 24 or 32 24 24 24

32 Volts: System voltage
(battery voltage) of the TQG.

P008 – This setpoint is not N/A N/A N/A N/A

currently being used by GSC
and cannot be programmed.

____________
8
Setpoints to be changed from factory defaults to 200 TQG setpoints at switch gear supplier.

0083-11 Change 1
 TM 9-6115-730-24 00 83

REPROGRAMMING OR VERIFYING GSC SETPOINTS - Continued

Table 4. 200 kW OP5-0 Engine/Generator Setpoint Programming - Continued.

240/416 120/208
FACTORY 60 Hz 60Hz
DESCRIPTION RANGE OF VALUES DEFAULT (50 Hz) 8 (50 Hz)

P009 – Number of Ring Gear 95 to 350 teeth in increments of 136 113 113
Teeth: Number of teeth on the one tooth.
ring gear of the engine. Used
by GSC to determine engine
speed.

P010 – Engine Overspeed: 500 to 4330 rpm in increments of 2120 rpm 2120 rpm 2120 rpm
Engine speed used by GSC to 10 rpm.
declare that an engine
overspeed fault exists. The
engine overspeed setpoint (for
all 60 Hz applications) is 1.18
times rated speed.

P011 – Crank Terminate 100 to 1000 rpm in increments of 400 rpm 400 rpm 400 rpm
Speed: Engine speed used by 10 rpm.
GSC to disengage starting
motor during engine cranking.

P012 – Oil Step Speed: 400 to 1800 rpm in increments of 1350 rpm 1350 rpm 1350 rpm
Engine speed used by GSC 10 rpm
for distinguishing between
rated speed and idle speed
when a low oil pressure fault
exists.

P013 – Low Oil Pressure 34 to 420 kPa (5 to 61 psi) in 205 kPa 30 psi 30 psi
Shutdown at Rated Speed: Oil increments of 1 (30 psi)
pressure used by GSC to
declare that a low oil pressure
shutdown fault exists with
engine at rated speed (the
engine speed must have
exceeded the oil step speed
for nine seconds). 2

____________
2
When oil pressure drops to within 34 kPa (5 psi) of the P013 or P014 setpoint, GSC issues a low oil pressure
alarm.
8
Setpoints to be changed from factory defaults to 200 TQG setpoints at switch gear supplier.

Change 1 0083-12
 TM 9-6115-730-24 0083

REPROGRAMMING OR VERIFYING GSC SETPOINTS - Continued

Table 4. 200 kW OP5-0 Engine/Generator Setpoint Programming - Continued.

240/416 120/208
FACTORY 60 Hz 60Hz
DESCRIPTION RANGE OF VALUES DEFAULT (50 Hz) 8 (50 Hz)

P014 – Low Oil Pressure 20 to 336 kPa (3 to 49 psi) in 70 kPa 10 psi 10 psi
Shutdown at Idle Speed: Oil increments of 1 (10 psi)
pressure used by GSC to
declare that a low oil pressure
shutdown fault exists with the
engine at idle speed (the
engine must have been
running for at least 9 seconds
and the engine speed must be
less than oil step speed). 2

P015 – High Water 85 to 123°C (185 to 253°F) in 107°C 230°F 230°F

Temperature Shutdown: increments of 1 (225°F)
Coolant temperature used by
GSC to declare a high coolant
temperature shutdown fault
exists (after a 10 second
delay). 3

P016 – Low Water 0 to 36°C (32 to 97°F) in 21°C (70°F) 70°F 70°F
Temperature Alarm: Coolant increments of 1
temperature used by GSC to
declare that a low coolant
temperature alarm fault exists
(after a 2 second delay).

P017 – Total Cycle Crank 5 to 120 seconds in increments 90 sec 90 sec 90 sec
Time: Cycle crank time used of 1 second
by GSC to declare that an
overcrank fault exists.

P018 – Cycle Crank Time: 5 to 60 seconds in increments of 10 sec 30 sec 30 sec

Amount of time GSC cranks 1 second
and then rests the starting
motor during a single crank
cycle.

____________
2
When oil pressure drops to within 34 kPa (5 psi) of the P013 or P014 setpoint, GSC issues a low oil pressure
alarm.
3
When coolant temperature rises to within 6°C (11°F) of the P015 setpoint, GSC issues high coolant
temperature alarm.
8
Setpoints to be changed from factory defaults to 200 TQG setpoints at switch gear supplier.

0083-13 Change 1
 TM 9-6115-730-24 00 83

REPROGRAMMING OR VERIFYING GSC SETPOINTS - Continued

Table 4. 200 kW OP5-0 Engine/Generator Setpoint Programming - Continued.

240/416 120/208
FACTORY 60 Hz 60Hz
DESCRIPTION RANGE OF VALUES DEFAULT (50 Hz) 8 (50 Hz)

P019 – Cooldown Time: 0 to 30 minutes in increments of 5 min 5 min 5 min

Amount of time GSC allows 1 minute.
the engine to run after a
normal shutdown is initiated.

P020 – AC Voltage: Nominal 700, 150, 300, 500, 600, 750, 700 700 700
AC voltage of generator. The 3.0k, 4.5k, 5.20k, 5.25k, 9.0k,
GSC measures and displays 15.0k, 18.0k, 30.0k
the AC voltage. 4

P021 – AC Current Full Scale: 75, 100, 150, 200, 300, 400, 600 800 800
Nominal full scale AC current 600, 800, 1000, 1200, 1500,
of generator. AC current full 2000, 2500, 3000, and 4000A
scale is equal to ratio of
external current transformers
in generator housing.

P022 – GSC Engine Number: 01 through 08 01 01 01

Informs other devices on the
CAT Data Link of the engine
number for GSC. 5

P023 – Engine Type: 0 – MUI diesel 0 2 2

Identifies the engine as a 1 – Gas
mechanical unit injector (MUI) 2 – EIU diesel
diesel, spark ignited (gas), or
electronic unit injector (EUI)
diesel engine.

____________
4
The values other than the default (700V) are for switch gear applications and require the use of external
potential transformers and the removal of the AC voltage range jumper located in the relay module. See the topic
AC Voltage Range Selection in the Testing and Adjusting section.
5
After setpoint P022 is reprogrammed, GSC must be power cycled (powered down and then powered up).
8
Setpoint to be changed from factory defaults to 200 TQG setpoints at switch gear supplier.

Change 1 0083-14
 TM 9-6115-730-24 0083

REPROGRAMMING OR VERIFYING GSC SETPOINTS - Continued

Table 4. 200 kW OP5-0 Engine/Generator Setpoint Programming - Continued.

240/416 120/208
FACTORY 60 Hz 60Hz
DESCRIPTION RANGE OF VALUES DEFAULT (50 Hz) 8 (50 Hz)

P024 – Crank Time Delay: 0 to 20 seconds in increments of 5 sec 5 sec 5 sec

Amount of time GSC delays 1 second
activation of the fuel control
relay (FCR) during a crank
cycle. This setpoint is for gas
engines only. The P024
setpoint only functions when
the P023 setpoint is set to 1
(gas engine). 7

P025 – Oil Temperature 0 – for TQGs without an oil 0 0 0

Sensor Installed: Tells temperature sensor
whether or not the optional 1 – for TQGs with an oil
engine oil temperature sensor temperature sensor
is installed on the TQG.

P026 – High Oil Temperature 85 to 123°C (185 to 253°F) in 107°C 253°F 253°F
Shutdown: Oil temperature increments of 1 (225°F)
used by GSC to declare a high
oil temperature shutdown fault
exists (after a 10 second
delay). Refer to the panel
model number.

P027 – Shutdown Override for 0 – for alarm only (shutdown 0 0 0

High Oil Temperature Fault: override, no engine shutdown)
GSC+ response to an engine 1 – for engine shutdown
high oil temperature fault.

P028 – Nameplate Voltage: 100 to 25kV in increments of 1 480V 416V 208V

Rated voltage of generator. (416V) (208V)
This setpoint is used for
protective relaying functions.

P029 – Nameplate Current: 0 to 4000 A in increments of 1 600A 347A 694A

Rated current output of (288A) (576A)
generator.

____________
7
The P024 setpoint only functions when the P023 setpoints is set to 1 (gas engine).
8
Setpoints to be changed from factory defaults to 200 TQG setpoint at switch gear supplier.

0083-15 Change 1
 TM 9-6115-730-24 00 83

REPROGRAMMING OR VERIFYING GSC SETPOINTS - Continued

Table 4. 200 kW OP5-0 Engine/Generator Setpoint Programming - Continued.

240/416 120/208
FACTORY 60 Hz 60Hz
DESCRIPTION RANGE OF VALUES DEFAULT (50 Hz) 8 (50 Hz)

P030 – Nameplate Power: 0 through 10 MW in increments 400 kW 200 kW 200 kW

Rated power capability of of 1 kW (166 kW) (166 kW)
generator.

P031 – Rated Frequency: 50 or 60 Hz 60 Hz 60 Hz 60 Hz

Nominal frequency rating of (50 Hz) (50 Hz)
TQG.

P032 – Connection 0 – Wye 0 0 0

Configuration of Generator: 1 – Delta
Wye or Delta configuration of
generator.

P033 – Number of Generator 0 through 254 in increments of 2 4 4 4

Poles. 6

1
The setpoints (stored or being programmed) must match the specified setpoints of the TQG.
6
When P033 is programmed to 0 poles, the AL15 (GSC Configuration Error) fault is disabled.
8
Setpoints to be changed from factory defaults to 200 TQG setpoints at switch gear supplier.

Table 5. OP5-1 Protective Relaying Setpoint Programming.

FACTORY SETPOINTS
DESCRIPTION RANGE OF VALUES DEFAULT 60 Hz (50 Hz) 3

P101 Generator Overvoltage Alarm 0 – disabled 1 1

Enable: GSC enables or disables 1 – enabled
generator overvoltage alarm function.

P102 – Generator Overvoltage Alarm 100 to 125% of nameplate 105% 125%

Threshold: Voltage GSC uses to issue voltage in increments of 1%
overvoltage alarm.

P103 – Generator Overvoltage Alarm 0 through 120 seconds 2 in 10 sec 0 sec

Time Delay: Amount of time the FSC+ increments of 1
waits before issuing overvoltage alarm.

____________
2
When programmed to 0 seconds, the actual time is from 0.5 to 1.0 seconds.
3
Setpoints to be changed from factory defaults to 200 TQG setpoints at switch gear supplier.
4
Setpoint values for disabled parameters are for fail safe/pack purposes.

Change 1 0083-16
 TM 9-6115-730-24 0083

REPROGRAMMING OR VERIFYING GSC SETPOINTS - Continued

Table 5. OP5-1 Protective Relaying Setpoint Programming - Continued.

FACTORY SETPOINTS
DESCRIPTION RANGE OF VALUES DEFAULT 60 Hz (50 Hz) 3

P104 – Generator Overvoltage 0 – disabled 1 1

Shutdown Enable: GSC enables or 1 – enabled
disables the generator overvoltage
shutdown function.

P105 – Generator Overvoltage 100 to 125% of nameplate 110% 125%

Shutdown Threshold: Voltage GSC voltage in increments of 1%
used to issue an overvoltage shutdown.

P106 – Generator Overvoltage 0 through 120 seconds 2 in 10 sec 1 sec

Shutdown Time Delay: Amount of time increments of 1
GSC waits before issuing an overvoltage
shutdown.

P107 – Generator Undervoltage Alarm 0 – disabled 1 1

Enable: GSC enables or disables the 1 – enabled
generator undervoltage alarm function.

P108 – Generator Undervoltage Alarm 60 to 100% of nameplate 90% 82%

Threshold: Voltage GSC uses to issue voltage in increments of 1%
an undervoltage alarm.

P109 – Generator Undervoltage Alarm 0 through 120 seconds 2 in 10 sec 6 sec

Time Delay: Amount of time GSC waits increments of 1
before issuing an undervoltage alarm.

P110 – Generator Undervoltage 0 – disabled 1 0

Shutdown Enable: GSC enables or 1 – enabled
disables the generator undervoltage
shutdown function.

P111 – Generator Undervoltage 60 to 100% of nameplate 85% 75%

Shutdown Threshold: Voltage GSC uses voltage in increments of 1%
to issue an undervoltage shutdown.

P112 – Generator Undervoltage 0 through 120 seconds 2 in 15 sec 6 sec

Shutdown Time Delay: Amount of time increments of 1
GSC waits before issuing an
undervoltage shutdown.

____________
2
When programmed to 0 seconds, the actual time is from 0.5 to 1.0 seconds.
3
Setpoints to be changed from factory defaults to 200 TQG setpoints at switch gear supplier.

0083-17 Change 1
 TM 9-6115-730-24 00 83

REPROGRAMMING OR VERIFYING GSC SETPOINTS - Continued

Table 5. OP5-1 Protective Relaying Setpoint Programming - Continued.

FACTORY SETPOINTS
DESCRIPTION RANGE OF VALUES DEFAULT 60 Hz (50 Hz) 3

P113 – Generator Overfrequency Alarm 0 – disabled 1 1

Enable: GSC enables or disables the 1 – enabled
generator overfrequency alarm function.

P114 – Generator Overfrequency Alarm 50-60 Hz, for 50 Hz 53 Hz 63 Hz/53 Hz

Threshold: Frequency GSC uses to generator
issue an overfrequency alarm. 60-70 Hz, for 60 Hz 63 Hz
generator
400-480 Hz, for 400 Hz 422 Hz
generator

P115 – Generator Overfrequency Alarm 0 through 120 seconds 2 in 10 sec 10 sec

Time Delay: Amount of Time GSC waits increments of 1
before issuing an overfrequency alarm.

P116 – Generator Overfrequency 0 – disabled 1 0

Shutdown Enable: GSC enables or 1 – enabled
disables the generator overfrequency
shutdown function.

P117 – Generator Overfrequency 50-60 Hz, for 50 Hz 55 Hz 66 Hz/55 Hz

Shutdown Threshold: Frequency GSC generator
uses to issue an overfrequency 60-70 Hz, for 60 Hz 66 Hz
shutdown. generator
400-480 Hz, for 400 Hz 440 Hz
generator

P118 – Generator Overfrequency 0 through 120 seconds 2 in 10 sec 10 sec

Shutdown Time Delay: Amount of time increments of 1
GSC waits before issuing an
overfrequency shutdown.

P119 – Generator Underfrequency Alarm 0 – disabled 1 1

Enable: GSC enables or disables the 1 – enabled
generator underfrequency alarm
function.

____________
2
When programmed to 0 seconds, the actual time is from 0.5 to 1.0 seconds.
3
Setpoints to be changed from factory defaults to 200 TQG setpoints at switch gear supplier.

Change 1 0083-18
 TM 9-6115-730-24 0083

REPROGRAMMING OR VERIFYING GSC SETPOINTS - Continued

Table 5. OP5-1 Protective Relaying Setpoint Programming - Continued.

FACTORY SETPOINTS
DESCRIPTION RANGE OF VALUES DEFAULT 60 Hz (50 Hz) 3

P120 – Generator Underfrequency Alarm 30-50 Hz, for 50 Hz 48 Hz 57 Hz/48 Hz

Threshold: Frequency GSC uses to generator
issue an underfrequency alarm. 36-60 Hz, for 60 Hz 57 Hz
generator
240-400 Hz, for 400 Hz 378 Hz
generator

P121 – Generator Underfrequency Alarm 0 through 120 seconds 2 in 10 sec 10 sec

Time Delay: Amount of time GSC waits increments of 1
before issuing an underfrequency alarm.

P122 – Generator Underfrequency 0 – disabled 1 0

Shutdown Enable: GSC enables or 1 – enabled
disables the generator underfrequency
shutdown function.

P123 – Generator Underfrequency 30-50 Hz, for 50 Hz 45 Hz 54 Hz/45 Hz

Shutdown Threshold: Frequency GSC generator
uses to issue an underfrequency 36-60 Hz, for 60 Hz 54 Hz
shutdown. generator
240-400 Hz, for 400 Hz 360 Hz
generator

P124 – Generator Underfrequency 0 through 120 seconds 2 in 15 sec 15 sec

Shutdown Time Delay: Amount of time increments of 1
GSC waits before issuing an
underfrequency shutdown.

P125 – Generator Reverse Power 0 – disabled 1 1

Shutdown Enable: GSC enables or 1 – enabled
disables the generator reverse power
shutdown function.

P126 – Generator Reverse Power 0 through 20% of rated 15% 17%

Shutdown Threshold: Level of reverse power in increments of 1%
power GSC uses to issue a reverse
power shutdown.

____________
2
When programmed to 0 seconds, the actual time is from 0.5 to 1.0 seconds.
3
Setpoints to be changed from factory defaults to 200 TQG setpoints at switch gear supplier.

0083-19 Change 1
 TM 9-6115-730-24 00 83

REPROGRAMMING OR VERIFYING GSC SETPOINTS - Continued

Table 5. OP5-1 Protective Relaying Setpoint Programming - Continued.

FACTORY SETPOINTS
DESCRIPTION RANGE OF VALUES DEFAULT 60 Hz (50 Hz) 3

P127 – Generator Reverse Power 0 through 30 seconds 2 in 10 sec 3 sec

Shutdown Time Delay: Amount of time increments of 1
the FSC+ waits before issuing a reverse
power shutdown.

P128 – Generator Overcurrent Alarm 0 – disabled 1 1

Enable: GSC enables or disables the 1 – enabled
overcurrent alarm.

P129 – Generator Phase Overcurrent 100 through 160% of 105% 160%

Alarm Threshold: Level of current GSC nameplate current in
uses to issue a phase overcurrent alarm. increments of 5%

P130 – Generator Phase Overcurrent 0 through 250 seconds 2 in 0 sec 0 sec

Alarm Time Delay: Amount of time GSC increments of 1
waits before issuing a phase overcurrent
alarm.

P131 – Generator Total Overcurrent 100 through 160% of 105% 160%

Alarm Threshold: Level of current GSC nameplate current in
uses to issue a total overcurrent alarm. increments of 5%

P132 – Generator Total Overcurrent 0 through 250 seconds 2 in 0 sec 0 sec

Alarm Time Delay: Amount of time GSC increments of 1
waits before issuing a total overcurrent
alarm.

P133 – Generator Overcurrent Shutdown 0 – disabled 1 0

Enable: GSC enables or disables the 1 – enabled
overcurrent shutdown.

P134 – Generator Phase Overcurrent 100 through 160% in 110% 160%

Shutdown Threshold: Level of current increments of 5%
GSC uses to issue a phase overcurrent
shutdown.

P135 – Generator Phase Overcurrent 0 through 500 seconds 2 in 0 sec 0 sec

Shutdown Time Delay: Amount of time increments of 1
GSC waits before issuing a phase
overcurrent shutdown.

____________
2
When programmed to 0 seconds, the actual time is from 0.5 to 1.0 seconds.
3
Setpoints to be changed from factory defaults to 200 TQG setpoints at switch gear supplier.

Change 1 0083-20
 TM 9-6115-730-24 0083

REPROGRAMMING OR VERIFYING GSC SETPOINTS - Continued

Table 5. OP5-1 Protective Relaying Setpoint Programming - Continued.

FACTORY SETPOINTS
DESCRIPTION RANGE OF VALUES DEFAULT 60 Hz (50 Hz) 3

P136 – Generator Total Overcurrent 100 through 160% of three 110% 160%
Shutdown Threshold: Level of current times nameplate current in
GSC uses to issue a total overcurrent increments of 5%
shutdown.

P137 – Generator Total Overcurrent 0 through 500 seconds 2 in 0 sec 0 sec

Shutdown Time Delay: Amount of time increments of 1
GSC waits before issuing a total
overcurrent shutdown.

P138 – KW Level Relay Enable: GSC 0 – disabled 1 1

enables or disables the kW level relay 1 – enabled
function.

P139 – KW Level Relay Threshold: 0 through 110% of 105% 110%

Level of power GSC uses to activate the nameplate power in
kW level relay function. increments of 1%

P140 – KW Level Relay Time Delay: 0 through 120 seconds 2 in 0 sec 0 sec
Amount of time GSC waits before increments of 1
activating the kW level relay function.

P141 – KW Level Relay Disengage 0 through 110% of 100% 100%

Threshold: Level of power GSC uses to nameplate power in
deactivate the kW level relay function. increments of 1%

P142 – KW Level Relay Disengage Time 0 through 120 seconds 2 in 10 sec 10 sec
Delay: Amount of time GSC waits before increments of 1
deactivating the kW level relay function.

1
Setpoints are programmed at the factory to default value. Some setpoints changed to satisfy application
requirements.
2
When programmed to 0 seconds, the actual time is from 0.5 to 1.0 seconds.
3
Setpoints to be changed from factory defaults to 200 TQG setpoints at switch gear supplier.

0083-21 Change 1
 TM 9-6115-730-24 00 83

REPROGRAMMING OR VERIFYING GSC SETPOINTS - Continued

Table 6. OP5-3 Synchronization Setpoint Programming.

FACTORY
DESCRIPTION RANGE OF VALUES DEFAULT SETPOINTS

P301 – Synchronization Enable: 0 – disabled 0 1

Enables or disables synchronization 1 – Woodward
function and specifies Load Share
control being driven.

P302 – Breaker Coil Time Limit: 0.2 to 5.0 seconds in 1.0 sec 1
Maximum amount of time breaker coil increments of 0.1 seconds
can be energized without damaging coil.

P303 – Voltage Limit Enable: Enables or 0 – disabled 1 1

disables generator-bus voltage checking 1 – enabled
during automatic synchronization.

P304 – Voltage Limit: Maximum 1% to 15% in increments of 1% 4%

acceptable difference between bus 1%
voltage and oncoming voltage,
expressed as a percentage of bus
voltage.

P305 – Phase Tolerance Limit: 1 to 25 degrees in 5 deg 5 deg

Maximum phase angle magnitude increments of 1 degree
allowed for breaker closure. 2

P306 – Dwell Time: Time during which 0.1 to 1.0 seconds in 0.5 sec 0.5 sec
the phase angle between generator and increments of 0.1 second
bus must be within Phase Tolerance
Limit for breaker closure. 2

P307 – Speed Control Gain: Controls 0.0% to 100.0% in 50.0% % varies typical
how fast engine speed will change increments of 0.1% 12%
during synchronization. 2 3

____________
2
P305, P306, P307, P308, and P309 can be adjusted to precisely match individual engine response and
breaker closure characteristics using OP11-Synchronization Setpoint Turning.
3
GSC used P-1-D (proportional-integral-derivation) control to accomplish synchronization quickly and
smoothly. The P, 1, and D parameters are independently controlled by setpoints P307, P308, and P309,
respectively. Adjusting any one of these setpoints will not affect the other two settings.

Change 1 0083-22
 TM 9-6115-730-24 0083

REPROGRAMMING OR VERIFYING GSC SETPOINTS - Continued

Table 6. OP5-3 Synchronization Setpoint Programming - Continued.

FACTORY
DESCRIPTION RANGE OF VALUES DEFAULT SETPOINTS

P308 – Speed Control Rate: Controls 0.0% to 100.0% in 50.0% % varies typical
rate of change of the phase angle increments of 0.1% 17%
difference between the generator and
bus during synchronization. 2 3

P309 – Speed Control Damping: 0.0% to 100.0% in 0.0% % varies typical

Controls rate of change of the phase increments of 0.1% 8%
angle difference between the generator
and bus during synchronization. 2 3

P310 – Dead Bus Closure Enabled: 0 – disabled 0 1

Enables or disables automatic closure to 1 – enabled
a dead bus.

P311 – Dead Bus Limit: Maximum 5% to 50% in increments of 20% 20%

acceptable voltage for bus to be 1%
considered dead as a percentage of
rated voltage.

P312 – Dead Bus On Time Delay: 0 to 120 seconds in 0 sec 2 sec

Amount of time GSC waits before closing increments of 1 second
to a dead bus.

P313 – Frequency Match Notification 5 to 1000 seconds in 20 sec 20 sec

Time: Amount of time before notification increments of 1 second
of possible synchronization failure. Must
not be greater than the Maximum
Synchronization Time.

P314 – Maximum Synchronization Time: 5 to 1000 seconds in 20 sec 30 sec

Maximum amount of time to spend increments of 1 second
attempting to synchronize before setting
Synchronization Timeout Alarm.

1
Setpoints are programmed at the factory to the default value. Setpoints changed to satisfy application
requirements.
2
P305, P306, P307, P308, and P309 ca be adjusted to precisely match individual engine response and
breaker closure characteristics using OP11-Synchronization Setpoint Turning.
3
GSC used P-1-D (proportional-integral-derivation) control to accomplish synchronization quickly and
smoothly. The P, 1, and D parameters are independently controlled by setpoints P307, P308, and P309,
respectively. Adjusting any one of these setpoints will not affect the other two settings.
4
Setpoints to be changed from factory defaults to 200 TQG setpoints at switch gear supplier.

0083-23 Change 1
 TM 9-6115-730-24 00 83

REPROGRAMMING OR VERIFYING GSC SETPOINTS - Continued

Table 7. OP6 Spare Input/Output Setpoint Programming.

FACTORY
DESCRIPTION RANGE OF VALUES DEFAULT SETPOINTS

SP01 – Spare Input 1 Active State: Input 0 – Active low 0 0

state used by GSC to declare that SP01 1 – Active high
fault exists.

SP02 – Spare Input 1 Response: GSC 0 – Shutdown 0 0

response to SP01 fault. 1 – Alarm

SP03 – Spare Input 1 Time Delay: 0 to 250 seconds in 1 seconds 1 seconds

Amount of time GSC waits before increments of 1
responding to a SP01 fault.

SP04 – Spare Input 2 Active State: Input 0 – Active low 1 1

stated used by GSC to declare that 1 – Active high
SP02 fault exists.

SP05 – Spare Input 2 Response: GSC 0 – Shutdown 0 0

response to SP02 fault. 1 – Alarm

SP06 – Spare Input 2 Time Delay: 0 to 250 seconds in 0 seconds 0 seconds

Amount of time GSC waits before increments of 1
responding to SP02 fault.

SP07 – Spare Input 3 Active State: Input 0 – Active low 0 0

state used by GSC to declare that SP03 1 – Active high
fault exists.

SP08 – Spare Input 3 Response: GSC 0 – Shutdown 0 0

response to SP03 fault. 1 – Alarm

SP09 – Spare Input 3 Time Delay: 0 to 250 seconds in 0 seconds 0 seconds

Amount of time GSC waits before increments of 1
responding to SP03 fault.

SP10 – Spare Input 4 Active State: Input 0 – Active low 0 0

state used by GSC to declare that SP04 1 – Active high
fault exists.

SP11 – Spare Input 4 Response: GSC 0 – Shutdown 0 0

response to SP04 fault. 1 – Alarm

Change 1 0083-24
 TM 9-6115-730-24 0083

REPROGRAMMING OR VERIFYING GSC SETPOINTS - Continued

Table 7. OP6 Spare Input/Output Setpoint Programming - Continued.

FACTORY
DESCRIPTION RANGE OF VALUES DEFAULT SETPOINTS

SP12 – Spare Input 4 Time Delay: 0 to 250 seconds in 0 seconds 0 seconds

Amount of time GSC waits before increments of 1
responding to SP04 fault.

SP13 – Spare Output Response: GSC 0 – Active low 0 0

response to the spare output trigger 1 – Active high
condition.

SP15 – Spare Relay Output Response: 0 – Relay inactive when 1 1

GSC response to the spare relay trigger triggered
condition. 1 – Relay active when
triggered

SP14 – Spare Output Trigger Condition: 0 – Unused 8 8

The condition used by GSC to trigger the 1 – Active SP01 fault 2
spare output trigger response. 2 – Active SP02 fault 2
3 – Active SP03 fault 2
4 – Active SP04 fault 2
5 – Any combination
of active SP01,
SP02, SP03, or
SP04 faults 2
6 – Any active shutdown
fault (AL1 thru AL14,
SP01 – SP04, or
SP16 – Spare Relay Output Trigger CID FMI) 8 12
Condition: The condition used by GSC 7 – Any active alarm
to trigger the spare relay. or shutdown fault

(AL1 thru AL15, SP01 thru

SP04, or CID FMI)

8 – Cooldown mode
2
9 – Coolant loss fault
10 – High oil temperature
fault 2
11 – CCM control 2
12 – Other protective relay

____________
2
Either alarm or shutdown faults are valid trigger conditions.

0083-25 Change 1
 TM 9-6115-730-24 00 83

REPROGRAMMING OR VERIFYING GSC SETPOINTS - Continued

Table 7. OP6 Spare Input/Output Setpoint Programming - Continued.

FACTORY
DESCRIPTION RANGE OF VALUES DEFAULT SETPOINTS

SP17 – Spare Indicator 1 Trigger 0 – Unused 0 0

Condition: The condition used by GSC 1 – Active SP01 fault 3
to trigger Spare Indicator 1. 2 – Active SP02 fault 3
3 – Active SP03 fault 3
SP18 – Spare Indicator 2 Trigger 4 – Active SP04 fault 3 0 0
Condition: The condition used by GSC 5 – Any combination
to trigger Spare Indicator 2. of active SP01,
SP02, SP03, or
SP19 – Spare Indicator 3 Trigger SP04 faults 3 0 0
Indicator: The condition used by GSC to 6 – Coolant loss fault 3
trigger Spare Indicator 3. 7 – High oil temperature
fault 3
8 – kW level relay active

1
The setpoints are programmed at the factory to the default value. The setpoints may be changed to satisfy
customer requirements or application requirements.
3
SP14 is programmed to 11 (CCM control), the spare output is always active low. When SP16 is programmed
to 11 (CCM control), the spare relay is always active when triggered.

Change 1 0083-26
 TM 9-6115-730-24 0083

REPROGRAMMING OR VERIFYING GSC SETPOINTS - Continued

Table 8. OP8 Voltmeter Ammeter Programming.

RANGE OF FACTORY
SETPOINT NAME DESCRIPTION VALUES DEFAULT SETPOINT

AC01 VA Phase A voltage calibration 0 to 255 in 0 Barcode on ATB

used by GSC to compensate increments of 1 A5
for voltage characteristics of
ATB A5.

AC02 VB Phase B voltage calibration 0 to 255 in 0 Barcode on ATB

used by GSC to compensate increments of 1 A5
for voltage characteristics of
ATB A5.

AC03 VC Phase C voltage calibration 0 to 255 in 0 Barcode on ATB

used by GSC to compensate increments of 1 A5
for voltage characteristics of
ATB A5.

AC04 IA Phase A current calibration 0 to 255 in 0 Barcode on ATB

used by GSC to compensate increments of 1 A5
for current characteristics of
ATB A5.

AC05 IB Phase B current calibration 0 to 255 in 0 Barcode on ATB

used by GSC to compensate increments of 1 A5
for current characteristics of
ATB A5.

AC06 IC Phase C current calibration 0 to 255 in 0 Barcode on ATB

used by GSC to compensate increments of 1 A5
for current characteristics of
ATB A5.

AC07 VA Phase A voltage calibration 0 to 255 in 0 Barcode on BTB

used by GSC to compensate increments of 1 A6
for voltage characteristics of
BTB A6.

END OF TASK

END OF WORK PACKAGE

0083-27/28 blank Change 1

 TM 9-6115-730-24 0084

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
INSTALLATION OF GENERATOR SET ON TRAILER

INITIAL SETUP:

Tools and Special Tools Personnel Required

Lifting Device, 10,000 lb (4535 kg) capacity Two

Shop Equipment, Automotive Maintenance,
Common No. 1 (WP 0123, Item 2) References
Tool Kit, General Mechanic’s (WP 0123, Item 1)
TM 9-2330-376-14&P
TM 9-6115-730-24P

WARNING
The 200 Kw TQG weighs approximately 9300 lb (4218 kg) and requires an assistant and a lifting
device (forklift, overhead lifting device) with sufficient capacity. Failure to comply can cause
serious injury or death to personnel.

Be extremely careful when working near the 200 kW TQG as it is being positioned on the trailer.
Failure to comply can cause injury to personnel.

INSTALLATION

1. Park XM1051 E1 trailer (Figure 1, Item 1) on level hard surface. Lower support legs (see TM 9-2330-376-
14&P). Level trailer and chock wheels.

2. Using lifting device with sufficient capacity, maneuver TQG (Figure 1, Item 2), with control panel end toward
tongue of trailer, into position over mounting holes on bed of trailer (Figure 1, Item 1).

3. Slowly lower TQG (Figure 1, Item 2) onto trailer (Figure 1, Item 1) and align with eight mounting holes.

4. Remove lifting device.

NOTE
All TQG-mounting screws are installed with nuts on top of bed of trailer, except at location A, at
right rear of trailer.

5. Install eight screws (Figure 1, Item 3), 16 washers (Figure 1, Item 4), and eight nuts (Figure 1, Item 5). Torque
eight nuts (Figure 1, Item 5) to 125 lb-ft (170 Nm).

0084-1
 TM 9-6115-730-24 0084

INSTALLATION - Continued

Figure 1. Installation of Generator Set on Trailer.

0084-2
 TM 9-6115-730-24 0084

INSTALLATION - Continued

6. Install two fire extinguisher brackets (Figure 1, Item 6), eight screws (Figure 1, Item 7), washers (Figure 1,
Item 8), and locknuts (Figure 1, Item 9).

7. Install accessory box (Figure 1, Item 10), four screws (Figure 1, Item 7), washers (Figure 1, Item 8), and
locknuts (Figure 1, Item 9).

8. Install load terminal (Figure 1, Item 11), washer (Figure 1, Item 12), and locknut (Figure 1, Item 13).

9. Install grommet (Figure 1, Item 14) in deck.

END OF TASK

END OF WORK PACKAGE

0084-3/4 blank
 TM 9-6115-730-24 0085

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
PREPARATION FOR STORAGE OR SHIPMENT

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, One

Common No. 1 (WP 0123, Item 2)
Tool Kit, General Mechanic’s (WP 0123, Item 1) References
Pneumatic Oil Gun
TM 9-6115-730-10
Materials/Parts TM 740-90-1
TO 35-1-4
Antifreeze (WP 0124, Item 5) MIL-STD-129
Fuel (WP 0124, Item 17) TM 9-6115-730-24P
Lubricating oil, preservation (WP 0124, Item 31)
Lubricating oil, preservation (WP 0124, Item 32)
Lubricating oil, general purpose
(WP 0124, Item 33)
Petroleum jelly (WP 0124, Item 34)
Tape (WP 0124, Item 50)
Wiping rags (WP 0124, Item 35)
Wood block, 1 in. (2.54 cm) thick

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the engine.

0085-1
 TM 9-6115-730-24 0085

PREPARATION FOR STORAGE OR SHIPMENT

SHORT TERM STORAGE

NOTE
Short term is storage from 1 to 45 days.

1. Perform Quarterly PMCS (WP 0015). Correct all deficiencies found.

2. Check that Modification Work Order (MWO), Maintenance Instructions (MI) and Time Compliance Technical
Orders (TCTO) have been applied.

3. Top off engine oil level with preservation oil (WP 0079).

4. Drain cooling system completely (WP 0068). Refill cooling system with a 50/50 mixture of antifreeze and water.
Operate engine for a minimum of five minutes to circulate mixture.

END OF TASK

LONG TERM STORAGE

NOTE
Long term is storage longer than 45 days

1. Perform Quarterly PMCS (WP 0015). Correct all deficiencies found.

2. Check that Modification Work Order (MWO), Maintenance Instructions (MI) and Time Compliance Technical
Orders (TCTO) have been applied.

3. Drain cooling system completely (WP 0068). Refill cooling system with 50/50 mixture of antifreeze and water
(WP 0124, Item 5). Operate engine for a minimum of five minutes to circulate the antifreeze. Stop engine and
allow to cool for 10 minutes.

4. Drain engine oil completely (WP 0079). Refill engine with preservation oil (WP 0124, Item 31).

5. Open left front doors.

6. Disconnect fuel pickup hose (Figure 1, Item 1) from fuel tank (Figure 1, Item 2). Disconnect fuel return hose
(Figure 1, Item 3) from elbow (Figure 1, Item 4) on fuel tank (Figure 1, Item 2).

7. Position three containers, with at least a two gallon capacity each, beside the left doors.

8. Place end of fuel return hose (Figure 1, Item 3) into container A (waste container).

9. Fill container B with one gallon fuel (WP 0124, Item 17). Fill container C with one gallon general purpose oil
(WP 0124, Item 32).

10. Place end of fuel pickup hose (Figure 1, Item 1) into container B (fuel).

11. Start engine and run for two minutes using the fuel in container B. After two minutes, place end of fuel pickup
hose (Figure 1, Item 1) into container C (oil). Operate until oil from container C comes out of fuel return line
into container A (waste container). Shut down engine and allow to cool at least 10 minutes.

0085-2
 TM 9-6115-730-24 0085

LONG TERM STORAGE - Continued

Figure 1. Preparation for Storage or Shipment.

12. Reconnect fuel pickup hose (Figure 1, Item 1) to fuel tank (Figure 1, Item 2). Connect fuel return hose (Figure
1, Item 3) to elbow (Figure 1, Item 4) on fuel tank (Figure 1, Item 2). Do not use waste fuel/oil mixture to
preserve other engines or damage may occur.

13. Dispose of fuel/oil mixture in container A (waste) in accordance with local regulations.

0085-3
 TM 9-6115-730-24 0085

LONG TERM STORAGE - Continued

14. Disconnect manifold in hose from intake manifold (WP 0067, Step 16). Set DEAD CRANK SWITCH to
CRANK to turn over engine, use a pneumatic oil gun to spray preservative oil (WP 0126, Item 32) into air inlet
for one minute. Release dead crank switch. Connect manifold in hose.

15. Remove air cleaner cover and both filter elements (WP 0071) Set DEAD CRANK SWITCH to CRANK to turn
over engine, use a pneumatic oil gun to spray preservative oil (WP 0124, Item 32) into air cleaner housing for
30 seconds. Release dead crank switch. Install both filter elements and air cleaner cover.

16. Allow muffler to cool. Use a pneumatic oil gun to spray preservative oil (WP 0124, Item 32) into exhaust outlet
housing for 30 seconds.

17. On left side of TQG, place a suitable container under the fuel drain. Remove cap from fuel drain and open the
fuel drain valve. Completely drain the fuel tank. Close fuel drain valve and install cap to first locking position.

18. Completely drain cooling system (WP 0068).

19. Apply preservative oil (WP 0124, Item 32) to all hinges and latches on the TQG.

20. Disconnect all battery cables from batteries (WP 0050). Secure battery cable terminals away from the
batteries with tape. Apply petroleum jelly to all battery terminals.

21. Close all doors.

22. Prepare tag with the following statements: “CRANKCASE FILLED WITH PRESERVATIVE OIL (MIL-PRF-
21260, GRADE 30). GOOD FOR OPERATION UNTIL FIRST REQUIRED OIL CHANGE.”

23. Prepare tag with the following statements: “COOLING SYSTEM DRAINED. FILL WITH PROPER
ANTIFREEZE MIXTURE BEFORE OPERATION.”

24. Prepare tag with the following statements: “FUEL SYSTEM PRESERVED WITH PRESERVATIVE OIL (MIL-
PRF-21260, GRADE 10W). DRAIN FUEL LINES BEFORE OPERATING. CHANGE FUEL FILTER AFTER
ONE HOUR OF OPERATION.

25. Place all the above tags on the control panel and secure with tape.

26. Secure all doors with tape.

END OF TASK

END OF WORK PACKAGE

0085-4
 TM 9-6115-730-24 0086

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
ILLUSTRATED LIST OF MANUFACTURED ITEMS

INITIAL SETUP:

Not Applicable

INTRODUCTION

Scope

This work package includes complete instructions for making items authorized to be manufactured or fabricated at
the field level maintenance.

How to Use the Index of Manufactured Items

A part number index in alphanumeric order is provided for cross-referencing the part number of the item to be
manufactured to the page which covers fabrication criteria.

Explanation of the Illustrations of Manufactured Items

All instructions needed by maintenance personnel to manufacture the item are included on the illustrations. All bulk
materials needed for manufacture of an item are listed by part number or specification number in a tabular list on
the illustration.

Table 1. Index of Manufactured Items.

ITEM NO. PART NO. NAME PAGE NO.

Not Applicable

END OF WORK PACKAGE

0086-1/2 blank
 TM 9-6115-730-24 0087

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
TORQUE LIMITS

INTRODUCTION

This work package contains the torque standards for specific types and sizes of hardware. It defines the different
types of bolts by grade. Special torque values and sequences are listed in the specific maintenance procedure.

TORQUE TABLES

How To Use Torque Tables 1 and 2

1. Measure diameter of screw being installed (Figure 1).

Figure 1. Measuring Screw.

2. Count number of threads per inch (TPI) or use a pitch grade.

3. Under heading SIZE, look down DIA IN. column until you find diameter of screw being installed. (There will
usually be two lines beginning with same size.)

4. Under heading SIZE, look down TPI column to find numbers of threads per inch that match number of threads
counted in step 2. (Not required for metric screws.)

Figure 2. Capscrew Head Markings.

NOTE
Manufacturer’s marks may vary. Standard is all SAE Grade 5 (3-line). Metric screws are of three
grades: 8.8, 10.9, and 12.9. Grades and manufacturer’s marks appear on the screw head.

5. To find the grade screw being installed, match markings on screw head to correct picture of CAPSCREW
HEAD MARKINGS in Figure 2.

0087-1
 TM 9-6115-730-24 0087

TORQUE TABLES - Continued

Table 1. Standard Dry Torque Limits.

SAE GRADE SAE GRADE SAE GRADE SAE GRADE

SIZE NO. 2 NO. 5 NO. 6 OR 7 NO. 8
DIA IN. TPI DIA MM LB-FT NM LB-FT NM LB-FT NM LB-FT NM

1/4 20 6.35 5 7 8 11 10 14 12 16

1/4 28 6.35 6 9 10 14 12 16 14 19

5/16 18 7.94 11 15 17 23 21 28 25 34

5/16 24 7.94 12 16 19 26 24 33 25 34

3/8 16 9.53 20 27 30 41 40 54 45 61

3/8 24 9.53 23 31 35 47 45 61 50 68

7/16 14 11.11 30 41 50 68 60 81 70 95

7/16 20 35 47 55 75 70 95 90 108

1/2 13 12.70 50 68 75 102 95 129 110 149

1/2 20 55 75 90 122 100 135 120 163

9/16 12 14.29 65 85 110 149 135 183 150 203

9/16 18 75 102 120 163 150 203 170 231

5/8 11 15.88 90 122 150 203 190 258 220 298

5/8 18 100 136 180 244 210 285 240 325

3/4 10 19.05 160 217 260 353 240 434 380 515

3/4 16 180 244 300 407 360 488 420 597

7/8 9 22.23 140 190 400 542 520 705 600 814

7/8 14 155 210 440 597 580 786 660 895

1 8 25.40 220 298 580 786 800 1085 900 1220

1 12 240 325 640 868 860 1166 1000 1350

1-1/8 7 25.58 300 407 800 1085 1120 1519 1280 1736

1-1/8 12 340 461 880 1193 1260 1709 1440 1953

0087-2
 TM 9-6115-730-24 0087

TORQUE TABLES - Continued

Table 1. Standard Dry Torque Limits - Continued.

SAE GRADE SAE GRADE SAE GRADE SAE GRADE

SIZE NO. 2 NO. 5 NO. 6 OR 7 NO. 8
DIA IN. TPI DIA MM LB-FT NM LB-FT NM LB-FT NM LB-FT NM

1-1/4 7 31.75 420 570 1120 1519 1580 2142 1820 2468

1-1/4 12 460 624 1240 1681 1760 2387 2000 2712

1-3/8 6 34.93 560 759 1460 1980 2080 2820 2380 3227

1-3/8 12 640 868 1680 2278 2360 3227 2720 3668

1-1/2 6 38.10 740 1003 1940 2631 2780 3770 3160 4285

1-1/2 12 840 1139 2200 2983 3100 4204 3560 4827

Table 2. Metric Dry Torque Limits.

METRIC GRADE METRIC GRADE METRIC GRADE

SIZE 8.8 10.9 12.9
DIA IN. DIA MM LB-FT NM LB-FT NM LB-FT NM

0.157 4 2 3 3 4 4 5

0.197 5 4 5 6 8 7 9

0.237 6 7 9 10 14 11 15

0.276 7 11 15 16 32 20 27

0.315 8 18 24 25 34 29 39

0.394 10 32 43 47 64 58 79

0.473 12 58 79 83 113 100 136

0.630 16 144 195 196 266 235 319

0.709 18 190 258 269 365 323 438

0.788 20 260 353 366 496 440 597

0087-3
 TM 9-6115-730-24 0087

TORQUE TABLES - Continued

Table 2. Metric Dry Torque Limits - Continued.

METRIC GRADE METRIC GRADE METRIC GRADE

SIZE 8.8 10.9 12.9
DIA IN. DIA MM LB-FT NM LB-FT NM LB-FT NM

0.867 22 368 499 520 705 678 919

0.946 24 470 637 664 900 794 1077

1.064 27 707 959 996 1351 1235 1675

1.182 30 967 1311 1357 1840 1630 2210

END OF WORK PACKAGE

0087-4
 TM 9-6115-730-24 0088

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
WIRE LISTS

INITIAL SETUP:

Tools and Special Tools References

Tool Kit, General Mechanic’s (WP 0123, Item 1) FO-1

FO-2
Personnel Required FO-3
FO-4
One TM 55-1500-323-24

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

Ensure that the engine cannot be started while maintenance is being performed (ENGINE
CONTROL switch set to OFF/RESET; Battery disconnect switch is OFF; DEAD CRANK SWITCH
is OFF).

INTRODUCTION

This work package contains the wire lists for the 200 kW Tactical Quiet Generator Set (TQG). The wire lists are
used in conjunction with the schematic diagrams (Figure FO-1 thru FO-4, located in the back of this manual) during
troubleshooting and repair of the TQG. All wiring information is provided, including wire color, wire gauge, wire type
by part number/specification, and wire splice data. The wire lists are double ended which lists each wire path twice.
The second wire path listing transposes the origin and destination components. Double ending a wire list facilitates
locating a particular wire path by permitting a search for either component as the origin.

0088-1
 TM 9-6115-730-24 0088

INTRODUCTION - Continued

Notes peculiar to each wire list are located on the first page of each wire list.

Location diagrams of the engine sensors and connector diagrams are on the following five pages, ahead of the
wire lists.

This work package contains the following wire lists:

Table 1. Control Panel Wire List

Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List
Table 3. ECM to EMCP Harness Wire List
Table 4. Engine Harness Wire List
Table 5. Engine Harness to Unit Injectors Wire List
Table 6. Winterization Control Panel Wire List
Table 7. Winterization Kit Heater Cable Wire List
Table 8. Winterization Kit Power Cable Wire List

GENERAL WIRING REPAIR PROCEDURES

The following general procedures should be followed as a guide to wiring repair and troubleshooting. Detailed
repair procedures and the use of standard repair tools and methods are found in TM 55-1500-323-24
(TO 1-1A-14/NAVAIR 01-1A-505).

1. Verify that the engine cannot be started while maintenance is being performed (ENGINE CONTROL switch set
to OFF/RESET; Battery disconnect switch is OFF; DEAD CRANK SWITCH is OFF).

2. Tag and identify all wires before removing or disconnecting.

3. Inspect wire labels and replace if missing or damaged.

4. Verify continuity of wires point to point using digital multimeter.

5. Inspect all wires for breaks, nicks, abrasions, and heat damage.

6. Inspect wiring for signs of arcing or electrical damage.

7. Tighten all connectors and check for cracks, signs of electrical damage, or missing pins or sockets.

8. Inspect for loose connections at electrical components and tighten as necessary.

9. Inspect terminal board connections and tighten spade connectors as necessary.

10. Inspect wire harnesses and ensure that wire ties are not broken or removed.

11. Replace wire ties as necessary to prevent wires from chafing or other damage.

0088-2
 TM 9-6115-730-24 0088

HARNESS INSPECTION PROCEDURES

Most electrical problems are caused by poor connections. The following procedure will assist in detecting problems
with connectors and wiring. If a problem is found, correct the condition and verify that the problem is resolved.
Intermittent electrical problems are sometimes resolved by disconnecting and reconnecting connectors. It is very
important to check for diagnostic codes immediately before disconnecting a connector. Also check for diagnostic
codes after reconnecting the connector. If the status of a diagnostic code is changed due to disconnecting and
reconnecting a connector, there are several possible reasons. The likely reasons are loose terminals, improperly
crimped terminals, moisture, corrosion, and inadequate mating of a connection. Follow these guidelines:

1. Always use the correct tools designed for each connector. Never solder the terminals onto the wires.

2. Always use a breakout harness for a voltmeter probe or a test light. Never break the insulation of a wire in
order to access to a circuit for measurements.

3. If a wire is cut, always install a new terminal as part of the repair.

WARNING
The connection or disconnection of any electrical equipment and the disconnection of any
electrical equipment may cause an explosion hazard which may result in injury or death. Do not
connect any electrical equipment or disconnect any electrical equipment in an explosive
atmosphere.

Moisture and Corrosion Inspection

1. Inspect all wiring harnesses. Ensure that the routing of the wiring harness allows the wires to enter the face
of each connector at a perpendicular angle. Otherwise, the wire will deform the seal and will create a path for
the entrance of moisture. Verify that the seals for the wires are sealing properly.

2. Ensure that the sealing plugs are in place. If any of the plugs are missing, replace the plug. Ensure that the
plugs are inserted correctly into the connector.

3. Disconnect the suspect connector and inspect the connector seal. Ensure that the seals are in good
condition. If necessary, replace the connector.

4. Thoroughly inspect the connectors for evidence of moisture.

NOTE
Minor abrasion on connector seals is normal and will not allow the entry of moisture.

5. If moisture or corrosion is evident in the connector, the source of the moisture must be found and repaired. If
the source of the moisture is not repaired, the problem will recur. Simply drying the connector will not fix the
problem. Check the following items for possible moisture entry.

a. Missing or improperly installed seals.

b. Nicks in exposed insulation

c. Improperly mated connectors

0088-3
 TM 9-6115-730-24 0088

HARNESS INSPECTION PROCEDURES - Continued

6. Moisture can also travel to a connector through the inside of a wire. If moisture is found in a connector,
thoroughly check the connector’s harness for damage. Also check other connectors that share the harness
for moisture. Repair the connectors or the wiring, as required. Ensure that all of the seals are properly in
place and that the connectors have been reconnected.

NOTE
The ECM is a sealed unit. If moisture is found in an ECM connector, the ECM is not the source
of the moisture. Do not replace the ECM.

7. If corrosion is evident on the terminals or the connector, use only denatured alcohol to remove the corrosion.
Use a cotton swab or a soft brush to remove the corrosion.

8. If moisture was found in the connectors, run the engine for several minutes and check again for moisture. If
moisture reappears, the moisture is wicking into the connector. Even if the moisture entry path is repaired, it
may be necessary to replace the wires.

Wire Insulation Damage Inspection

1. Carefully inspect each wire for signs of abrasion, of nicks, and of cuts. Inspect the wires for the following
conditions:

a. Exposed conductors

b. Wire rubbing against the engine

c. Wire rubbing against a sharp point

2. Check all wiring harness fasteners and verify that the harness is properly secured. Also check all of the
fasteners and verify that the harness is not compressed. Pull back the harness sleeves in order to check for a
flattened portion of wire. A fastener that has been over-tightened flattens the harness. This damages the
wires that are inside the harness. Repair or replace damaged wires, as required.

Connector Terminal Inspection

Visually inspect each terminal in the connector. Verify that the terminals are not damaged. Verify that the
terminals are properly aligned in the connector and verify that the terminals are properly located in the connector.
Repair the terminals and/or replace the terminals, as required.

Wire Terminal Connection Pull Test

1. Ensure that the locking wedge for the connector is installed properly. Terminals cannot be retained inside the
connector if the locking wedge is not installed properly.

2. Conduct an adequate pull test on each wire. Each terminal and each connector should easily withstand
10 lb (45 N) of tension and each wire should remain in the connector body. This test checks whether the wire
was properly crimped in the terminal and whether the terminal was properly inserted into the connector.
Replace damaged connectors, as required.

0088-4
 TM 9-6115-730-24 0088

HARNESS INSPECTION PROCEDURES - Continued

Terminal Retention into Socket Inspection

Verify that the connector sockets provide good retention for the terminals. Insert a new terminal into each
connector socket one at a time in order to check for a good grip on the terminal by the socket. If a new terminal is
not secure in the connector socket, replace the connector.

Connector Locking Mechanism Inspection

1. Ensure that the connectors lock properly. After locking the connectors, ensure that the two mating connector
sections cannot be pulled apart. Repair the connector or replace the connector, as required.

2. Verify that the latch tab of the connector is properly latched. Also verify that the latch tab of the connector
returns to the locked position. Repair the connector or replace the connector, as required.

Connector Allen Head Screw Inspection

1. Visually inspect the allen head screws on the ECM connectors (Figure 2, Sheet 2).

2. Ensure that the threads on each allen head screw are not damaged.

3. Connect the engine harness connectors to the ECM connectors J1 and J2. Connect P37 to J37.

a. Torque the allen head screw for the ECM harness connectors to 55.0 +13.0 –4.0 lb in. (6.0 +1.5 -0.5 Nm).
If connector cannot be tightened, repair or replace the connector, as required.

b. Torque the allen head screw for the ECM harness connector J37 to 20.0 ±2.0 lb in. (2.25 ± 0.25 Nm). If
connector cannot be tightened, repair or replace the connector, as required.

0088-5
 TM 9-6115-730-24 0088

HARNESS INSPECTION PROCEDURES - Continued

Figure 1. Engine Sensors (Sheet 1 of 2).

0088-6
 TM 9-6115-730-24 0088

HARNESS INSPECTION PROCEDURES - Continued

Figure 1. Engine Sensors (Sheet 2 of 2).

0088-7
 TM 9-6115-730-24 0088

HARNESS INSPECTION PROCEDURES - Continued

Figure 2. Wire Harness Connectors (Sheet 1 of 3).

0088-8
 TM 9-6115-730-24 0088

HARNESS INSPECTION PROCEDURES - Continued

Figure 2. Wire Harness Connectors (Sheet 2 of 3).

0088-9
 TM 9-6115-730-24 0088

HARNESS INSPECTION PROCEDURES - Continued

Figure 2. Wire Harness Connectors (Sheet 3 of 3).

0088-10
 TM 9-6115-730-24 0088

Table 1. Control Panel Wire List.

NOTES

Color Code

0 Black 5 Green
1 Brown 6 Blue
2 Red 7 Violet
3 Orange 8 Gray
4 Yellow 9 White

Abbreviations used in table can be found in FO-1 at the back of this manual or in List of Abbreviations/Acronyms
(WP 0001).

The list below describes End Prep in Table 1:

Code Part Number Nomenclature

1 88-20274-1 Terminal, Spade, 22-18 AWG #6

2 88-20274-5 Terminal, Spade, 16-14 AWG #6
3 88-20274-10 Terminal, Spade, 12-10 AWG #6
4 88-2219-18 Terminal, Ring Tongue, 16-14 AWG 1/4
5 0116-1201-19 Socket, Connector
6 88-21943 Pin
7 0116-1201-17 Plug, Seal
8 0116-1223 Pin, Connector
9 0116-1201-16 Pin, Connector
10 98-19529-02 Contact, Electrical, Female, 18-24 AWG
11 88-20274-11 Terminal, Spade, 16-14 AWG #8
12 88-20274-6 Terminal, Spade, 16-14 AWG #10
13 88-22119-17 Terminal Lug, Ring Tongue 12-10 AWG 1/4
14 88-20274-3 Terminal, Spade, 22-18 AWG #8
15 88-20274-4 Terminal, Spade, 22-18 AWG #10
16 MS25036-102 Terminal Lug
17 - Solder to terminal
18 0116-1207-02 Contact, Electrical, Male

The list below describes Wire Type column in Table 1:

Wire Code Nomenclature Part Number

A Wire, Electric, 14 Ga M22759/16-14-9

B Wire, Electric, 16 Ga M22759/16-16-9
C Wire, Electric, 18 Ga M22759/16-18-9
D Wire, Electric, 10 Ga M22759/16-10-9
E Cable, Shielded 2 Conductor, 18 AWG 0116-1262-01
F Cable, Shielded 3 Conductor, 18 AWG 0116-1262-02

0088-11
 TM 9-6115-730-24 0088

Table 1. Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
A1 B+ 4 A 14 9 TB4 22B 27C14

A1 1 1 C 18 9 AR 1 41E18

A1 2 A 14 9 A1 B (+)

A1 10 2 B 16 9 A1 24 61A16

A1 13 1 C 18 9 TB3 14B 44C18

A1 14 1 C 18 9 J37 26 45A18

A1 18 1 C 18 9 KFF 12 14A18

A1 22 1 C 18 9 GFR 14 43A18

A1 24 2 B 16 9 A1 10 61A16

A1 26 2 B 16 9 TB4 11A 54A16

A1 27 1 C 18 9 TB3 7A 2AL18

A1 28 A 14 9 A1 B (-) -

A1 28 SH9$ 511 GND

SHIELD

A1 28 SH10$ 512 GND

SHIELD

A1 28 SH4$ 504 GND

SHIELD

A1 29 A 14 9 A1 B (+)

A1 38 1 C 18 9 TB4 21A 27F18

A1 38 1 C 18 9 TB4 21A 27F18

A1 39 2 A 14 9 TB4 19B 21Al4

A1 B(-) 4 B 16 9 CB GND 2J16

A1 B(-) 4 B 16 9 CP GND 2K16

A2 1 1 C 18 9 TB4 19B 21H18

A2 4 1 C 18 9 TB3 19A 4A18

0088-12
 TM 9-6115-730-24 0088

Table 1. Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
A2 12 1 C 18 9 AR 13 3A18

A2 7 1 C 18 9 TB3 5A 2AG18

A2 8 1 C 18 9 P51 18 5A18

A2 9 1 C 18 9 P51 5 6A18

A3 B(-) 1 C 18 9 TB3 9A 2AT18

A3 B+ 1 C 18 9 TB4 18A 21L18

A3 F1 2 A 14 9 TB3 22B 99A14

A3 F2 2 A 14 9 TB3 21B 98A14

A3 GND 2 A 14 9 CB GND 2BN14

A3 3 2 E 18 9 P7 24 34A18

A3 5 2 B 16 9 A7 5 116A16

A3 6 2 B 16 9 A7 6 115A16

A3 7 1 E 18 2 SH5 VAR 3 505

A3 20 2 B 16 9 TB4 6B 109D16

A3 22 2 B 16 9 TB4 8B 107D16

A3 24 2 B 16 9 TB4 7B 108D16

A3 26 2 A 14 9 J31 6 135A14

A3 28 2 A 14 9 J31 7 136A14

A3 30 2 A 14 9 J31 5 134A14

A3 45 1 E - - SH5$ Dead

A3 45 1 E 18 9 SH5 VAR 1 505

A4 GND 1 C 18 9 TB3 5A 2AA18

A4 1 1 C 18 9 TB4 8A 107E18

A4 2 1 C 18 9 TB4 7A 108E18

A4 3 1 C 18 9 TB4 6A 109H18

A4 4 2 B 16 9 J31 16 111B16

0088-13
 TM 9-6115-730-24 0088

Table 1. Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
A4 5 2 B 16 9 P51 2 127A16

A4 6 2 B 16 9 J31 15 112B16

A4 7 2 B 16 9 P51 1 128A16

A4 8 2 B 16 9 J31 18 113B16

A4 9 2 B 16 9 P51 12 129A16

A4 10 1 E 18 2 SH1 PAR 10 501

A4 11 1 E 18 9 SH1 PAR 9 501

A4 12 1 E - - SH1$ Dead 501

End

A4 13 1 C 18 9 A7 1 137A18

A4 14 1 C 18 9 J30 32 139A18

A4 15 2 A 14 9 TB4 19A 21C14

A4 16 2 A 14 9 TB3 4A 2T14

A4 19 1 E 18 2 SH8 J37 23 508

A4 20 1 E 18 9 SH8 J37 11 508

A4 21 1 F - - SH6$ Dead 506

End

A4 21 1 E - - SH7$ Dead 507

End

A4 21 1 E - - SH8$ J37 12 508

A4 24 1 E 18 2 SH7 P7 27 507

A4 25 1 E 18 9 SH7 P7 28 507

A4 25 2 B 16 9 TB3 9A 2AW16

A4 26 1 F 18 0 SH6 SSP 3 506

A4 27 1 F 18 9 SH6 SSP 2 506

A4 28 1 F 18 2 SH6 SSP 1 506

A5 F1 14 C 18 9 J31 1 101D18

0088-14
 TM 9-6115-730-24 0088

Table 1. Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
A5 F2 14 C 18 9 J31 3 102D18

A5 F3 14 C 18 9 J31 12 103D18

A5 H21 1 C 18 9 TB4 2A 110G18

A5 TBC 50 2 B 16 9 J31 14 150B16

A5 TBC 51 2 B 16 9 J31 4 151B16

A5 TBC 52 2 B 16 9 J31 9 152B16

A5 TBC 53 2 B 16 9 J31 13 153B16

A5P1 1 9 C 18 9 P7 10 149A18

A5P1 2 9 C 18 9 P7 11 148A18

A5P1 3 9 C 18 9 P7 12 147A18

A5P1 4 9 C 18 9 P7 4 144A18

A5P1 5 9 C 18 9 P7 5 145A18

A5P1 6 9 C 18 9 P7 6 146A18

A5P1 7 9 C 18 9 P7 16 110E18

A5P1 8 9 C 18 9 A6P1 C 110D18

A6 B21 1 C 18 9 TB4 1A 110F18

A6 F1 14 C 18 9 J31 19 121D18

A6 F2 14 C 18 9 DBHI 14 123F18

A6P1 A 9 C 18 9 P7 17 155A18

A6P1 B 9 C 18 9 P7 18 156A18

A6P1 C 9 C 18 9 A5P1 8 110D18

A7 1 1 C 18 9 A4 13 137A18

A7 11 2 A 14 9 J30 9 17B14

A7 12 2 A 14 9 TB4 22A 27B14

A7 2 1 C 18 9 J30 31 138B18

A7 3 1 C 18 9 DBHI 4 122E18
A7 4 1 C 18 9 DBHI 13 154A18

0088-15
 TM 9-6115-730-24 0088

Table 1. Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
A7 5 2 B 16 9 A3 5 116A16

A7 5 2 B 16 9 J30 35 116B16

A7 6 2 B 16 9 A3 6 115A16

A7 6 2 B 16 9 J30 36 115B16

A7 8 1 C 18 9 KFF 8 8 15A18

A7 9 1 C 18 9 TB3 22A 99D18

AFPR 5 1 C 18 9 TB4 20A 21E18

AFPR 8 1 C 18 9 J30 2 10Al8

AFPR 9 1 C 18 9 J30 1 8A18

AFPR 12 1 C 18 9 AFPR 14 11B18

AFPR 13 1 C 18 9 TB3 1B 2U18

AFPR 14 1 C 18 9 AFPR 12 11B18

AFPR 14 1 C 18 9 J30 3 11A18

AFPS 1 1 C 18 9 J30 5 69A18

AFPS 2 1 C 18 9 TB4 18B 21K18

AR 1 1 C 18 9 A1 1 41E18

AR 1 1 C 18 9 TB4 16B 41D18

AR 9 1 C 18 9 P51 8 42A18

AR 13 1 C 18 9 A2 12 3A18

AR 14 1 C 18 9 TB4 20A 21F18

BSS 1 2 C 18 9 TB3 16B 56A18

BSS 2 2 C 18 9 GFR 9 52B18

BSS 4 1 C 18 9 J37 35 73A18

BSS 5 1 C 18 9 TB3 3B 2AS18

0088-16
 TM 9-6115-730-24 0088

Table 1. Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
CB GND 14 A 14 9 A3 GND 2BN14

CB GND 4 B 16 9 Al B(-) 2J16

CB GND 13 D 10 9 TB3 4A 2H10

CCL 1 17 C 18 9 TB4 22B 27D18

CCL 2 17 C 18 9 TB3 12B 68B18

CCL 3 17 C 18 9 TB3 8B 2AX18

CCS 1 2 C 18 9 PSU 2 65A18

CCS 2 2 C 18 9 TB4 15B 49B18

CCS 4 2 C 18 9 TB4 15B 49A18

CCS 5 2 C 18 9 TB3 16B 56B18

CDR 4 2 C 18 9 TB4 11B 54D18

CDR 12 1 C 18 9 KR 14 36A18

CDR 13 1 C 18 9 P7 36 78A18

CDR 14 2 C 18 9 KR 12 54C18

CP GND 11 B 16 9 A1 B(-) 2K16

DBHI 1 1 C 18 9 DBLO 1 58A18

DBHI 2 1 C 18 9 P7 29 29A18

DBHI 4 1 C 18 9 A7 3 122E18

DBHI 4 1 C 18 9 J31 8 122D18

DBHI 9 1 C 18 9 PSU 3 57A18

DBHI 10 1 C 18 9 DBLO 12 59A18

DBHI 12 1 C 18 9 DBLO 13 157A18

DBHI 13 1 C 18 9 A7 4 154A18

DBHI 14 1 C 18 9 A6 F2 123F18

0088-17
 TM 9-6115-730-24 0088

Table 1. Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
DBHI 14 1 C 18 9 DBLO 14 123E18

DBLO 1 1 C 18 9 DBHI 1 58A18

DBLO 4 1 C 18 9 TB3 3B 2Y18

DBLO 9 1 C 18 9 TB3 4B 2Z18

DBLO 12 1 C 18 9 DBHI 10 59A18

DBLO 13 1 C 18 9 DBHI 12 157A18

DBLO 14 1 C 18 9 DBHI 14 123E18

DBLO 14 1 C 18 9 J31 17 123D18

DCA (-) 4 C 18 9 J30 24 24G18

DCA (+) 4 C 18 9 J30 25 25D18

ECS 1 15 C 18 9 TB3 6A 2AJ18

ECS 2 15 C 18 9 P7 39 39A18

ECS 3 15 C 18 9 P7 40 40A18

ECS 4 7 C 18 9 TB3 17B 33B18

ECS 5 15 C 18 9 P7 32 32A18

ECS 6 15 C 18 9 TB4 21B 27H18

ECS 8 15 C 18 9 TB4 16A 41A18

ECS 9 15 C 18 9 TB4 16A 41B18

ECS 10 15 C 18 9 TB4 16B 41C18

End - 505 -

ESPB 1 1 C 18 9 KFF 14 14C18

ESPB 1A 1 C 18 9 TB3 14B 44A18

ESPB 2 1 C 18 9 J30 15 60A18

ESPB 2A 1 C 18 9 TB3 6A 2AH18

0088-18
 TM 9-6115-730-24 0088

Table 1. Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
ESPB 3 1 C 18 9 P7 38 38A18

ESPB 4 1 C 18 9 TB3 7A 2AK18

FLG G 14 C 18 9 TB3 5B 2AB18

FLG I 14 C 18 9 TB4 20B 21D18

FLG S 14 C 18 9 J30 7 80B18

GFR 1 2 C 18 9 P51 10 53A18

GFR 9 2 C 18 9 BSS 2 52B18

GFR 9 2 C 18 9 P51 7 52A18

GFR 13 1 C 18 9 TB3 1B 2V18

GFR 14 1 C 18 9 A1 22 43A18

J101 G 11 C 16 9 TB3 7B 2AV16

J30 1 6 C 18 9 AFPR 9 8A18

J30 2 6 C 18 9 AFPR 8 10Al8

J30 3 6 C 18 9 AFPR 14 11A18

J30 4 6 C 18 9 TB3 19A 4C18

J30 5 6 C 18 9 AFPS 1 69A18

J30 7 6 C 18 9 FLG S 80B18

J30 8 6 B 16 9 TB4 19A 21B16

J30 9 8 A 14 9 A7 11 17B14

J30 10 6 B 16 9 TB4 6A 109C16

J30 12 6 C 18 9 TB3 12A 68C18

J30 13 6 B 16 9 TB4 21A 27J16

J30 14 6 C 18 9 TB4 10A 76B18

J30 15 6 C 18 9 ESPB 2 60A18

0088-19
 TM 9-6115-730-24 0088

Table 1. Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
J30 16 8 A 14 9 TB4 5A 109F14

J30 17 8 A 14 9 TB4 1A 110M14

J30 18 6 B 16 9 TB4 17A 21M16

J30 19 6 C 18 9 TB4 15A 49C18

J30 20 6 B 16 9 TB3 4B 2S16

J30 23 6 B 16 9 KR 8 50A16

J30 24 6 C 18 9 DCA (-) 25D18

J30 25 6 C 18 9 DCA (+) 24G18

J30 28 8 A 14 9 TB3 21A 98C14

J30 29 8 A 14 9 TB3 22A 99C14

J30 31 6 C 18 9 A7 2 138B18

J30 32 6 C 18 9 A4 14 139A18

J30 33 7 C 18 9 TB3 17A 33C18

J30 34 6 B 16 9 TB4 7A 108C16

J30 35 6 B 16 9 A7 5 116B16

J30 36 6 B 16 9 A7 6 115B16

J30 37 6 B 16 9 TB4 8A 107C16

J31 1 6 C 18 9 A5 F1 101D18

J31 3 6 C 18 9 A5 F2 102D18

J31 4 6 B 16 9 A5 TBC-51 151B16

J31 5 8 A 14 9 A3 30 134A14

J31 6 8 A 14 9 A3 26 135A14

J31 7 8 A 14 9 A3 28 136A14

J31 8 6 C 18 9 DBHI 4 122D18

0088-20
 TM 9-6115-730-24 0088

Table 1. Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
J31 9 6 B 16 9 A5 TBC-52 152B16

J31 10 6 B 16 9 TB4 3A 110C16

J31 11 6 B 16 9 TB4 14A 114D16

J31 12 6 C 18 9 A5 F3 103D18

J31 13 6 B 16 9 A5 TBC-53 153B16

J31 14 6 B 16 9 A5 TBC-50 150B16

J31 15 6 B 16 9 A4 6 112B16

J31 16 6 B 16 9 A4 4 111B16

J31 17 6 C 18 9 DBLO 14 123D18

J31 18 6 B 16 9 A4 8 113B16

J31 19 6 C 18 9 A6 F1 121D18

J32 A 17 E 18 9 SH2 PAR 5 502

J32 B 17 E 18 2 SH2 PAR 6 502

J32 E - C 18 9 RP GND 2JA18

J33 A 17 E 18 9 SH3 PAR 5 503

J33 B 17 E 18 2 SH3 PAR 6 503

J33 E - C 18 9 RP GND 2JB18

J37 1 9 E 18 2 SH4 P7 1 504

J37 2 9 E 18 9 SH4 P7 2 504

J37 3 18 E - - SH4$ A1 28 504

J37 7 9 C 18 9 P7 7 19A18

J37 8 9 C 18 9 P7 8 20Al8

J37 9 9 C 18 9 P7 9 9A18

0088-21
 TM 9-6115-730-24 0088

Table 1. Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
J37 11 9 E 18 9 SH8 A4 20 508

J37 12 18 E - - SH8$ A4 21 508

J37 13 9 C 18 9 P7 13 13A18

J37 14 9 C 18 9 P7 14 16A18

J37 19 9 E 18 2 SH9 P7 19 511

J37 20 9 E 18 9 SH9 P7 20 511

J37 21 9 E 18 2 SH10 P7 21 512

J37 22 9 E 18 9 SH10 P7 22 512

J37 23 9 E 18 2 SH8 A4 19 508

J37 26 9 C 18 9 A1 14 45A18

J37 27 9 C 18 9 TB3 14A 44B18

J37 30 9 C 18 9 P7 30 18A18

J37 31 6 C 18 9 P7 31 31A18

J37 35 9 C 18 9 BSS 4 73A18

J37 40 9 B 16 9 TB4 17A 21N16

KFF 5 1 C 18 9 TB3 21A 98E18

KFF 8 1 C 18 9 A7 8 15A18

KFF 9 1 C 18 9 TB3 2B 2X18

KFF 12 1 C 18 9 A1 18 14A18

KFF 12 1 C 18 9 KFF 14 14B18

KFF 13 1 C 18 9 TB3 2B 2W18

KFF 14 1 C 18 9 ESPB 1 14C18

0088-22
 TM 9-6115-730-24 0088

Table 1. Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
KFF 14 1 C 18 9 KFF 12 14B18

KR 8 2 B 16 9 J30 23 50A16

KR 12 2 C 18 9 CDR 14 54C18

KR 12 2 B 16 9 TB4 11B 54B16

KR 13 6 C 18 9 P51 6 51A18

KR 14 1 C 18 9 CDR 12 36A18

P51 6 10 C 18 9 KR 13 51A18

P51 1 10 B 16 9 A4 7 128A16

P51 2 10 B 16 9 A4 5 127A16

P51 3 10 B 16 9 TB4 14B 114E16

P51 4 10 C 18 9 TB3 2A 2N18

P51 5 10 C 18 9 A2 9 6A18

P51 7 10 C 18 9 GFR 9 52A18

P51 8 10 C 18 9 AR 9 42A18

P51 9 10 C 18 9 TB3 3A 2M18

P51 10 2 C 18 9 GFR 1 53A18

P51 11 10 B 16 9 TB4 14B 114F16

P51 12 10 B 16 9 A4 9 129A16

P51 13 10 B 16 9 TB4 14A 114G16

P51 15 10 C 18 9 TB4 5A 109G18

P51 16 10 C 18 9 TB4 2A 110H18

P51 18 10 C 18 9 A2 8 5A18

P51 19 10 C 18 9 TB3 2A 2P18

P51 20 10 C 18 9 TB3 16A 56C18

P7 1 5 E 18 2 SH4 J37 1 504

0088-23
 TM 9-6115-730-24 0088

Table 1. Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
P7 2 5 E 18 9 SH4 J37 2 504

P7 4 5 C 18 9 A5P1 4 144A18

P7 5 5 C 18 9 A5P1 5 145A18

P7 6 5 C 18 9 A5P1 6 146A18

P7 7 5 C 18 9 J37 7 19A18

P7 8 5 C 18 9 J37 8 20Al8

P7 9 5 C 18 9 J37 9 9A18

P7 10 5 C 18 9 A5P1 1 149A18

P7 11 5 C 18 9 A5P1 2 148A18

P7 12 5 C 18 9 A5P1 3 147A18

P7 13 5 C 18 9 J37 13 13A18

P7 14 7 C 18 9 J37 14 16A18

P7 15 5 C 18 9 SMS 1 55A18

P7 16 5 C 18 9 A5P1 7 110E18

P7 17 5 C 18 9 A6P1 A 155A18

P7 18 5 C 18 9 A6P1 B 156A18

P7 19 5 E 18 2 SH9 J37 19 511

P7 20 5 E 18 9 SH9 J37 20 511

P7 21 5 E 18 2 SH10 J37 21 512

P7 22 5 E 18 9 SH10 J37 22 512

P7 23 7 C 18 9 TB3 19B 4D18

P7 24 5 C 18 9 A3 3 34A18

P7 25 5 C 18 9 TB3 12A 68D18

P7 26 5 C 18 9 SMS 6 46A18

0088-24
 TM 9-6115-730-24 0088

Table 1. Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
P7 27 5 E 18 2 SH7 A4 24 507

P7 28 5 E 18 9 SH7 A4 25 507

P7 29 5 C 18 9 DBHI 2 29A18

P7 30 5 C 18 9 J37 30 18A18

P7 31 5 C 18 9 J37 31 31A18

P7 32 5 C 18 9 ECS 5 32A18

P7 33 5 C 18 9 TB3 17B 33A18

P7 36 5 C 18 9 CDR 13 78A18

P7 37 5 C 18 9 SMS 11 47A18

P7 38 5 C 18 9 ESPB 3 38A18

P7 39 5 C 18 9 ECS 2 39A18

P7 40 5 C 18 9 ECS 3 40A18

PAR 5 1 E 18 9 SH2 J32 A 502

PAR 5 1 E 18 9 SH3 J33 A 503

PAR 6 1 E 18 2 SH2 J32 B 502

PAR 6 1 E 18 2 SH3 J33 B 503

PAR 9 1 E 18 9 SH1 A4 11 501

PAR 10 1 E 18 2 SH1 A4 10 501

PAR 13 1 C 18 9 PSU 5 64A18

PAR 14 1 C 18 9 TB4 22A 27E18

PL1 (-) 1 C 18 9 TB3 8A 2AM18

PL1 (+) 1 C 18 9 TB3 11B 30D18

PL2 (-) 1 C 18 9 TB3 8A 2AN18

PL2 (+) 1 C 18 9 TB3 11A 30B18

0088-25
 TM 9-6115-730-24 0088

Table 1. Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
PL3 (-) 1 C 18 9 TB3 8B 2AP18

PL3 (+) 1 C 18 9 TB3 11B 30C18

PLS 1 1 C 18 9 TB4 21B 27G18

PLS 2 1 C 18 9 TB3 11A 30A18

PSU 1 2 C 18 9 TB3 15A 48A18

PSU 2 1 C 18 9 CCS 1 65A18

PSU 3 1 C 18 9 DBHI 9 57A18

PSU 4 1 C 18 9 TB3 12B 68A18

PSU 5 1 C 18 9 PAR 13 64A18

RP GND 15 C 18 9 TB3 9B 2AR18

RP GND - C 18 9 J32E 2JA18

RP GND 15 C 18 9 J33E 2JB18

RP GND 15 E - - SH2$ Dead 502

End

RP GND 15 E - - SH3$ Dead 503

End

SMS 1 15 C 18 9 P7 15 55A18

SMS 4 15 C 18 9 TB3 5B 2AC18

SMS 5 15 C 18 9 TB3 6B 2AD18

SMS 6 15 C 18 9 P7 26 46A18

0088-26
 TM 9-6115-730-24 0088

Table 1. Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
SMS 8 15 C 18 9 TB3 6B 2AE18

SMS 10 15 C 18 9 TB3 7B 2AF18

SMS 11 15 C 18 9 P7 37 47A18

SMS 13 2 C 18 9 TB3 15B 48C18

SMS 14 2 C 18 9 TB4 13A 63A18

SMS 15 12 C 18 9 TB3 15B 48B18

SSP 1 17 F 18 2 SH6 A4 28 506

SSP 2 17 F 18 9 SH6 A4 27 506

SSP 3 17 F 18 0 SH6 A4 26 506

TB3 1B 1 C 18 9 AFPR 13 2U18

TB3 1B 1 C 18 9 GFR 13 2V18

TB3 2A 1 C 18 9 P51 4 2N18

TB3 2A 1 C 18 9 P51 19 2P18

TB3 2B 1 C 18 9 KFF 13 2W18

TB3 2B 1 C 18 9 KFF 9 2X18

TB3 3A 1 C 18 9 P51 9 2M18

TB3 3B 1 C 18 9 BSS 5 2AS18

TB3 3B 1 C 18 9 DBLO 4 2Y18

TB3 4A 3 D 10 9 CB GND 2H10

TB3 4A 2 A 14 9 A4 16 2T14

TB3 4B 1 C 18 9 DBLO 9 2Z18

TB3 4B 1 B 16 9 J30 20 2S16

TB3 5A 1 C 18 9 A2 7 2AG18

TB3 5A 1 C 18 9 A4 GND 2AA18

0088-27
 TM 9-6115-730-24 0088

Table 1. Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
TB3 5B 1 C 18 9 FLG G 2AB18

TB3 5B 1 C 18 9 SMS 4 2AC18

TB3 6A 1 C 18 9 ECS 1 2AJ18

TB3 6A 1 C 18 9 ESPB 2A 2AH18

TB3 6B 1 C 18 9 SMS 5 2AD18

TB3 6B 1 C 18 9 SMS 8 2AE18

TB3 7A 1 C 18 9 A1 27 2AL18

TB3 7A 1 C 18 9 ESPB 4 2AK18

TB3 7B 2 B 16 9 J101 3 2AV16

TB3 7B 1 C 18 9 SMS 10 2AF18

TB3 8A 1 C 18 9 PL1 (-) 2AM18

TB3 8A 1 C 18 9 PL2 (-) 2AN18

TB3 8B 1 C 18 9 CCL 3 2AX18

TB3 8B 1 C 18 9 PL3 (-) 2AP18

TB3 9A 1 C 18 9 A3 B(-) 2AT18

TB3 9A 2 B 16 9 A4 25 2AW16

TB3 9B 1 C 18 9 RP GND 2AR18

TB3 10B 1 C 18 9 HTR2 1 2BM18

TB3 11A 1 C 18 9 PL2 (+) 30B18

TB3 11A 1 C 18 9 PLS 2 30A18

TB3 11B 1 C 18 9 PL1 (+) 30D18

TB3 11B 1 C 18 9 PL3 (+) 30C18

TB3 12A 1 C 18 9 J30 12 68C18

TB3 12A 1 C 18 9 P7 25 68D18

TB3 12B 1 C 18 9 CCL 2 (-) 68B18

0088-28
 TM 9-6115-730-24 0088

Table 1. Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
TB3 12B 1 C 18 9 PSU 4 68A18

TB3 14A 1 C 18 9 J37 27 44B18

TB3 14B 1 C 18 9 A1 13 44C18

TB3 14B 1 C 18 9 ESPB 1A 44A18

TB3 15A 2 C 18 9 PSU 1 48A18

TB3 15B 2 C 18 9 SMS 15 48B18

TB3 15B 2 C 18 9 SMS 13 48C18

TB3 16A 2 C 18 9 P51 20 56C18

TB3 16B 2 C 18 9 CCS 5 56B18

TB3 16B 2 C 18 9 BSS 1 56A18

TB3 17A 5 C 18 9 J30 33 33C18

TB3 17B 15 C 18 9 ECS 4 33B18

TB3 17B 15 C 18 9 P7 33 33A18

TB3 19A 1 C 18 9 A2 4 4A18

TB3 19A 1 C 18 9 J30 4 4C18

TB3 19B 1 C 18 9 P7 23 4D18

TB3 21A 2 A 14 9 J30 28 98C14

TB3 21A 1 C 18 9 KFF 5 98E18

TB3 21B 2 A 14 9 A3 F2 98A14

TB3 22A 1 C 18 9 A7 9 99D18

TB3 22A 2 A 14 9 J30 29 99C14

TB3 22B 2 A 14 9 A3 F1 99A14

TB4 1A 1 C 18 9 A6 B21 110F18

TB4 1A 2 A 14 9 J30 17 110M14

TB4 1B 9 CB3 LINE

0088-29
 TM 9-6115-730-24 0088

Table 1. Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
TB4 2A 1 C 18 9 A5 H21 110G18

TB4 2A 1 C 18 9 P51 16 110H18

TB4 3A 1 B 16 9 J31 10 110C16

TB4 5A 2 A 14 9 J30 16 109F14

TB4 5A 1 C 18 9 P51 15 109G18

TB4 5B 1 CB3 LINE

TB4 6A 1 C 18 9 A4 3 109H18

TB4 6A 2 B 16 9 J30 10 109C16

TB4 6B 2 B 16 9 A3 20 109D16

TB4 7A 1 C 18 9 A4 2 108E18

TB4 7A 2 B 16 9 J30 34 108C16

TB4 7B 2 B 16 9 A3 24 108D16

TB4 8A 1 C 18 9 A4 1 107E18

TB4 8A 2 B 16 9 J30 37 107C16

TB4 8B 2 B 16 9 A3 22 107D16

TB4 10A 1 C 18 9 J30 14 76B18

TB4 10B 1 C 18 9 HTR1 1 76C18

TB4 11A 2 B 16 9 A1 26 54A16

TB4 11B 2 C 18 9 CDR 4 54D18

TB4 11B 2 B 16 9 KR 12 54B16

TB4 12B 2 C 18 9 TS 2 87WP18

TB4 13A 2 C 18 9 SMS 14 63A18

TB4 14A 2 B 16 9 J31 11 114D16

TB4 14A 2 B 16 9 P51 13 114G16

TB4 14B 2 B 16 9 P51 3 114E16

0088-30
 TM 9-6115-730-24 0088

Table 1. Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
TB4 14B 2 B 16 9 P51 11 114F16

TB4 15A 2 C 18 9 J30 19 49C18

TB4 15B 2 C 18 9 CCS 4 4 49A18

TB4 15B 2 C 18 9 CCS 2 49B18

TB4 16A 1 C 18 9 ECS 8 41A18

TB4 16A 1 C 18 9 ECS 9 41B18

TB4 16B 1 C 18 9 AR 1 41D18

TB4 16B 1 C 18 9 ECS 10 41C18

TB4 17A 2 B 16 9 J30 18 21M16

TB4 17A 2 B 16 9 J37 40 21N16

TB4 17B 1 C 18 9 TS 1 27WA18

TB4 18A 1 C 18 9 A3 B+ 21L18

TB4 18B 1 C 18 9 AFPS 2 21K18

TB4 19A 2 A 14 9 A4 15 21C14

TB4 19A 2 B 16 9 J30 8 21B16

TB4 19B 2 A 14 9 A1 39 21A14

TB4 19B 1 C 18 9 A2 1 21H18

TB4 20A 1 C 18 9 AFPR 5 21E18

TB4 20A 1 C 18 9 AR 14 21F18

TB4 20B 1 C 18 9 FLG I 21D18

TB4 21A 1 C 18 9 A1 38 27F18

TB4 21A 2 B 16 9 J30 13 27J16

TB4 21B 1 C 18 9 ECS 6 27H18

TB4 21B 1 C 18 9 PLS 1 27G18

TB4 22A 2 A 14 9 A7 12 27B14

0088-31
 TM 9-6115-730-24 0088

Table 1. Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
TB4 22A 1 C 18 9 PAR 14 27E18

TB4 22B 2 A 14 9 A1 (B+) 27C14

TB4 22B 1 C 18 9 CCL 1 (+) 27D18

VAR 1 17 E 18 9 SH5 A3 45 505

VAR 3 17 E 18 2 SH5 A3 7 505

0088-32
 TM 9-6115-730-24 0088

Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List.

NOTES
Color Code

0 Black 5 Green
1 Brown 6 Blue
2 Red 7 Violet
3 Orange 8 Gray
4 Yellow 9 White

Abbreviations used in table can be found in FO-1 at the back of this manual or in List of Abbreviations/Acronyms
(WP 0001).

The list below describes End Prep in Table 2:

Code Part Number Nomenclature

1 88-21944 Socket (18-16 AWG)

2 88-20274-1 Terminal, Spade 20 AWG, #6
3 88-20477 Contact, Electrical, Female
4 88-20274-3 Terminal, Spade 20 AWG, #8
5 88-20274-10 Terminal, Spade 12 AWG, #6
6 MS25036-158 Terminal Lug, Ring Tongue, 10 AWG
7 88-20274-5 Terminal, Spade 16 AWG, #6
8 401256-001 Terminal Lug, Push-on
9 0116-1215 Adapter, Terminal Disconnect
10 88-22119-19 Terminal Lug, Ring Tongue, 10-12 AWG
11 401256-002 Terminal Lug, Push-on
12 88-22119-21 Terminal Lug, Ring Tongue, 4AWG
13 MS25036-125 Terminal Lug, Ring Tongue, 4 AWG
14 0116-1224 Socket, Connector (18 - 14 AWG)
15 88-20274-9 Terminal, Spade 12 AWG, #8
16 88-20274-7 Terminal, Spade 12 AWG, #10
17 - Solder to terminal
18 88-20274-11 Terminal, Spade 16 AWG, #8
19 88-22119-17 Terminal Lug, Ring Tongue
20 88-22119-18 Terminal Lug, Ring Tongue
21 MS25036-155 Terminal Lug, Ring Tongue, 16 AWG
22 MS25036-151 Terminal Lug, Ring Tongue, 20 AWG
23 0116-1232-02 Terminal, Pin, 16-14 AWG
24 88-22119-13 Terminal Lug, Ring Tongue
25 MS25036-105 Terminal Lug, Ring Tongue, 20 AWG

The list below describes Wire Type column in Table 2:

Wire Code Nomenclature Part Number

A Wire, Electric, Extruded ETFE 14 Ga M22759/16-14-9

B Wire, Electric, Extruded ETFE 16 Ga M22759/16-16-9
C Wire, Electric, Extruded ETFE 18 Ga M22759/16-18-9
D Wire, Electric, Extruded ETFE 10 Ga M22759/16-18-9
E Wire, Electrical, 4 AWG 88-20540-10

0088-33
 TM 9-6115-730-24 0088

Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
AFP CASE - C 18 9 AFPV 2 2BH18

AFP 1 - 0 AFPV 1

AFPV 1 1 C 18 9 P30 1 8B18

AFPV 2 1 C 18 9 AFP CASE 2BH18

AFPV 2 3 C 18 9 TB5 17B 2BG18

ALT (-) 10 D 10 9 SM (-) 2BE10

ALT (+) 6 D 10 9 CB5 2 28A10

BDS 1 - - - 0 BT2 (-) 1A410

BDS 2 - - - 0 SM (-) 2A410

BT1 (-) - - - 0 BT2 (+) 12A410

BT1 (+) - - - 0 PS (+) 24A410

BT1 (+) - - - 0 SR (+) 24D410

BT2 (-) - - - 0 BDS 1 1A410

BT2 (-) - - - 0 SR (-) 1C410

BT2 (+) - - - 0 BT1 (-) 12A410

BDS A 8 C 16 9 TB5 5A 22B16

Field

BDS B B 16 9 TB5 6A 91A16

Field

CATSW1 2 2 C 18 9 TB5 21A 2BJ18

CATSW2 2 2 C 18 9 TB5 21A 2BK18

0088-34
 TM 9-6115-730-24 0088

Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
CB GND 10 D 10 9 SM (-) 2D10

CB2 1 15 D 10 9 PS (+) 24C10

CB2 2 11 D 10 9 SMMS 1 75A10

CB4 1 18 A 14 9 R4 4 25E14

CB4 2 18 A 14 9 SRY 30 74A14

CB5 1 16 D 10 9 R4 4 25A10

CB5 2 18 D 10 9 ALT (+) 28A10

CCCT X1 11 B 16 9 P30 36 115C16

CCCT X2 11 B 16 9 P30 35 116C16

CT1 X1 11 B 16 9 P31 4 151A16

CT1 X2 11 B 16 9 CT2 X2 150C16

CT1 X2 11 B 16 9 P31 14 150A16

CT2 X1 11 B 16 9 P31 9 152A16

CT2 X2 11 B 16 9 CT1 X2 150C16

CT2 X2 11 B 16 9 CT3 X2 150D16

CT3 X1 11 B 16 9 P31 13 153A16

CT3 X2 11 B 16 9 CT2 X2 150D16

CT7 X1 11 B 16 9 P31 16 111A16

CT7 X2 11 B 16 9 CT8 X2 114C16

CT8 X1 11 B 16 9 P31 15 112A16

CT8 X2 11 B 16 9 CT7 X2 114C16

CT8 X2 11 B 16 9 CT9 X2 114B16

CT9 X1 11 B 16 9 P31 18 113A16

0088-35
 TM 9-6115-730-24 0088

Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
CT9 X2 11 B 16 9 CT8 X2 114B16

CT9 X2 11 B 16 9 P31 11 114A16

D1 Anode 17 D 10 9 R4 4 25B10

D1 Cathode 21 A 14 9 DCS 2 26A14

DCS 1 2 C 18 9 TB5 5A 22A18

DCS 2 7 A 14 9 D1 Cathode 26A14

DCS 3 7 A 14 9 P30 9 17A14

F1 1 23 B 16 9 TB5 7A 107F16

F1 2 23 B 16 9 PT3 IN-115 124A16

F2 1 23 B 16 9 TB5 8A 108F16

F2 2 23 B 16 9 PT2 IN-0 125A16

F3 1 23 B 16 9 TB5 9A 109J16

F3 2 23 B 16 9 PT2 IN-115 126A16

FLSU 1 15 C 18 9 P30 7 80A18

FLSU G 4 C 18 9 TB5 20A 2AZ18

Frame Gnd 13 E 4 9 TB2 GND 2F4

GEN GND 13 E 4 9 TB2 GND 2E4

K1 A1 - - - 0 TB1 1 101A410

K1 A2 25 C 18 9 P31 19 121C1 8

K1 B1 - - - 0 TB1 2 102A410

K1 B2 25 C 18 9 P31 8 122C18

K1 C1 - - - 0 TB1 3 103A410

K1 C2 27 C 18 9 P31 17 123C18

0088-36
 TM 9-6115-730-24 0088

Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
K1 X1 7 B 16 9 P30 23 50B16

K1 X2 7 B 16 9 TB5 19B 2BR16

K1 21 7 B 16 9 TB5 20B 2BB16

K1 22 2 C 18 9 P30 12 68E18

K1 41 7 B 16 9 TB5 20B 2BC16

K1 42 2 C 18 9 P30 19 49D18

P11 1 3 C 18 9 P30 4 4B18

P11 2 3 C 18 9 TB5 19A 2AY18

P12 1 3 C 18 9 P30 1 8B18

P30 1 1 C 18 9 AFPV 1 8B18

P30 2 1 C 18 9 P8 2 10B18

P30 3 1 C 18 9 P8 3 11C18

P30 4 1 C 18 9 P11 1 4B18

P30 5 1 C 18 9 P8 1 69B18

P30 7 1 C 18 9 FLSU-S 1 80A18

P30 8 1 B 16 9 TB5 12B 21P16

P30 9 14 A 14 9 DCS 3 17A14

P30 10 1 B 16 9 TB1 9 109B16

P30 12 1 C 18 9 K1 22 68E18

P30 13 1 B 16 9 TB5 16B 27K16

P30 14 1 C 18 9 TB5 15B 76A18

P30 15 1 C 18 9 TB5 4B 60B18

P30 16 14 A 14 9 TB1 9 109E14

P30 17 14 A 14 9 TB1 13 110N14

P30 18 1 B 16 9 TB5 11B 21R16

0088-37
 TM 9-6115-730-24 0088

Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
P30 19 1 C 18 9 K1 42 49D18

P30 20 1 B 16 9 TB5 20A 2AU16

P30 23 1 B 16 9 K1 X1 50B16

P30 24 1 C 18 9 R4 2 24F18

P30 25 1 C 18 9 R4 3 25C18

P30 28 14 A 14 9 TB5 1B 98B14

P30 29 14 A 14 9 TB5 2B 99B14

P30 33 1 C 18 9 TB5 22A 33D18

P30 34 1 B 16 9 TB5 8B 108B16

P30 35 1 B 16 9 CCCT X2 116C16

P30 36 1 B 16 9 CCCT X1 115C16

P30 37 1 B 16 9 TB5 7B 107B16

P31 1 1 C 18 9 TB1 1 101C18

P31 3 1 C 18 9 TB1 2 102C18

P31 4 1 B 16 9 CT1 X1 151A16

P31 5 14 A 14 9 PT2 OP-115 134B14

P31 6 14 A 14 9 PT3 OP-0 135B14

P31 7 14 A 14 9 PT3 OP-115 136B14

P31 8 1 C 18 9 K1 B2 122C18

P31 9 1 B 16 9 CT2 X1 152A16

P31 10 1 B 16 9 TB5 10A 110B16

P31 11 1 B 16 9 CT9 X2 114A16

P31 12 1 C 18 9 TB1 3 103C18

0088-38
 TM 9-6115-730-24 0088

Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
P31 13 1 B 16 9 CT3 X1 153A16

P31 14 1 B 16 9 CT1 X2 150A16

P31 15 1 B 16 9 CT8 X1 112A16

P31 16 1 B 16 9 CT7 X1 111A16

P31 17 1 C 18 9 K1 C2 123C18

P31 18 1 B 16 9 CT9 X1 113A16

P31 19 1 C 18 9 K1 A2 121C18

P8 1 3 C 18 9 P30 5 69B18

P8 2 3 C 18 9 P30 2 10B18

P8 3 3 C 18 9 P30 3 11C18

PS (+) 6 D 10 9 CB2 1 24C10

PS (+) 6 D 10 9 R4 1 24E10

PS Coil (+) 16 D 10 9 SMMS 2 23A10

PT2 ESS 11 B 16 9 PT3 ESS 2BS16

PT2 IN-0 11 & 9 B 16 9 F2 2 125A16

PT2 IN-0 23 B 16 9 PT2 IN-115 Jumper

PT2 IN-0 23 B 16 9 PT3 IN-0 125B16

PT2 IN-115 11 B 16 9 F3 2 126A16

PT2 IN-115 23 B 16 9 PT2 IN-0 Jumper

PT2 OP-0 23 A 14 9 PT2 OP-0 135E14

PT2 OP-0 23 A 14 9 PT2 OP-0 135E14

PT2 OP-0 11 & 9 A 14 9 PT3 OP-0 135D14

0088-39
 TM 9-6115-730-24 0088

Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
PT2 OP-115 23 A 14 9 PT2 OP-115 134C14

PT2 OP-115 23 A 14 9 PT2 OP-115 134C14

PT2 OP-115 11 A 14 9 P31 5 134B14

PT2 OP-ESS 23 B 16 9 PT2 OP-GND Jumper

PT2 OP- 18 B 16 9 PT2 OP-ESS Jumper

GND
PT3 ESS 11 B 16 9 PT2 ESS 2BS16

PT3 GND 11 B 16 9 TB5 18B 2BT16

PT3 IN-0 23 B 16 9 PT3 IN-115 Jumper

PT3 IN-0 23 B 16 9 PT2 IN-0 125B16

PT3 IN-115 11 B 16 9 F1 2 124A16

PT3 IN-115 23 B 16 9 PT3 IN-0 Jumper

PT3 OP-ESS 23 B 16 9 PT3 OP-GND Jumper

PT3 OP- 18 B 16 9 PT3 OP-ESS Jumper

GND
PT3 OP-0 11 A 14 9 PT2 OP-0 135D14

PT3 OP-0 23 A 14 9 PT3 OP-0 135C14

PT3 OP-0 23 A 14 9 PT3 OP-0 135C14

PT3 OP-0 11 A 14 9 P31 6 135B14

PT3 OP-115 23 A 14 9 PT3 OP-115 136C14

PT3 OP-115 23 A 14 9 PT3 OP-115 136C14

PT3 OP-115 11 A 14 9 P31 7 136B14

R4 1 10 D 10 9 PS (+) 24E10

R4 2 4 C 18 9 P30 24 24F18

R4 3 5 C 18 9 P30 25 25C18

0088-40
 TM 9-6115-730-24 0088

Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
R4 4 20 A 14 9 CB4 1 25E14

R4 4 10 D 10 9 CB5 1 25A10

R4 4 10 D 10 9 D1 Anode 25B10

SM (-) 0 BDS 2 2A410

SM (-) 6 D 10 9 ALT GND 2BE10

SM (-) 0 TB2 GND 2C410

SM (-) 6 D 10 9 CB GND 2D10

SM (-) 6 D 10 9 TB5 19B 2BA10

SMMS 1 15 D 10 9 CB2 2 75A10

SMMS 2 15 D 10 9 PS Coil (+) 23A10

SMMS 3 7 B 16 9 TB5 6A 91B16

SMMS 4 8 C 18 9 TB5 18A 2BD18

SRY 30 11 A 14 9 CB4 2 74A14

SRY 85 8&9 C 18 9 TB5 12A 21S18

SRY 86 8&9 C 18 9 TB5 18B 2BF18

TB1 1 4 0 K1 A1 101A410

TB1 1 22 C 18 9 P31 1 101C18

TB1 2 4 0 K1 B1 102A410

TB1 2 22 C 18 9 P31 3 102C18

TB1 3 4 0 K1 C1 103A410

TB1 3 22 C 18 9 P31 12 103C18

TB1 7 21 B 16 9 TB5 7B 107A16

TB1 8 21 B 16 9 TB5 8B 108A16

0088-41
 TM 9-6115-730-24 0088

Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
TB1 9 21 B 16 9 TB5 9B 109A16

TB1 9 21 B 16 9 P30 10 109B16

TB1 9 21 A 14 9 P30 16 109E14

TB1 9 21 A 14 9 P30 16 109E14

TB1 10 4 TB2 N 110K410

TB1 12 TB2 N 110K410

TB1 13 21 B 16 9 TB5 10B 110A16

TB2 GND 5 E 4 9 Frame Gnd 2F4

TB2 GND 12 E 14 9 GEN GND 2E4

TB2 GND SM (-) 2C410

TB2 L1 24 B 16 9 V1 1 121E16

TB2 L1 K1 A2 121A410

TB2 L1 K1 A2 121B410

TB2 L2 24 B 16 9 V2 1 122F16

TB2 L2 K1 B2 122A410

TB2 L2 K1 B2 122B410

TB2 L3 24 B 16 9 V3 1 123H16

TB2 L3 K1 C2 123A410

TB2 L3 K1 C2 123B410

TB2 N 24 B 16 9 V4 1 110J16

TB2 N 4 0 TB1 10 110K410

TB2 N 4 0 TB1 12 110L410

TB5 1A 7 A 14 9 G1 F2

TB5 1B 7 A 14 9 P30 28 98B14

TB5 2A 7 A 14 9 G1 F1

0088-42
 TM 9-6115-730-24 0088

Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
TB5 2B 7 A 14 9 P30 29 99B14

TB5 4 2 C 18 9 P30 15 60B18

TB5 5A 2 C 18 9 DCS 1 22A18

TB5 5A 2 C 18 9 BDS A 22B16

Field

TB5 6A 7 B 16 2 SMMS 3 91A16

TB5 6A 8 B 16 2 BDS B 91B16

FIELD

TB5 7A 7 B 16 9 F1 1 107F16

TB5 7B 7 B 16 9 P30 37 107B16

TB5 7B 7 B 16 9 TB1 7 107A16

TB5 8A 7 B 16 9 F2 1 108F16

TB5 8B 7 B 16 9 P30 34 108B16

TB5 8B 7 B 16 9 TB1 8 108A16

TB5 9A 7 B 16 9 F3 1 109J16

TB5 9B 7 B 16 9 TB1 9 109A16

TB5 10A 7 B 16 9 P31 10 110B16

TB5 10B 7 B 16 9 TB1 13 110A16

TB5 11B 7 B 16 9 P30 18 21R16

TB5 12A 2 C 18 9 SRY 85 21S18

TB5 12B 7 B 16 9 P30 8 21P16

TB5 15A 2 C 18 9 P26 B 76WA18

TB5 15B 2 C 18 9 P30 14 76A18

TB5 16A 2 C 18 9 P26 E 27WA14

TB5 16B 7 B 16 9 P30 13 27K16

TB5 17A 2 C 18 9 P26 A 2WB14

0088-43
 TM 9-6115-730-24 0088

Table 2. Generator Set Harness (Generator, Engine, Control Panel) Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
TB5 17B 2 C 18 9 P12 2 2BG18

TB5 18A 2 C 18 9 SMMS 4 2BD18

TB5 18B 7 B 16 9 PT3 GND 2BT16

TB5 18B 2 C 18 9 SRY 86 2BF18

TB5 19A 2 C 18 9 P11 2 2AY18

TB5 19B 7 B 16 9 K1 X2 2BR16

TB5 19B 5 D 10 9 SM (-) 2BA10

TB5 20 2 C 18 9 FLSU G 2AZ18

TB5 20A 2 B 16 9 P30 20 2AU16

TB5 20B 7 B 16 9 K1 21 2BB16

TB5 20B 7 B 16 9 K1 41 2BC16

TB5 21A 2 C 18 9 CATSW1 2 2BJ18

TB5 21A 2 C 18 9 CATSW2 2 2BK18

TB5 22A 2 C 18 9 P30 33 33D18

V1 1 3 B 16 9 TB2 L1 121E16

V2 1 3 B 16 9 TB2 L2 122F16

V3 1 3 B 16 9 TB2 L3 123H16

V4 1 3 B 16 9 TB2 N 110J16

0088-44
 TM 9-6115-730-24 0088

Table 3. ECM to EMCP Harness Wire List.

NOTES
Color Code

0 Black 5 Green
1 Brown 6 Blue
2 Red 7 Violet
3 Orange 8 Gray
4 Yellow 9 White

Abbreviations used in table can be found in FO-1 at the back of this manual or in List of Abbreviations/Acronyms
(WP 0001).

The list below describes End Prep in Table 3:

Code Part Number Nomenclature

1 9X-3402 Socket
2 9X-0141 Plug Assy
3 9W-0852 Pin
4 126-1768 Socket
5 8T-8730 Socket
6 8T-8729 Pin

The list below describes Wire Type in Table 3:

Wire Code Nomenclature Part Number

A Wire, 16 GA T (twisted pair) 6A-3770

B Wire, 14 GA T (twisted pair) 5P-4704
C Wire, 16 GA GN/YEL 6V-8241
D Wire, 18 GA BK 5P-3075
E Wire, 18 GA WH 6V-2648

The list below describes the ECM J1 to EMCP Harness Connectors

Connector Description

CDC-P7 Plug, Cat Diagnostic Computer Connector

ENG-P1 Plug, ECM Connector J1
ENG-P8 Plug, Turbo Inlet Pressure Sensor
ENG-P14 Plug, Magnetic Speed Pickup (MPU) Connector
ENG-P16 Plug, Low Coolant Sensor Connector
ENG-P20 Plug, Filtered Fuel Pressure Sensor
ENG-P37 Plug, EMCP Connector
ENG-P213 Plug, Ether Injection Relay

0088-45
 TM 9-6115-730-24 0088

Table 3. ECM to EMCP Harness Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
BATT (-) 7 C 16 54 Splice 3 2

CATSW 1 1 7 D 18 0 ENG-P1 6

CATSW 2 1 7 D 18 0 ENG-P1 60

ENG-P1 1 1 D 18 0 ENG-P7 J

ENG-P1 2 1 A 16 T Splice 1 1

ENG-P1 3 1 A 16 T Splice 2 1

ENG-P1 5 1 E 18 9 ENG-P37 11

ENG-P1 6 1 D 18 0 CATSW 1 1

ENG-P1 8 1 D 18 0 CDC-P7 D

ENG-P1 9 1 E 18 9 CDC-P7 E

ENG-P1 14 1 E 18 9 CDC-P7 H

ENG-P1 16 1 A 16 T ENG-P20 C

ENG-P1 17 1 A 16 T ENG-P8 C

ENG-P1 21 1 A 16 T ENG-P213 1

ENG-P1 23 1 A 16 T ENG-P37 27

ENG-P1 34 1 E 18 9 CDC-P7 G

ENG-P1 40 1 A 16 T ENG-P37 26

ENG-P1 42 1 D 18 0 CDC-P7 C Shield

ENG-P1 48 4 B 14 T Splice 4 1

ENG-P1 50 1 D 18 0 CDC-P7 F

0088-46
 TM 9-6115-730-24 0088

Table 3. ECM to EMCP Harness Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES

ENG-P1 52 4 B 14 T Splice 4 1

ENG-P1 53 4 B 14 T Splice 4 1

ENG-P1 58 1 A 16 T ENG-P37 35

ENG-P1 60 1 D 18 0 CATSW 2 1

ENG-P1 61 1 C 16 54 Splice 3 1

ENG-P1 63 1 C 16 54 Splice 3 1

ENG-P1 65 1 C 54 T Splice 3 1

ENG-P1 66 1 D 18 0 ENG-P37 23

ENG-P1 70 1 A 16 T ENG-P37 40

ENG-P1 - - D 18 0 ENG-P37 12 Shield

CDC-P7 A 3 B 14 T Splice 4 2

CDC-P7 B 3 C 16 54 Splice 3 2

CDC-P7 C 6 D 18 0 ENG-P1 42 Shield

CDC-P7 D 3 D 18 0 ENG-P1 8

CDC-P7 D 3 D 18 0 ENG-P37 19

CDC-P7 E 3 E 18 9 ENG-P1 9

CDC-P7 E 3 E 18 9 ENG-P37 20

CDC-P7 F 6 D 18 0 ENG-P1 50

CDC-P7 G 6 E 18 9 ENG-P1 34

CDC-P7 H 6 E 18 9 ENG-P1 14

0088-47
 TM 9-6115-730-24 0088

Table 3. ECM to EMCP Harness Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
CDC-P7 J 6 D 18 0 ENG-P1 1

CDC-P7 D 18 0 ENG-P37 18 Shield

ENG-P8 A 6 A 16 T Splice 2 2

ENG-P8 B 6 A 16 T Splice 1 2

ENG-P8 C 6 A 16 T ENG-P1 17

ENG-P14 1 5 D 18 0 ENG-P37 1

ENG-P14 2 5 E 18 9 ENG-P37 2

ENG-P14 D 18 0 ENG-P37 3 Shield

ENG-P16 A 5 A 16 T ENG-P37 9

ENG-P16 B 5 A 16 T ENG-P37 31

ENG-P16 C 5 A 16 T ENG-P37 13

ENG-P20 A 6 A 16 T Splice 2 2

ENG-P20 B 6 A 16 T Splice 1 2

ENG-P20 C 6 A 16 T ENG-P1 16

ENG-P37 1 5 D 18 0 ENG-P14 1

ENG-P37 2 5 E 18 9 ENG-P14 2

ENG-P37 3 5 D 18 0 ENG-P14 Shield

ENG-P37 9 1 A 16 T ENG-P16 A

0088-48
 TM 9-6115-730-24 0088

Table 3. ECM to EMCP Harness Wire List - Continued.

FROM TO
REF PI END WIRE TWISTED REF
DES N PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
ENG-P37 11 5 E 18 9 ENG-P1 5

ENG-P37 12 5 D 18 0 ENG-P1 Shield

ENG-P37 13 1 A 16 T ENG-P16 C

ENG-P37 18 5 D 18 0 CDC-P7 Shield

ENG-P37 19 18 CDC-P7

ENG-P37 20 5 E 18 9 CDC-P7 E

ENG-P37 23 5 D 18 0 ENG-P1 66

ENG-P37 26 2 A 16 T ENG-P1 40

ENG-P37 27 2 A 16 T ENG-P1 23

ENG-P37 31 1 A 16 T ENG-P16 B

ENG-P37 35 1 A 16 T ENG-P1 58

ENG-P37 40 1 A 16 T ENG-P1 70

ENG-P213 1 5 A 16 T ENG-P1 21

ENG-P213 2 5 C 16 54 Splice 3 2

Splice 1 1 A 16 T ENG-P1 2

Splice 1 2 A 16 T ENG-P1 B

Splice 1 2 A 16 T ENG-P20 B

Splice 2 1 A 16 T ENG-P1 3

Splice 2 2 A 16 T ENG-P15 A

Splice 2 2 A 16 T ENG-P20 A

Splice 3 1 C 16 54 ENG-P1 61

0088-49
 TM 9-6115-730-24 0088

Table 3. ECM to EMCP Harness Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES

Splice 3 1 C 16 54 ENG-P1 63

Splice 3 1 C 16 54 ENG-P1 65

Splice 3 2 C 16 54 BATT (-)

Splice 3 2 C 16 54 CDC-P7 B

Splice 3 2 C 16 54 ENG-P13 2

Splice 4 1 B 14 T ENG-P1 48

Splice 4 1 B 14 T ENG-P1 52

Splice 4 1 B 14 T ENG-P1 53

Splice 4 2 B 14 T CDC-P7 A

Splice 4 2 B 14 T SRY 87

SRY 87 7 B 14 T Splice 4 2

0088-50
 TM 9-6115-730-24 0088

Table 4. Engine Harness Wire List.

NOTES
Color Code

0 Black 5 Green
1 Brown 6 Blue
2 Red 7 Violet
3 Orange 8 Gray
4 Yellow 9 White

Abbreviations used in table can be found in FO-1 at the back of this manual or in List of Abbreviations/Acronyms
(WP 0001).

The list below describes End Prep in Table 4:

Code Part Number Nomenclature

1 180-9340 Socket
2 180-9339 Pin
3 TBD Splice

The list below describes Wire Type in Table 4:

Wire Code Nomenclature Part Number

A Wire, 18 GA OR 130-4674
B Wire, 18 GA YL 130-4673
C Wire, 18 GA GN 130-4676
D Wire, 18 GA WH 130-4669
E Wire, 18 GA BU 130-4670
F Wire, 18 GA PU 130-4671
G Wire, 18 GA GY 5P-3074
H Wire, 18 GA BK 5P-3075
I Wire, 18 GA GY 130-4672
J Wire, 18 GA BR 130-4675
K Wire, 18 GA BR 5P-9072
L Wie, 18 GA BU 5P-9082
M Wire, 18 GA PK 5P-9076
N Wire, 18 GA GN 5P-9080
O Wire, 18 GA WH 6V-2648
P Wire, 18 GA YL 5P-9074

0088-51
 TM 9-6115-730-24 0088

Table 4. Engine Harness Wire List - Continued.

The list below describes ECM J2 Engine Harness Connectors

Connector Description

ENG-P2 Plug, ECM Connector J2

ENG-P100 Plug, Coolant Temperature Sensor
ENG-P103 Plug, Intake Manifold Air Temperature Sensor
ENG-P105 Plug, Fuel Temperature Sensor
ENG-P200 Plug, Turbo Outlet Pressure Sensor
ENG-P201 Plug, Oil Pressure Sensor
ENG-P202 Plug, Fuel Pressure Sensor
ENG-P203 Plug, Atmospheric Pressure Sensor
ENG-P300 Plug, Fuel Injector Harness Connector
ENG-P400 Plug, TDC Probe Connector (Timing Calibration)
ENG-P401 Plug, Bottom Crankshaft Timing Sensor
ENG-P402 Plug, Top Camshaft Timing Sensor

0088-52
 TM 9-6115-730-24 0088

Table 4. Engine Harness Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
ENG-
1 1 L 18 6 ENG-P2 32
P100
ENG-
2 1 M 18 PK Splice 3 2
P100
ENG-
1 1 L 18 6 ENG-P2 12
P101
ENG-
2 1 H 18 0 Splice 4 2
P101
ENG-
1 1 L 18 6 ENG-P2 35
P103
ENG-
2 1 M 18 PK Splice 3 2
P103
ENG-
1 1 P 18 4 ENG-P2 33
P105
ENG-
2 1 M 18 PK Splice 3 2
P105
ENG-P2 2 1 O 18 9 Splice 1 1

ENG-P2 3 1 N 18 5 Splice 2 1

ENG-P2 9 1 H 18 0 Splice 4 1
ENG-
ENG-P2 10 1 K 18 1 11
P300
ENG-
ENG-P2 11 1 N 18 5 9
P300
ENG-
ENG-P2 12 1 L 18 6 1
P101
ENG-
ENG-P2 14 1 G 18 8 C
P203
ENG-
ENG-P2 16 1 M 18 PK C
P202
ENG-P2 18 1 M 18 PK Splice 3 1
ENG-
ENG-P2 22 1 O 18 9 TW3 1
P400
ENG-
ENG-P2 23 1 P 18 4 TW3 2
P400
ENG-
ENG-P2 24 1 G 18 8 C
P201
ENG-
ENG-P2 32 1 L 18 6 1
P100
ENG-
ENG-P2 33 1 P 18 4 1
P105
ENG-
ENG-P2 35 1 L 18 6 1
P103
ENG-
ENG-P2 36 1 I 18 8 1
P300
ENG-
ENG-P2 37 1 F 18 7 2
P300

0088-53
 TM 9-6115-730-24 0088

Table 4. Engine Harness Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
ENG-
ENG-P2 38 1 J 18 1 3
P300
ENG-
ENG-P2 39 1 C 18 5 4
P300
ENG-
ENG-P2 40 1 M 18 PK C
J200
ENG-
ENG-P2 44 1 D 18 9 12
P300
ENG-
ENG-P2 45 1 A 18 3 10
P300
ENG-
ENG-P2 46 1 B 18 4 8
P300
ENG-
ENG-P2 48 1 O 18 9 TW1 2
P401
ENG-
ENG-P2 49 1 H 18 0 TW1 1
P401
ENG-
ENG-P2 54 1 E 18 6 5
P300
ENG-
ENG-P2 55 1 I 18 8 6
P300
ENG-
ENG-P2 58 1 P 18 4 TW2 2
P402
ENG-
ENG-P2 59 1 L 18 6 TW2 1
P402
ENG-
A 2 O 18 9 Splice 1 2
P200
ENG-
B 2 N 18 5 Splice 2 2
P200
ENG-
C 2 M 18 PK ENG-P2 40
P200
ENG-
A 2 O 18 9 Splice 1 1
P201
ENG-
B 2 N 18 5 Splice 2 1
P201
ENG-
C 2 G 18 8 ENG-P2 24
P201
ENG-
A 2 O 18 9 Splice 1 2
P202
ENG-
B 2 N 18 5 Splice 2 2
P202
ENG-
C 2 M 18 PK ENG-P2 16
P202
ENG-
A 2 O 18 9 Splice 1 2
P203
ENG-
B 2 N 18 5 Splice 2 2
P203
ENG-
C 2 G 18 8 ENG-P2 14
P203
ENG-
ENG-P2 37 1 F 18 7 2
P300

0088-54
 TM 9-6115-730-24 0088

Table 4. Engine Harness Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
ENG-
1 1 I 18 8 ENG-P2 36
P300
ENG-
2 1 F 18 7 ENG-P2 37
P300
ENG-
3 1 J 18 1 ENG-P2 38
P300
ENG-
4 1 C 18 5 ENG-P2 39
P300
ENG-
5 1 E 18 6 ENG-P2 54
P300
ENG-
6 1 I 18 8 ENG-P2 55
P300
ENG-
7 1 H 18 0 Splice 4 2
P300
ENG-
8 1 B 18 4 ENG-P2 46
P300
ENG-
9 1 N 18 5 ENG-P2 11
P300
ENG-
10 1 A 18 3 ENG-P2 45
P300
ENG-
11 1 K 18 1 ENG-P2 10
P300
ENG-
12 1 D 18 9 ENG-P2 44
P300
ENG-
1 1 O 18 9 TW3 ENG-P2 22
P400
ENG-
2 1 P 18 4 TW3 ENG-P2 23
P400
ENG-
1 1 H 18 0 TW1 ENG-P2 49
P401
ENG-
2 1 O 18 9 TW1 ENG-P2 48
P401
ENG-
1 1 L 18 6 TW2 ENG-P2 59
P402
ENG-
2 1 P 18 4 TW2 ENG-P2 58
P402
ENG-
Splice 1 1 3 O 18 9 A
P201
Splice 1 1 3 O 18 9 ENG-P2 2

0088-55
 TM 9-6115-730-24 0088

Table 4. Engine Harness Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
ENG-
Splice 1 2 3 O 18 9 A
P200
ENG-
Splice 1 2 3 O 18 9 A
P202
ENG-
Splice 1 2 3 O 18 9 A
P203
ENG-
Splice 2 1 3 N 18 5 B
P201
Splice 2 1 3 N 18 5 ENG-P2 3
ENG-
Splice 2 2 3 N 18 5 B
P200
ENG-
Splice 2 2 3 N 18 5 B
P202
ENG-
Splice 2 2 3 N 18 5 B
P203
Splice 3 1 3 M 18 PK ENG-P2 18
ENG-
Splice 3 2 3 M 18 PK 2
P100
ENG-
Splice 3 2 3 M 18 PK 2
P103
ENG-
Splice 3 2 3 M 18 PK 2
P105
Splice 4 1 3 H 18 0 ENG-P2 9
ENG-
Splice 4 2 3 H 18 0 2
P101
ENG-
Splice 4 2 3 H 18 0 7
P300

0088-56
 TM 9-6115-730-24 0088

Table 5. Engine Harness to Unit Injectors Wire List.

NOTES

Color Code

0 Black 5 Green
1 Brown 6 Blue
2 Red 7 Violet
3 Orange 8 Gray
4 Yellow 9 White

Abbreviations used in table can be found in FO-1 at the back of this manual or in List of Abbreviations/Acronyms
(WP 0001).

The list below describes End Prep in Table 5:

Code Part Number Nomenclature

1 8T-8729 Pin
2 7E-6513 Connector Assembly
3 066-8391 Terminal
4 Splice

The list below describes Wire Type in Table 5:

Wire Code Nomenclature Part Number

A Wire 16 Ga YL 3E-9467
B Wire 16 Ga GY 3E-9470
C Wire 16 Ga PU 3E-9475
D Wire 16 Ga BR 3E-9472
E Wire 16 Ga GN 3E-9469
F Wire 16 Ga BU 3E-9471
G Wire 16 Ga BK 3E-9476
H Wire 16 Ga WH 3E-9474
I Wire 16 Ga OR 3E-9468

0088-57
 TM 9-6115-730-24 0088

Table 5. Engine Harness to Unit Injectors Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES

ENG-
Splice 2 1 4 G 16 BK 7 Not Used
J300

Splice 2 2 4 G 16 BK ER1/2 C Not Used

Splice 2 2 4 G 16 BK ER3/4 C Not Used

Splice 2 2 4 G 16 BK ER5/6 C Not Used

ENG-
1 B 16 GY SOL 1 A701B
J300
ENG-
Splice 3 1 4 H 16 WH 12
J300

Splice 3 2 4 H 16 WH SOL 1 D789C

ENG-
2 C 16 PU SOL 2 A702B
J300
Splice 3 2 4 H 16 WH SOL 2 D789D
ENG-
3 D 16 BR SOL 3 A703B
J300
ENG-
Splice 4 1 4 I 16 OR 10
J300

Splice 4 2 4 I 16 OR SOL 3 D790C

ENG-
4 E 16 GN SOL 4 A704B
J300

Splice 4 2 4 I 16 OR SOL 4 D790D

ENG-
5 F 16 BU SOL 5 A705B
J300
ENG-
Splice 5 1 4 A 16 YL 8
J300

Splice 5 2 4 A 16 YL SOL 5 D791 C

ENG-
6 B 16 GY SOL 6 A706B
J300
Splice 5 2 4 A 16 YL SOL 6 D791D
ENG-
9 E 16 GN ER3/4 + Not Used
J300
ENG-
Splice 6 1 4 D 16 BR 11 Not Used
J300

Splice 6 2 4 D 16 BR ER1/2 + Not Used

Splice 6 2 4 D 16 BR ER5/6 + Not Used

0088-58
 TM 9-6115-730-24 0088

Table 6. Winterization Control Panel Wire List.

NOTES

Color Code

0 Black 5 Green
1 Brown 6 Blue
2 Red 7 Violet
3 Orange 8 Gray
4 Yellow 9 White

Abbreviations used in table can be found in FO-1 at the back of this manual or in List of Abbreviations/Acronyms
(WP 0001).

The list below describes End Prep in Table 6:

Code Part Number Nomenclature

1 - Solder to terminal
2 MS25036-102 Terminal Lug Ring Terminal 22-18 AWG .138 Stud
3 MS25036-153 Terminal Lug Ring Terminal 16-14 AWG .164 Stud
4 MS25036-149 Terminal Lug Ring Terminal 22-18 AWG .164 Stud

The list below describes Wire Type in Table 6:

Wire Code Nomenclature Part Number

A Wire, Electric, Extruded ETFE 14 Ga M22759/16-14-9

B Wire, Electric, Extruded ETFE 18 Ga M22759/16-18-9

0088-59
 TM 9-6115-730-24 0088

Table 6. Winterization Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
CB1 1 3 A1 14 9 J26 E

CB1 2 3 A 14 9 J27 E

CB1 2 4 B 18 9 S1 4

CR1 1 2 B 18 9 K20 9

CR1 3 2 B 18 9 J26 B

DS1 1 1 B 18 9 K20 13

DS1 1 1 B 18 9 J26 A

DS1 2 1 B 18 9 K20 9

DS1 3 1 B 18 9 S1 1

DS2 (+) 1 B 18 9 S1 3

DS2 (-) 1 B 18 9 J27 D

J26 A 1 B 18 9 DS1 1

J26 A 1 A 14 9 J27 A

J26 B 1 B 18 9 CR1 3

J26 E 1 A 14 9 CB1 1

J27 A 1 A 14 9 J26 A

J27 B 1 B 18 9 K20 14

J27 C 1 B 18 9 S1 3

J27 D 1 B 18 9 DS2 (-)

J27 E 1 A 14 9 CB1 2

K20 9 1 B 18 9 CR1 1

K20 9 1 B 18 9 DS1 2

K20 5 1 B 18 9 S1 6

K20 13 1 B 18 9 DS1 1

K20 14 1 B 18 9 J27 B

0088-60
 TM 9-6115-730-24 0088

Table 6. Winterization Control Panel Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES
S1 1 2 B 18 9 DS1 3

S1 1 2 B 18 9 S1 4

S1 3 2 B 18 9 J27 C

S1 3 2 B 18 9 DS2 (+)

S1 4 2 B 18 9 S1 1

S1 4 2 B 18 9 CB1 2

S1 6 2 B 18 9 K20 5

0088-61
 TM 9-6115-730-24 0088

Table 7. Winterization Kit Heater Cable Wire List.

NOTES

Color Code

0 Black 5 Green
1 Brown 6 Blue
2 Red 7 Violet
3 Orange 8 Gray
4 Yellow 9 White

Abbreviations used in table can be found in FO-1 at the back of this manual or in List of Abbreviations/Acronyms
(WP 0001).

The list below describes End Prep in Table 7:

Code Part Number Nomenclature

1 - Solder to terminal
2 0116-1811-006 Connector Kit (comes with pins)
3 88-20274-1 Terminal, Spade 22-18 AWG #6

The list below describes Wire Type in Table 7:

Wire Code Nomenclature Part Number

A Wire, Electric, Extruded ETFE 14 Ga M22759/16-14-9

B Wire, Electric, Extruded ETFE 18 Ga M22759/16-18-9

0088-62
 TM 9-6115-730-24 0088

Table 7. Winterization Kit Heater Cable Wire List - Continued.

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES

P27 A 1 A 14 9 P28 C3 2WA14

P27 B 1 B 18 9 P27 C 82WB18

P27 C 1 B 18 9 P27 B 82WB18

P27 C 1 B 18 9 P28 A1 82WA18

P27 D 1 B 18 9 P28 B3 83WA18

P27 E 1 A 14 9 P28 C2 27WB14

P28 A1 2 B 18 9 P27 C 82WA18

P28 B3 2 B 18 9 P27 D 83WA18

P28 C2 2 A 14 9 P27 E 27WB14

P28 C3 2 A 14 9 P27 A 2WA14

P28 C4 2 B 18 9 P29 2 84WB18

P29 1 2 B 18 9 TB5 17B 2WC18

P29 2 2 B 18 9 P28 C4 84WB18

TB5 17B 3 B 18 9 P29 1 2WC18

0088-63
 TM 9-6115-730-24 0088

Table 8. Winterization Kit Power Cable Wire List.

NOTES

Color Code

0 Black 5 Green
1 Brown 6 Blue
2 Red 7 Violet
3 Orange 8 Gray
4 Yellow 9 White

Abbreviations used in table can be found in FO-1 at the back of this manual or in List of Abbreviations/Acronyms
(WP 0001).

The list below describes End Prep in Table 8:

Code Part Number Nomenclature

1 88-20274-5 Terminal, Spade 16-14 AWG #6

2 88-20274-1 Terminal, Spade 22-18 AWG #6
3 - Solder to terminal

The list below describes Wire Type in Table 8:

Wire Code Nomenclature Part Number

A Wire, Electric, Extruded ETFE 14 Ga M22759/16-14-9

B Wire, Electric, Extruded ETFE 18 Ga M22759/16-18-9

FROM TO
REF END WIRE TWISTED REF
DES PIN PREP TYPE GAGE COLOR WITH SHIELD DES PIN NOTES

TB5 15A 2 B 18 9 P26 B

TB5 16A 1 A 14 9 P26 E

TB5 17A 1 A 14 9 P26 A

P26 A 3 A 14 9 TB5 17A

P26 B 3 B 18 9 TB5 15A

P26 E 3 A 14 9 TB5 16A

END OF WORK PACKAGE

0088-64
 TM 9-6115-730-24

CHAPTER 4

UNIT (FIELD) LEVEL

MAINTENANCE INSTRUCTIONS WINTERIZATION KIT
 TM 9-6115-730-24

CHAPTER 4

UNIT (FIELD) LEVEL MAINTENANCE INSTRUCTIONS WINTERIZATION KIT

WORK PACKAGE INDEX

Title WP Sequence No.

WINTERIZATION HEATER CONTROL BOX ASSEMBLY MAINTENANCE ............................................ 0089

WINTERIZATION HEATER ASSEMBLY MAINTENANCE ...................................................................... 0090
WINTERIZATION HEATER HOSES MAINTENANCE ............................................................................. 0091
WINTERIZATION THERMOSTAT, RESISTORS, AND DIODE MAINTENANCE ..................................... 0092
WINTERIZATION WIRING HARNESSES MAINTENANCE..................................................................... 0093
 TM 9-6115-730-24 0089

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
WINTERIZATION HEATER CONTROL BOX ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) Two

Materials/Parts References

Marker tags (WP 0124, Item 49) TM 9-6115-730-24P

Tiedown straps (WP 0124, Item 47)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF, Battery Disconnect Switch is OFF,
and DEAD CRANK SWITCH is OFF before proceeding.

2. Open left rear doors.

3. Disconnect connector P26 from connector J26 (Figure 1, Item 1) and connector P27 from connector J27
(Figure 1, Item 2) of winterization heater control box assembly.

4. Remove two screws (Figure 1, Item 3), lockwashers (Figure 1, Item 4), and washers (Figure 1, Item 5), and
remove winterization heater control box assembly (Figure 1, Item 6) from rear of generator housing.

0089-1
 TM 9-6115-730-24 0089

REMOVAL - Continued

Figure 1. Winterization Heater Control Box Assembly.

END OF TASK

0089-2
 TM 9-6115-730-24 0089

DISASSEMBLY

1. Remove two screws (Figure 1, Item 7), control box mounting bracket (Figure 1, Item 8), and control box
faceplate (Figure 1, Item 9) from control box frame (Figure 1, Item 10).

NOTE
Tag and disconnect wiring during component removal.

2. Remove collar (Figure 1, Item 11), jam nut and lockwasher (Figure 1, Item 12), and LED holder (Figure 1,
Item 13) from control box faceplate (Figure 1, Item 8).

3. Remove jam nut and lockwasher (Figure 1, Item 14), and press-test indicator light (Figure 1, Item 15) from
control box faceplate (Figure 1, Item 8).

4. Remove jam nut and lockwasher (Figure 1, Item 16) and circuit breaker (Figure 1, Item 17) from control box
faceplate (Figure 1, Item 8).

5. Remove jam nut and lockwasher (Figure 1, Item 18) and toggle switch (Figure 1, Item 19) from control box
faceplate (Figure 1, Item 8).

6. Remove two screws (Figure 1, Item 20) and control box cover (Figure 1, Item 21) from control box frame
(Figure 1, Item 9).

7. Remove eight nuts (Figure 1, Item 22), screws (Figure 1, Item 23), connector J26 (Figure 1, Item 1) and J27
(Figure 1, Item 2) from control box frame (Figure 1, Item 9).

8. Remove two nuts (Figure 1, Item 24), washers (Figure 1, Item 25), screws (Figure 1, Item 26), and relay
(Figure 1, Item 27) from control box frame (Figure 1, Item 9).

9. Remove two nuts (Figure 1, Item 28), screws (Figure 1, Item 29), and terminal block and rectifier assembly
(Figure 1, Item 30) from control box frame (Figure 1, Item 9).

END OF TASK

ASSEMBLY

NOTE
Connect wiring as tagged and remove tags during component installation.

1. Install terminal block and rectifier assembly (Figure 1, Item 30) on control box frame (Figure 1, Item 9) with
two screws (Figure 1, Item 29) and nuts (Figure 1, Item 28).

2. Install relay (Figure 1, Item 27) on control box frame (Figure 1, Item 9) with two screws (Figure 1, Item 26),
washers (Figure 1, Item 25), and nuts (Figure 1, Item 24).

3. Install connectors J27 and J26 (Figure 1, Item 2) and (Figure 1, Item 1) on control box frame (Figure 1, Item
9) with eight screws (Figure 1, Item 23) and nuts (Figure 1, Item 22).

0089-3
 TM 9-6115-730-24 0089

ASSEMBLY - Continued

4. Install control box cover (Figure 1, Item 21) on control box frame (Figure 1, Item 9) with two screws (Figure 1,
Item 20).

5. Install toggle switch (Figure 1, Item 19) on control box faceplate (Figure 1, Item 8) with jam nut and
lockwasher (Figure 1, Item 18).

6. Install circuit breaker (Figure 1, Item 17) on control box faceplate (Figure 1, Item 8) with jam nut and
lockwasher (Figure 1, Item 16).

7. Install press-test indicator light (Figure 1, Item 15) and install jam nut and lockwasher (Figure 1, Item 14) on
control box faceplate (Figure 1, Item 8),

8. Install LED holder (Figure 1, Item 13) on control box faceplate (Figure 1, Item 9) and install jam nut and
lockwasher (Figure 1, Item 12) and collar (Figure 1, Item 11).

9. Install control box faceplate (Figure 1, Item 9) and control box mounting bracket (Figure 1, Item 8) on control
box frame (Figure 1, Item 10) with two screws (Figure 1, Item 7).

END OF TASK

INSTALLATION

1. Install winterization heater control box assembly (Figure 1, Item 6) on rear of generator housing and secure
with two washers (Figure 1, Item 5), lockwashers (Figure 1, Item 4), and screws (Figure 1, Item 3).

2. Connect connector P27 to connector J27 (Figure 1, Item 2) and connector P26 to connector J26 (Figure 1,
Item 1).

3. Close left rear doors.

END OF TASK

END OF WORK PACKAGE

0089-4
 TM 9-6115-730-24 0090

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
WINTERIZATION HEATER ASSEMBLY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Cap and plug set (WP 0124, Item 6) TM 9-6115-730-24P

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

When running, winterization heater has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow heater to cool before performing maintenance. Wear gloves and
additional protective clothing as required. Failure to comply can cause serious injury to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the heater system.

0090-1
 TM 9-6115-730-24 0090

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF, Battery Disconnect Switch is OFF,
and DEAD CRANK SWITCH is OFF before proceeding.

2. Open right and left battery access doors and right front doors.

3. Close shutoff valves (Figure 1, Item 1) and (Figure 1, Item 2).

4. Disconnect and remove hose clamp (Figure 1, Item 3) and disconnect low-pressure hose (Figure 1, Item 4),
fuel pump harness (Figure 1, Item 9), fuel metering pump (Figure 1, Item 5) from inside of heater (Figure 1,
Item 6).

5. Remove hose clamp (Figure 1, Item 7) and disconnect flexible braided leak-off hose (Figure 1, Item 8) from
OUT side of fuel metering pump (Figure 1, Item 5) on heater (Figure 1, Item 6).

6. Disconnect generator set wiring harness (Figure 1, Item 9) (2 places) from heater (Figure 1, Item 6).

7. Remove hose clamp (Figure 1, Item 10) and disconnect 90-degree elbow coolant hose (Figure 1, Item 11)
from fitting on top of heater (Figure 1, Item 6).

8. Remove hose clamp (Figure 1, Item 12) and disconnect coolant hose (Figure 1, Item 13) from bottom of
heater (Figure 1, Item 6).

9. Remove screw (Figure 1, Item 14), washer (Figure 1, Item 15), clamp (Figure 1, Item 16), and fuel metering
pump (Figure 1, Item 5) from heater (Figure 1, Item 6).

10. Remove hose clamp (Figure 1, Item 17) and disconnect flexible exhaust tubing (Figure 1, Item 18) from
heater (Figure 1, Item 6).

11. Remove screw (Figure 1, Item 19), lockwasher (Figure 1, Item 20), and clamp (Figure 1, Item 21).

12. Remove four screws (Figure 1, Item 22), lockwashers (Figure 1, Item 23), washers (Figure 1, Item 24), and
heater (Figure 1, Item 6) from skid base.

END OF TASK

INSTALLATION

1. Install heater (Figure 1, Item 6) and secure with four screws (Figure 1, Item 22), lockwashers (Figure 1, Item
23), and washers (Figure 1, Item 24).

2. Install clamp (Figure 1, Item 21), and secure with lockwasher (Figure 1, Item 20) and screw (Figure 1, Item
19).

3. Connect flexible exhaust tubing (Figure 1, Item 18) on heater (Figure 1, Item 6) and install hose clamp (Figure
1, Item 17).

4. Install fuel metering pump (Figure 1, Item 5) and clamp (Figure 1, Item 16) on heater (Figure 1, Item 6) and
secure with washer (Figure 1, Item 15) and screw (Figure 1, Item 14).

0090-2
 TM 9-6115-730-24 0090

INSTALLATION - Continued

Figure 1. Winterization Heater Assembly.

0090-3
 TM 9-6115-730-24 0090

INSTALLATION - Continued

5. Connect coolant hose (Figure 1, Item 13) to bottom of heater (Figure 1, Item 6) and install hose clamp (Figure
1, Item 12).

6. Connect 90-degree elbow coolant hose (Figure 1, Item 11) to top of heater (Figure 1, Item 6) and install hose
clamp (Figure 1, Item 10).

7. Connect generator set wiring harness (Figure 1, Item 9) to heater (Figure 1, Item 6) in two places.

8. Connect flexible braided leak-off hose (Figure 1, Item 8) to OUT side of fuel metering pump (Figure 1, Item 5)
and install hose clamp (Figure 1, Item 7).

9. Connect low-pressure hose (Figure 1, Item 4), hose clamp (Figure 1, Item 3) and fuel metering pump (Figure
1, Item 5) to inside of fuel pump (Figure 1, Item 6)

10. Open shutoff valves (Figure 1, Item 1) and (Figure 1, Item 2).

WARNING
Operating the generator set with any access door open exposes personnel to a high noise level.
Hearing protection must be worn when operating or working near the generator set with any
access door open. Failure to comply can cause hearing damage to personnel.

11. Operate engine and check for leaks.

12. Close right and left battery access doors and right front doors.

END OF TASK

END OF WORK PACKAGE

0090-4
 TM 9-6115-730-24 0091

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
WINTERIZATION HEATER HOSES MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Cap and plug set (WP 0124, Item 6) TM 9-6115-730-24P

Sealing compound (WP 0124, Item 40)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

When running, winterization heater has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow heater to cool before performing maintenance. Wear gloves and
additional protective clothing as required. Failure to comply can cause serious injury to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the heater system.

0091-1
 TM 9-6115-730-24 0091

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF, Battery Disconnect Switch is OFF,
and DEAD CRANK SWITCH is OFF before proceeding.

2. Open battery access doors, right front doors, and left front door.

3. Use suitable container and drain cooling system (see WP 0064).

4. Remove hose clamp (Figure 1, Item 1) and disconnect hose (Figure 1, Item 2) from shutoff valve (Figure 1,
Item 3) located behind alternator.

5. Remove hose clamp (Figure 1, Item 4) and disconnect hose (Figure 1, Item 2) from hose mender fitting
(Figure 1, Item 5) at top of heater (Figure 1, Item 6), and remove hose (Figure 1, Item 2).

6. Remove two hose clamps (Figure 1, Item 7), hose mender fitting (Figure 1, Item 5), and 90-degree hose
elbow (Figure 1, Item 8) from heater (Figure 1, Item 6).

7. Remove hose clamp (Figure 1, Item 9) and disconnect hose (Figure 1, Item 10) from shutoff valve (Figure 1,
Item 11) located below alternator.

8. Disconnect and remove hose clamp (Figure 1, Item 12) and disconnect hose (Figure 1, Item 10) from bottom
of heater (Figure 1, Item 6), and remove hose (Figure 1, Item 10).

9. Remove screw (Figure 1, Item 13), lockwasher (Figure 1, Item 14), and clamp (Figure 1, Item 15).

10. Remove hose clamp (Figure 1, Item 16) and disconnect low-pressure hose (Figure 1, Item 17) from IN side of
fuel metering pump (Figure 1, Item 18).

11. Disconnect and remove hose clamp (Figure 1, Item 19) and disconnect low-pressure hose (Figure 1, Item 17)
from nose fitting (Figure 1, Item 20) on left side of fuel tank, and remove hose (Figure 1, Item 17).

12. Remove two hose clamps (Figure 1, Item 21) and remove flexible braided leak-off hose (Figure 1, Item 22)
from OUT side of fuel filter (Figure 1, Item 18) and from bottom of heater (Figure 1, Item 6).

13. Remove hose clamp (Figure 1, Item 23) and disconnect flexible exhaust tubing (Figure 1, Item 24) from
heater (Figure 1, Item 6) and from heater exhaust adapter (Figure 1, Item 25).

14. Remove four screws (Figure 1, Item 26), lockwashers (Figure 1, Item 27), washers (Figure 1, Item 28), and
heater exhaust adapter (Figure 1, Item 25) from skid base.

15. Remove shutoff valve (Figure 1, Item 11) and shutoff valve (Figure 1, Item 3).

END OF TASK

INSTALLATION

NOTE
Apply sealing compound to all male pipe threads before connecting.

1. Install shutoff valve (Figure 1, Item 11) and shutoff valve (Figure 1, Item 3).

0091-2
 TM 9-6115-730-24 0091

INSTALLATION - Continued

Figure 1. Winterization Heater Hoses.

0091-3
 TM 9-6115-730-24 0091

INSTALLATION - Continued

2. Install heater exhaust adapter (Figure 1, Item 25) on skid base and secure with four washers (Figure 1, Item
28), lockwashers (Figure 1, Item 27), and screws (Figure 1, Item 26).

3. Connect flexible exhaust tubing (Figure 1, Item 24) to heater exhaust adapter (Figure 1, Item 25) and to
heater (Figure 1, Item 6) and install hose clamp (Figure 1, Item 23).

4. Connect flexible braided leak-off hose (Figure 1, Item 22) to OUT side of fuel metering pump (Figure 1, Item
18) and to bottom of heater (Figure 1, Item 6) and install two hose clamps (Figure 1, Item 21).

5. Connect low-pressure hose (Figure 1, Item 17) to male hose barb fitting (Figure 1, Item 20) on left side of fuel
tank and install hose clamp (Figure 1, Item 19).

6. Connect low-pressure hose (Figure 1, Item 17) to IN side of fuel metering pump (Figure 1, Item 18) and install
hose clamp (Figure 1, Item 16).

7. Install clamp (Figure 1, Item 15), lockwasher (Figure 1, Item 14), and screw (Figure 1, Item 13) on hose
(Figure 1, Item 17).

8. Connect hose (Figure 1, Item 10) to bottom of heater (Figure 1, Item 6) and install hose clamp (Figure 1,
Item 12).

9. Connect hose (Figure 1, Item 10) to shutoff valve (Figure 1, Item 11) located below alternator and install hose
clamp (Figure 1, Item 9).

10. Install 90-degree hose elbow (Figure 1, Item 8) and hose mender fitting (Figure 1, Item 5) on heater (Figure 1,
Item 6) and install two hose clamps (Figure 1, Item 7).

11. Connect hose (Figure 1, Item 2) to hose mender fitting (Figure 1, Item 5) and install hose clamp (Figure 1,
Item 4).

12. Connect hose (Figure 1, Item 2) to shutoff valve (Figure 1, Item 3) located behind alternator and install hose
clamp (Figure 1, Item 1).

13. Refill cooling system (see WP 0064).

14. Close left front door, battery access doors, and right front doors.

END OF TASK

END OF WORK PACKAGE

0091-4
 TM 9-6115-730-24 0092

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
WINTERIZATION THERMOSTAT, RESISTORS, AND DIODE MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Insulation sleeving (WP 0124, Item 22) TM 9-6115-730-24P

Marker tags (WP 0124, Item 49)
Solder (WP 0124, Item 44)
Tiedown strap (WP 0124, Item 47)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut down. Avoid
shorting any positive with ground/negative. Failure to comply can cause injury to personnel and damage to
equipment.

Avoid breathing fumes generated by soldering. Eye protection is required. Good general ventilation is
normally adequate. Failure to comply can cause injury to personnel.

0092-1
 TM 9-6115-730-24 0092

REMOVAL

NOTE
Cut tiedown straps as required.

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF, Battery Disconnect Switch is OFF,
and DEAD CRANK SWITCH is OFF before proceeding.

2. Open control box door and control box panel.

3. To remove thermostat (Figure 1, Item 1), at left side of control box assembly, tag and disconnect spade
terminals as follows:

Lead from TS-1 to TB 4-17

Lead from TS-2 to TB 4-12

4. Remove two nuts (Figure 1, Item 2), screws (Figure 1, Item 3), and thermostat (Figure 1, Item 1).

5. To remove either resistor HTR1 (Figure 1, Item 4), located below GSC, or HTR2 (Figure 1, Item 5), located on
right side of control panel, unsolder leads and remove two nuts (Figure 1, Item 6), screws (Figure 1, Item 7),
and resistor (Figure 1, Item 4) or (Figure 1, Item 5).

6. Tag and disconnect spade terminals and wiring as follows:

HTR-1 lead 1 to TB4-10B

HTR-2 lead 1 to TB3-10B
HTR-1 lead 2 to HTR-2 lead 2

NOTE
Note orientation of diode before removing.

7. To remove diode (Figure 1, Item 8), tag and disconnect spade terminals as follows:

Cathode of diode to TB4-10

Anode of diode to TB4-12

8. Remove diode (Figure 1, Item 8).

END OF TASK

INSTALLATION

NOTE
Install tiedown straps as required.

1. To install diode (Figure 1, Item 8), connect spade terminals as follows:

Cathode of diode to TB4-10

Anode of diode to TB4-12

0092-2
 TM 9-6115-730-24 0092

INSTALLATION - Continued

Figure 1. Winterization Thermostat, Resistors, and Diode.

0092-3
 TM 9-6115-730-24 0092

INSTALLATION - Continued

NOTE
Replace heat shrink sleeving when soldering wiring on resistor leads.

2. To install resistor HTR1 (Figure 1, Item 4) or HTR2 (Figure 1, Item 5), position resistor and secure with two
screws (Figure 1, Item 7) and nuts (Figure 1, Item 6).

3. Connect spade terminals as follows:

HTR-1 lead 1 to TB4-10B

HTR-2 lead 1 to TB3-10B
HTR-1 lead 2 to HTR-2 lead 2

4. To install thermostat (Figure 1, Item 1), position thermostat and secure with two screws (Figure 1, Item 3) and
nuts (Figure 1, Item 2).

5. Connect spade terminals to TB 4 as follows:

Lead from TS-1 to TB 4-17

Lead from TS-2 to TB 4-12

6. Close control box panel and control box door.

END OF TASK

END OF WORK PACKAGE

0092-4
 TM 9-6115-730-24 0093

UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
WINTERIZATION WIRING HARNESSES MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Tool Kit, General Mechanic’s (WP 0123, Item 1) One

Materials/Parts References

Marker tags (WP 0124, Item 49) TM 9-6115-730-24P

Tiedown strap (WP 0124, Item 47)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

When running, winterization heater has hot metal surfaces that will burn flesh on contact. Shut
down generator set and allow heater to cool before performing maintenance. Wear gloves and
additional protective clothing as required. Failure to comply can cause serious injury to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the air cleaner system.

0093-1
 TM 9-6115-730-24 0093

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF, Battery Disconnect Switch is OFF,
and DEAD CRANK SWITCH is OFF before proceeding.

2. On winterization heater (Figure 1, Item 7), disconnect connector P28 (Figure 1, Item 8) from/to heater
metering pump, and connector P29 (Figure 1, Item 9) from end of heater.

NOTE
Cut tiedown straps as required.

3. Open left rear doors and battery access doors.

4. To remove winterization power input wiring harness, disconnect connector P26 (Figure 1, Item 1) from
connector J26 (Figure 1, Item 2) on rear of winterization heater control box (Figure 1, Item 3).

5. On terminal board TB5 (Figure 1, Item 4), tag and disconnect three spade terminals from TB5-15A, TB5-16A,
and TB5-17A.

6. To remove heater to heater control box wiring harness, disconnect connector P27 (Figure 1, Item 5) from
connector J27 (Figure 1, Item 6) on rear of winterization heater control box (Figure 1, Item 3).

7. On terminal board TB5 (Figure 1, Item 4), tag and disconnect spade terminal from TB5-17B.

8. Remove winterization heater to heater control box wiring harness.

END OF TASK

INSTALLATION

NOTE
Install tiedown straps as required.

1. To install winterization heater to heater control box wiring harness, connect spade terminal to TB5-17B
on terminal board TB5 (Figure 1, Item 4).

2. Connect connector P27 (Figure 1, Item 5) to connector J27 (Figure 1, Item 6) on rear of winterization heater
control box (Figure 1, Item 3).

3. To install winterization power wiring harness, connect three spade terminals to TB5-17A, TB5-16A, and
TB5-15A on terminal board TB5 (Figure 1, Item 4).

4. Connect connector J26 (Figure 1, Item 2) to connector P26 (Figure 1, Item 1) on rear of winterization heater
control box (Figure 1, Item 3).

5. Connect connector P29 (Figure 1, Item 9) to end of heater (Figure 1, Item 7), and connector P28 (Figure 1,
Item 8) to top of heater.

6. Close left rear doors and battery access doors.

0093-2
 TM 9-6115-730-24 0093

INSTALLATION - Continued

Figure 1. Winterization Wiring Harnesses.

END OF TASK

END OF WORK PACKAGE

0093-3/4 blank
 TM 9-6115-730-24

CHAPTER 5

DIRECT SUPPORT (FIELD) LEVEL

MAINTENANCE INSTRUCTIONS
 TM 9-6115-730-24

CHAPTER 5

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE INSTRUCTIONS

WORK PACKAGE INDEX

Title WP Sequence No.

GENERATOR REPAIR ................................................................................................................................ 0094

GENERATOR REPLACEMENT................................................................................................................... 0095
ENGINE REPLACEMENT............................................................................................................................ 0096
ENGINE/GENERATOR BASE ASSEMBLY REPAIR .................................................................................. 0097
ENGINE ELECTRICAL SYSTEM REPAIR .................................................................................................. 0098
FAN PULLEY MAINTENANCE .................................................................................................................... 0099
VALVE COVER AND BASE MAINTENANCE.............................................................................................. 0100
FUEL FILTER BASE AND MANIFOLD MAINTENANCE............................................................................. 0101
FUEL TRANSFER PUMP MAINTENANCE ................................................................................................. 0102
TURBOCHARGER MAINTENANCE............................................................................................................ 0103
CRANKSHAFT VIBRATION DAMPER AND PULLEY MAINTENANCE ..................................................... 0104
CRANKSHAFT FRONT SEAL MAINTENANCE .......................................................................................... 0105
FRONT COVER MAINTENANCE ................................................................................................................ 0106
OIL FILTER BASE MAINTENANCE............................................................................................................. 0107
OIL COOLER MAINTENANCE .................................................................................................................... 0108
OIL PUMP MAINTENANCE ......................................................................................................................... 0109
WATER PUMP MAINTENANCE .................................................................................................................. 0110
FLYWHEEL MAINTENANCE ....................................................................................................................... 0111
CRANKSHAFT REAR SEAL MAINTENANCE............................................................................................. 0112
FLYWHEEL HOUSING MAINTENANCE ..................................................................................................... 0113
CRANKSHAFT REAR SEAL CARRIER MAINTENANCE ........................................................................... 0114
EXHAUST MANIFOLD MAINTENANCE...................................................................................................... 0115
INLET MANIFOLD MAINTENANCE............................................................................................................. 0116
OIL PAN MAINTENANCE ............................................................................................................................ 0117
UNIT INJECTOR MAINTENANCE ............................................................................................................... 0118
ROCKER SHAFT AND PUSHROD MAINTENANCE .................................................................................. 0119
CYLINDER HEAD MAINTENANCE ............................................................................................................. 0120
 TM 9-6115-730-24 0094

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
GENERATOR REPAIR

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, One

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic References
(WP 0123, Item 3)
TM 9-237
Materials/Parts TM 9-6115-730-24P

Alcohol (WP 0124, Item 4) Equipment Condition

Breakthrough cleaning solvent
(WP 0124, Item 45) If necessary for disassembly/repair,
Crocus cloth (WP 0124, Item 9) generator removed from generator set
Grease (WP 0124, Item 19) (WP 0097)
Oil (WP 0124, Items 23-30)
Wiping rags (WP 0124, Item 35)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

0094-1
 TM 9-6115-730-24 0094

DISASSEMBLY

1. Remove twelve screws (Figure 1, Item 1) and cover (Figure 1, Item 2) from body assembly (Figure 1, Item 3).

CAUTION
Bearing bracket supports the main rotor, which will drop and sustain damage when bearing
bracket is removed. To avoid damage to rotor, bar rotor so that two main rotor poles are vertical
in stator. This will limit amount of rotor drop.

2. Bar rotor (Figure 1, Item 4) so that two main rotor poles are vertical in body assembly (Figure 1, Item 3).

NOTE
Tag and disconnect wiring before removal of components as required.

3. Remove eight screws (Figure 1, Item 5), lockwashers (Figure 1, Item 6), nuts (Figure 1, Item 7), and bearing
bracket (Figure 1, Item 8) with exciter stator (Figure 1, Item 9) attached.

CAUTION
If bearing needs to be removed, it is easily damaged, and should be replaced.

4. Use bearing puller to remove bearing (Figure 1, Item 10) from shaft of rotor (Figure 1, Item 4) and discard
bearing.

5. Remove rotating rectifier (Figure 1, Item 11) from rotor (Figure 1, Item 4).

CAUTION
Magnets in exciter stator are very strong and will attract loose screws, washers, etc, which may
cause damage to stator. Keep loose hardware away from stator. Strong magnets in stator will
also impede removal of stator.

6. Note orientation of Belleville washers (Figure 1, Item 12) and remove four screws (Figure 1, Item 13),
Belleville washers (Figure 1, Item 12), and exciter stator (Figure 1, Item 9) from bearing bracket (Figure 1,
Item 8).

7. Remove two nuts (Figure 1, Item 14), screws (Figure 1, Item 15), and exhaust screen (Figure 1, Item 16).

8. Remove 16 screws (Figure 1, Item 17), lockwashers (Figure 1, Item 18), washers (Figure 1, Item 19), and
flywheel housing adapter (Figure 1, Item 20).

CAUTION
Rotor and attached parts must be removed carefully to avoid damaging rotor or stator windings.
Do not apply any force to fan when removing rotor to avoid damage to fan.

9. Use suitable rotor lifting device to carefully remove rotor (Figure 1, Item 4) and attached parts from body
assembly (Figure 1, Item 3).

0094-2
 TM 9-6115-730-24 0094

DISASSEMBLY - Continued

Figure 1. Generator Repair.

0094-3
 TM 9-6115-730-24 0094

DISASSEMBLY - Continued

10. Mark drive discs (Figure 1, Item 21), spacer discs (Figure 1, Item 22), and drive hub (Figure 1, Item 23) for
proper alignment during assembly.

11. Remove six screws (Figure 1, Item 24), washers (Figure 1, Item 25), five drive discs (Figure 1, Item 21) and
six spacer discs (Figure 1, Item 22) from drive hub (Figure 1, Item 23).

12. Mark fan (Figure 1, Item 26) and drive hub (Figure 1, Item 23) for proper alignment and balancing of fan
during assembly.

13. Note orientation of Belleville washers (Figure 1, Item 27) as they are removed, and remove four screws
(Figure 1, Item 28), Belleville washers (Figure 1, Item 27), and fan (Figure 1, Item 26) from drive hub
(Figure 1, Item 23).

WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
generator drive hub has been heated. Wear additional protective clothing as required. Failure to
comply can cause injury to personnel.

14. Install suitable puller to drive hub (Figure 1, Item 23). Use torch to rapidly heat only outside diameter of drive
hub (Figure 1, Item 23) (to avoid expanding rotor shaft) while tightening puller. Remove drive hub (Figure 1,
Item 23) from rotor (Figure 1, Item 4).

15. Remove rectifier mounting hub (Figure 1, Item 29) and exciter rotor (Figure 1, Item 30) from rotor (Figure 1,
Item 4).

16. If necessary, remove lead block assembly (Figure 1, Item 31).

17. Remove four screws (Figure 1, Item 32) and intake air screen (Figure 1, Item 33).

18. If necessary, remove nameplate and three decals.

19. Remove two nuts (Figure 1, Item 34), two lockwashers (Figure 1, Item 35), and grounding stud (Figure 1,
Item 36).

END OF TASK

CLEANING

CAUTION
Winding varnishes are epoxy or polyester based. Do not use any cleaning materials which will
attack these materials. Be careful not to damage magnet wire or winding insulation. Do not use a
wire brush

1. Most components of the generator can be cleaned with alcohol or Breakthrough cleaning solvent and a soft
brush or cloth.

0094-4
 TM 9-6115-730-24 0094

CLEANING - Continued

WARNING
Cleaning with compressed air can cause flying particles. When using compressed air, wear
protective glasses and use clean, low pressure air, less than 30 psi (208 kPa). Failure to comply
can cause eye injury to personnel.

2. Compressed air may be used to clean dirt from areas where a cloth will not reach. Use low pressure
compressed air, 30 psi maximum.

3. Dry dust and dirt may be removed by vacuum cleaning.

4. When completely disassembled, most generator components (except electronic parts) may be steam
cleaned.

5. Make sure all components are completely dry before assembly.

END OF TASK

ASSEMBLY

1. Install grounding stud (Figure 1, Item 36), two lockwashers (Figure 1, Item 35), and two nuts (Figure 1,
Item 34).

2. If removed, install three decals and nameplate.

3. Install intake air screen (Figure 1, Item 33) and four screws (Figure 1, Item 32).

4. If removed, install lead block assembly (Figure 1, Item 31).

5. Install exciter rotor (Figure 1, Item 30) and rectifier mounting hub (Figure 1, Item 29) on rotor (Figure 1,
Item 4).

WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
generator drive hub has been heated. Wear additional protective clothing as required. Failure to
comply can cause injury to personnel.

6. Heat new drive hub (Figure 1, Item 23) in oven to 500-600 degrees F (260-316 degrees C). Using suitable
heat resistant gloves, slide drive hub (Figure 1, Item 23) on shaft until it seats against shaft shoulder. Allow
drive hub (Figure 1, Item 23) to cool for one hour.

CAUTION
Fan and drive hub must be install and aligned properly to avoid an unbalanced condition and
considerable vibration.

7. Align marks on fan (Figure 1, Item 26) with marks on drive hub (Figure 1, Item 23). Note orientation of
Belleville washers (Figure 1, Item 27). Install fan (Figure 1, Item 26), four Belleville washers (Figure 1, Item
27), and screws (Figure 1, Item 28). Torque screws (Figure 1, Item 28) in an alternating pattern to 60 lb-ft
(81 Nm).

0094-5
 TM 9-6115-730-24 0094

ASSEMBLY - Continued

8. Align marks made on drive discs (Figure 1, Item 21) and spacer discs (Figure 1, Item 22) with marks on drive
hub (Figure 1, Item 23). Install five spacer discs (Figure 1, Item 22), five drive discs (Figure 1, Item 21), six
washers (Figure 1, Item 25) and screws (Figure 1, Item 24). Torque screws (Figure 1, Item 24) in an
alternating pattern to 192 lb-ft (260 Nm).

CAUTION
Rotor and attached parts must be installed carefully to avoid damaging rotor or stator windings.

9. Use suitable lifting device and carefully install rotor (Figure 1, Item 4) and attached parts into body assembly
(Figure 1, Item 3).

10. Install flywheel housing adapter (Figure 1, Item 20), 16 washers (Figure 1, Item 19), lockwashers (Figure 1,
Item 18), and screws (Figure 1, Item 17). Torque screws (Figure 1, Item 17) in an alternating pattern to
25 lb-ft (34 Nm).

11. Install exhaust screen (Figure 1, Item 16), two screws (Figure 1, Item 15), and nuts (Figure 1, Item 14).

12. Note orientation of Belleville washers (Figure 1, Item 12). Install exciter stator (Figure 1, Item 9) in bearing
bracket (Figure 1, Item 8) and install four Belleville washers (Figure 1, Item 12) and screws (Figure 1,
Item 13). Torque screws (Figure 1, Item 13) to 60 lb-ft (81 Nm).

13. Install rotating rectifier assembly (Figure 1, Item 11) on rotor (Figure 1, Item 4).

WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after
generator bearing has been heated. Wear additional protective clothing as required. Failure to
comply can cause injury to personnel.

CAUTION
Do not strike bearing directly with hammer. Do not apply pressure to outer race. Use only light
taps from a soft mallet, or bearing will be damaged.

14. Heat new bearing (Figure 1, Item 10) in an oven to a maximum of 212 degrees F (100 degrees C). Apply a
thin coat of clean oil to the press fit area of the shaft on rotor (Figure 1, Item 4). Using heat resistant gloves,
install bearing (Figure 1, Item 10) over end of shaft until it seats against shaft shoulder. Bearing should slide
on shaft and be seated without excessive force. If bearing binds on shaft before fully seated, use a piece of
tubing slightly larger than the press fit area and a soft mallet to drive bearing into place. Use light taps and
apply pressure only to inner race of bearing. After installation, allow bearing to cool for one hour before
continuing assembly of generator.

15. After bearing (Figure 1, Item 10) has cooled, fill bearing grease cavity one third to one half full of grease.

0094-6
 TM 9-6115-730-24 0094

ASSEMBLY - Continued

16. Install bearing bracket (Figure 1, Item 8) with exciter stator (Figure 1, Item 9) attached onto body assembly
(Figure 1, Item 3) with eight washers (Figure 1, Item 7), lockwashers (Figure 1, Item 6), and screws (Figure 1,
Item 5). Torque screws (Figure 1, Item 5) in an alternating pattern to 25 lb-ft (34 Nm).

17. Install cover (Figure 1, Item 2) and 12 screws (Figure 1, Item 1). Torque screws (Figure 1, Item 1) in an
alternating pattern to 25 lb-ft (34 Nm).

END OF TASK

END OF WORK PACKAGE

0094-7/8 blank
 TM 9-6115-730-24 0095

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
GENERATOR REPLACEMENT

INITIAL SETUP:

Tools and Special Tools Equipment Condition (cont.)

Lifting Device, 2,600 lb (1180 kg) Capacity Right rear door assembly removed
Shop Equipment, Automotive Maintenance, (WP 0027)
Common No. 1 (WP 0123, Item 2) Right rear door assembly (latch) removed
Shop Equipment, Field Maintenance, Basic (WP 0028)
(WP 0123, Item 3) Front roof section housing assembly
removed (WP 0030)
Personnel Required Rear roof section housing assembly
removed (WP 0031)
Two Engine generator compartment ceiling
assembly removed (WP 0032)
References Generator access cover assembly removed
(WP 0033)
TM 9-6115-730-24P Rear section housing assembly removed
(WP 0035)
Equipment Condition Right rear panel assembly removed
(WP 0038)
Left rear door assembly removed (WP 0022) Left rear panel assembly removed
Left rear door assembly (latch) removed (WP 0039)
(WP 0023)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

0095-1
 TM 9-6115-730-24 0095

REMOVAL

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF, Battery Disconnect Switch is OFF,
and DEAD CRANK SWITCH is OFF before proceeding.

2. Disconnect wiring from generator (Figure 1, Item 1).

3. Remove eight screws (Figure 1, Item 2) and lockwashers (Figure 1, Item 3), and 12 screws (Figure 1, Item 4)
and lockwashers (Figure 1, Item 5) connecting generator (Figure 1, Item 1) to engine (Figure 1, Item 6).

4. Remove two locknuts (Figure 1, Item 7), two screws (Figure 1, Item 8), four washers (Figure 1, Item 9), and
two snubbing washers (Figure 1, Item 10) from generator shock mounts (Figure 1, Item 11).

WARNING
The generator weighs more than 2530 pounds (1148 kg) and requires an assistant and a lifting
device (forklift, overhead lifting device) with sufficient capacity. Be careful and keep hands and
arms out of the way when lifting generator out of engine generator base. Failure to comply can
cause serious injury or death to personnel.

5. Attach suitable lifting device with at least 2600 lb (1180 kg) capacity to lifting eye (Figure 1, Item 12) on
generator (Figure 1, Item 1) and take slack out of lifting device.

6. Loosen two nuts (Figure 1, Item 13) and turn two jackscrews (Figure 1, Item 14) clockwise (CW) to raise
engine (Figure 1, Item 6) approximately 1/2 inch (1.27 cm) to allow separation of generator (Figure 1, Item 1)
and engine (Figure 1, Item 6).

7. Carefully lift generator (Figure 1, Item 1) out of engine generator base.

END OF TASK

INSTALLATION

WARNING
The generator weighs more than 2530 pounds (1148 kg) and requires an assistant and a lifting
device (forklift, overhead lifting device) with sufficient capacity. Be careful and keep hands and
arms out of the way when lifting generator out of engine generator base. Failure to comply can
cause serious injury or death to personnel.

1. Using suitable lifting device with at least 2600 lb (1180 kg) capacity, carefully lower generator (Figure 1, Item
1) onto engine generator base and align with engine (Figure 1, Item 6).

2. Turn two jackscrews (Figure 1, Item 14) counterclockwise (CCW) to lower engine (Figure 1, Item 6) into
proper alignment with generator (Figure 1, Item 1). Tighten two nuts (Figure 1, Item 13).

3. Allow slack in lifting device and disconnect from lifting eye (Figure 1, Item 12) on generator (Figure 1, Item 1).

4. Install two snubbing washers (Figure 1, Item 10), four washers (Figure 1, Item 9), two screws (Figure 1,
Item 8) and two locknuts (Figure 1, Item 7) on two generator shock mounts (Figure 1, Item 11).

0095-2
 TM 9-6115-730-24 0095

INSTALLATION - Continued

Figure 1. Generator.

0095-3
 TM 9-6115-730-24 0095

INSTALLATION - Continued

5. Install 12 lockwashers (Figure 1, Item 5) and screws (Figure 1, Item 4). Torque twelve screws (Figure 1,
Item 4) to 41-49 lb-ft (56-66 Nm).

6. Install eight lockwashers (Figure 1, Item 3) and screws (Figure 1, Item 2). Torque eight screws (Figure 1,
Item 2) to 63-77 lb-ft (86-104 Nm).

7. Torque two screws (Figure 1, Item 8) to 216-264 lb-ft (293-358 Nm).

8. Connect wiring to generator (Figure 1, Item 1).

9. Install left rear panel assembly (WP 0039).

10. Install right rear panel assembly (WP 0038).

11. Install rear section housing assembly (WP 0035).

12. Install generator access cover assembly (WP 0033).

13. Install engine generator compartment ceiling assembly (WP 0032).

14. Install rear roof section housing assembly (WP 0031).

15. Install front roof section housing assembly (WP 0030).

16. Install right rear door assembly (latch) (WP 0028).

17. Install right rear door assembly (WP 0027).

18. Install left rear door assembly (latch) (WP 0023).

19. Install left rear door assembly (WP 0022).

END OF TASK

END OF WORK PACKAGE

0095-4
 TM 9-6115-730-24 0096

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
ENGINE REPLACEMENT

INITIAL SETUP:

Tools and Special Tools Equipment Condition (cont.)

Lifting Device, 2,500 lb (1134 kg) Capacity Right front door assembly removed (WP 0026)
Shop Equipment, Automotive Maintenance, Right rear door assembly removed (WP 0027)
Common No. 1 (WP 0123, Item 2) Right rear door assembly (latch) removed
Shop Equipment, Field Maintenance, Basic (WP 0028)
(WP 0123, Item 3) Access covers removed (WP 0029)
Front roof section housing assembly removed
Personnel Required (WP 0030)
Control box assembly removed (WP 0042)
Two Rear roof section housing assembly removed
(WP 0031)
References Coolant recovery system bottle removed
(WP 0064)
WP 0056 Surge tank removed (WP 0065)
WP 0057 Exhaust system removed (WP 0069)
WP 0062 Fan guards and shrouds removed (WP 0066)
WP 0074 Coolant hoses removed from engine (WP 0067)
WP 0076 Radiator removed (WP 0068)
WP 0088 Engine generator compartment ceiling assembly
WP 0091 removed (WP 0032)
WP 0095 Front section housing assembly removed
WP 0098 (WP 0034)
TM 9-6115-730-24P Left center panel assembly removed (WP 0036)
Right center panel assembly removed
Equipment Condition (WP 0037)
Right rear panel assembly removed (WP 0038)
Batteries removed (WP 0050) Left rear panel assembly removed (WP 0039)
Left front door assembly (latch) removed Door support assembly removed (WP 0040)
(WP 0021) Auxiliary fuel pump assembly and solenoid valve
Left rear door assembly removed (WP 0022) removed (WP 0059)
Left rear door assembly (latch) removed Air cleaner system removed (WP 0072)
(WP 0023) Wires from fuel level switch tagged and
Load board door assembly removed (WP 0024) disconnected (WP 0056).
Right front door assembly (latch) removed Hoses from winterization kit heater tagged
(WP 0025) and disconnected (WP 0091).

0096-1 Change 1
 TM 9-6115-730-24 0096

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

REMOVAL

1. Tag and disconnect wires from fuel level switch (WP 0056).

2. Tag and disconnect wires from alternator (WP 0074).

3. Tag and disconnect magnetic speed pickup from engine harness connector ENG-P14 (WP 0098).

4. Tag and disconnect engine harness connector ENG-P1 from ECM connector J1 (WP 0088).

5. Tag and disconnect fuel hose from engine fuel pump (WP 0057).

6. Tag and disconnect all wires and cables from starter (WP 0076).

7. Tag and disconnect winterization heater hoses from engine (if installed) (WP 0090).

8. Remove two locknuts (Figure 1, Item 1), two screws (Figure 1, Item 2), four washers (Figure 1, Item 3), and
two snubbing washers (Figure 1, Item 4) and bottom engine shock mounts (Figure 1, Item 5).

9. Attach suitable lifting device with at least 2000 lb (907 kg)capacity to front lifting bracket (Figure 1, Item 6) and
rear lifting bracket (Figure 1, Item 7) on engine (Figure 1, Item 8) and take slack out of lifting device.

10. Loosen two nuts (Figure 1, Item 9) and snug down two jackscrews (Figure 1, Item 10). Retighten two nuts.

Change 1 0096-2
 TM 9-6115-730-24 0096

REMOVAL - Continued

Figure 1. Engine.

0096-3 Change 1
 TM 9-6115-730-24 0096

REMOVAL - Continued

14. Adjust generator jackscrews to support generator (WP 0095).

15. Remove hardware connecting generator to engine and flywheel (WP 0095).

WARNING
The engine weighs more than 2000 pounds (907 kg) and requires an assistant and a lifting device
(forklift, overhead lifting device) with sufficient capacity. Be careful and keep hands and arms out
of the way when lifting engine out of engine generator base. Failure to comply can cause serious
injury or death to personnel.

16. Carefully lift engine (Figure 1, Item 8) off engine generator base.

17. Remove two top snubbing washers (Figure 1, Item 4) and two top engine shock mounts (Figure 1, Item 5).

END OF TASK

INSTALLATION

WARNING
The engine weighs more than 2000 pounds (907 kg) and requires an assistant and a lifting device
(forklift, overhead lifting device) with sufficient capacity. Be careful and keep hands and arms out
of the way when lifting engine out of engine generator base. Failure to comply can cause serious
injury or death to personnel.

1. Install two top engine shock mounts (Figure 1, Item 5) and snubbing washers (Figure 1, Item 4).

2. Using a suitable lifting device with at least 2000 lb (907 kg) capacity, connected to front lifting bracket
(Figure 1, Item 6) and rear lifting bracket (Figure 1, Item 7), carefully lower engine (Figure 1, Item 8) onto
engine generator base and top engine shock mounts assemblies. Align flywheel to generator.

3. Install two bottom engine shock mounts (Figure 1, item 5), snubbing washers (Figure 1, Item 4), four washers
(Figure 1, Item 3), two screws (Figure 1, Item 2), and two locknuts (Figure 1, Item 1). Torque screws (Figure 1,
Item 5) to 216-264 lb-ft (293-357 Nm).

4. Install hardware connecting generator to engine and flywheel (WP 0095).

5. Draw-up generator jackscrews (WP 0095).

6. Loosen two jackscrews (Figure 1, Item 10) and two nuts (Figure 1, Item 9). Draw-up bolts and tighten nuts.

7. Connect winterization heater hoses to engine (WP 0090, Items 11 and 13) (if previously installed).

8. Remove tags and connect wires and cables to starter (WP 0076).

9. Connect fuel hose to engine fuel pump (WP 0057).

10. Remove tag and connect engine harness connector ENG-P1 to ECM connector J1 (WP 0088).

Change 1 0096-4
 TM 9-6115-730-24 0096

INSTALLATION - Continued

11. Remove tag and connect magnetic speed pickup to engine harness connector ENG-P14 (WP 0098).

12. Remove tags and connect wires to alternator (WP 0074).

13. Remove tags and connect wires to fuel level switch (WP 0056).

14. Install air cleaner system (WP 0072).

15. Install radiator (WP 0068).

16. Remove tags and connect coolant hoses to engine (WP 0067).

17. Install fan guards and shrouds (WP 0066).

18. Install auxiliary fuel pump assembly and solenoid valve (WP 0059).

19. Install doors and panels (WP 0040 thru WP 0036 and WP 0034).

20. Install engine generator compartment ceiling assembly (WP 0032).

21, Install exhaust system (WP 0069).

22. Install surge tank (WP 0065).

23. Install coolant recovery system bottle (WP 0064).

24. Install rear roof section housing assembly (WP 0031).

25. Install control box assembly (WP 0042).

26. Install front roof section housing assembly (WP 0030).

27. Install door and panels (WP 0029 and WP 0021).

28. Install batteries (WP 0050).

END OF TASK

END OF WORK PACKAGE

0096-5/6 blank Change 1

 TM 9-6115-730-24 0097

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
ENGINE/GENERATOR BASE ASSEMBLY REPAIR

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, Two

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic References
(WP 0123, Item 3)
MIL-DTL-53072C
Materials/Parts TC 9-237
TM 9-6115-730-24P
Crocus cloth (WP 0124, Item 9)
Foam damping sheet (WP 0124, Item 10)
Foam damping sheet (WP 0124, Item 13)
Foam damping sheet (WP 0124, Item 15)
Wiping rags (WP 0124, Item 35)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REPAIR OR REPLACEMENT

1. Ensure generator set is fully stopped, ENGINE CONTROL switch is OFF, Battery Disconnect Switch is OFF,
and DEAD CRANK SWITCH is OFF before proceeding.

0097-1
 TM 9-6115-730-24 0097

REPAIR OR REPLACEMENT - Continued

NOTE
Repair of the engine/generator base assembly is limited to removal of corrosion, welding of
cracks, and painting.

2. Remove attached assemblies as required to gain access to parts of engine/generator base assembly
requiring repair.

3. Remove corrosion as required using crocus cloth.

4. Repair cracks in weldment by welding in accordance with TC 9-237.

5. Clean weld surface and surrounding area, pretreat, and paint in accordance with MIL-DTL-53072C, with top
coat to a thickness of 1-2 mils.

6. Replace foam damping sections by using the old sections as templates to cut the new sections.

7. Install attached assemblies that were removed.

END OF TASK

END OF WORK PACKAGE

0097-2
 TM 9-6115-730-24 0098

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
ENGINE ELECTRICAL SYSTEM REPAIR

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, One

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic References
(WP 0123, Item 3)
TM 9-6115-730-24P
Materials/Parts
Equipment Condition
Alcohol (WP 0124, Item 4)
Breakthrough cleaning solvent Fuel drained to prevent spillage when
(WP 0124, Item 45) removing fuel pressure sensor (WP 0057)
Cap and plug set (WP 0124, Item 6) Coolant drained below the coolant
Crocus cloth (WP 0124, Item 9) temperature sensor (WP 0065)
Tiedown straps (WP 0124, Item 46)
Wiping rags (WP 0124, Item 35)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

DC voltages are present at generator set electrical components even with generator set shut
down. Avoid shorting any positive with ground/negative. Failure to comply can cause injury to
personnel and damage to equipment.

WARNING
When running, generator set engine has hot metal surfaces that will burn flesh on contact. Shut
down generator set, and allow engine to cool before performing checks, services, and
maintenance. Wear gloves and additional protective clothing as required. Failure to comply can
cause injury or death to personnel.

0098-1
 TM 9-6115-730-24 0098

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the fuel system.

NOTE
Cut tiedown straps as required during removal. Install tiedown straps as required during
installation. Table 1 identifies removal and installation steps for engine sensors.

REMOVAL

Table 1. WP 0098 Guide.

FIGURE 1 REMOVAL INSTALLATION RELATED

NAME ITEM STEPS STEPS WP
Oil pressure sensor 1 1 and 2 34 and 35
Fuel temperature sensor 4 3 and 4 32 and 33
Fuel pressure sensor 5 5 thru 7 29 thru 31 WP 0057
Magnetic speed pickup 9 8 and 9 25 thru 28
Coolant temperature sensor 10 10 thru 13 21 thru 24 WP 0065
Intake manifold air 16 14 thru 16 18 thru 20
temperature sensor
Turbo outlet pressure sensor 17 17 and 18 16 and 17
Low coolant sensor 18 19 and 20 14 and 15
Turbo inlet pressure sensor 19 21 and 22 12 and 13
Atmospheric temperature 20 23 thru 25 9 thru 11
sensor
Camshaft speed/timing 23 26 and 27 7 and 8 WP 0013
sensor (top)
Crankshaft speed/timing 27 29 and 30 1 thru 6 WP 0013
sensor (bottom)

1. Tag and disconnect engine harness connector ENG-P201 from oil pressure sensor (Figure 1, Sheet 1,
Item 1),

2. Remove engine oil pressure sensor (Figure 1, Sheet 1, Item 1), seal (Figure 1, Sheet 1, Item 2) and elbow
(Figure 1, Sheet 1, Item 3).

3. Tag and engine harness connector ENG-P105 from fuel temperature sensor (Figure 1, Sheet 1, Item 4).

4. Remove fuel temperature sensor (Figure 1, Sheet 1, Item 4) with O-ring.

5. Drain sufficient fuel from system so fuel does not spill during removal of sensor.

6. Tag and disconnect engine harness connector ENG-P202 from fuel pressure sensor (Figure 1, Sheet 1,
Item 5).

0098-2
 TM 9-6115-730-24 0098

REMOVAL - Continued

Figure 1. Engine Electrical System Repair (Sheet 1 of 3).

0098-3
 TM 9-6115-730-24 0098

REMOVAL - Continued

Figure 1. Engine Electrical System Repair (Sheet 2 of 3).

0098-4
 TM 9-6115-730-24 0098

REMOVAL - Continued

Figure 1. Engine Electrical System Repair (Sheet 3 of 3).

7. Remove fuel pressure sensor (Figure 1, Sheet 1, Item 5), seal (Figure 1, Sheet 1, Item 6), and adapter
(Figure 1, Sheet 1, Item 7).

8. Tag and disconnect ECM to EMCP harness connector ENG-P14 from magnetic speed pickup (Figure 1,
Sheet 1, Item 9).

9. Loosen locknut (Figure 1, Sheet 1, Item 8) and remove magnetic speed pickup (Figure 1, Sheet 1, Item 9).

10. Drain level of coolant below coolant temperature sensor (WP 0065).

11. Remove bolt (Figure 1, Sheet 2, Item 12) and clamp (Figure 1, Sheet 2, Item 11).

12. Tag and disconnect engine harness connector ENG-P100 from coolant temperature sensor (Figure 1,
Sheet 2, Item 10).

13. Remove coolant temperature sensor (Figure 1, Sheet 2, Item 10) with O-ring from water outlet manifold
(Figure 1, Sheet 2, Item 13).

14. Remove bolt (Figure 1, Sheet 2, Item 14) and clamp (Figure 1, Sheet 2, Item 15).

0098-5
 TM 9-6115-730-24 0098

REMOVAL - Continued

15. Tag and disconnect engine harness connector ENG-P103 from intake manifold air temperature sensor
(Figure 1, Sheet 2, Item 16).

16. Remove intake manifold air temperature sensor (Figure 1, Sheet 2, Item 16) with O-ring from engine.

17. Tag and disconnect engine harness connector ENG-P200 from turbo outlet pressure sensor (Figure 1, Sheet
2, Item 17).

18. Remove turbo outlet pressure sensor (Figure 1, Sheet 2, Item 17) with O-ring.

19. Tag and disconnect ECM to EMCP harness connector ENG-P16 from low coolant sensor (Figure 1, Sheet 2,
Item 18).

20. Remove low coolant sensor (Figure 1, Sheet 2, Item 18) from coolant surge tank.

21. Tag and disconnect ECM to EMCP harness connector ENG-P8 from turbo inlet pressure sensor (Figure 1,
Sheet 2, Item 19).

22. Remove turbo inlet pressure sensor (Figure 1, Sheet 2, Item 19) with O-ring.

23. Remove bolt (Figure 1, Sheet 2, Item 22) and clamp (Figure 1, Sheet 2, Item 21).

24. Tag and disconnect engine harness connector ENG-P203 from atmospheric pressure sensor (Figure 1,
Sheet 2, Item 20).

25. Remove atmospheric pressure sensor (Figure 1, Sheet 2, Item 20) with O-ring.

26. Tag and disconnect engine harness connector ENG-P402 from camshaft timing sensor (Figure 1, Sheet 3,
Item 23).

27. Remove camshaft timing sensor (Figure 1, Sheet 3, Item 23) with O-ring.

28. Remove bolt (Figure 1, Sheet 3, Item 25) and clamp (Figure 1, Sheet 3, Item 26).

29. Tag and disconnect engine harness connector ENG-P401 from crankshaft timing sensor (Figure 1, Sheet 3,
Item 27).

30. Remove crankshaft timing sensor (Figure 1, Sheet 3, Item 27) with O-ring.

END OF TASK

INSTALLATION

1. Install crankshaft timing sensor (Figure 1, Sheet 3, Item 27) with O-ring.

2. Remove tag and connect engine harness connector ENG-P401 to crankshaft timing sensor (Figure 1,
Sheet 3, Item 27).

3. Install bolt (Figure 1, Sheet 3, Item 25) and clamp (Figure 1, Sheet 3, Item 26).

4. Set cylinder no. 1 at top center of intake or exhaust stroke (WP 0013, SYMPTOM 8).

0098-6
 TM 9-6115-730-24 0098

INSTALLATION - Continued

5. Extend slip head (Figure 1, Sheet 3, Item 24) from camshaft timing sensor (Figure 1, Sheet 3, Item 23).

6. Ensure top of gear tooth is visible through sensor opening in the housing prior to installation of sensor.

7. Install camshaft timing sensor (Figure 1, Sheet 3, Item 23) with O-ring. Torque sensor to 26-34 lb-ft
(35-45 Nm).

8. Remove tag and connect engine harness connector ENG-P402 to camshaft timing sensor (Figure 1, Sheet 3,
Item 23). Perform Engine Timing Sensor Calibration (WP 0013, SYMPTOM 8).

9. Install atmospheric pressure sensor (Figure 1, Sheet 2, Item 20) with O-ring.

10. Remove tag and connect engine harness connector ENG-P203 to atmospheric pressure sensor (Figure 1,
Sheet 2, Item 20).

11. Install bolt (Figure 1, Sheet 2, Item 22) and clamp (Figure 1, Sheet 2, Item 21).

12. Install turbo inlet pressure sensor (Figure 1, Sheet 2, Item 19) with O-ring.

13. Remove tag and connect ECM to EMCP harness connector ENG-P8 to turbo inlet pressure sensor (Figure 1,
Sheet 2, Item 19).

14. Install low coolant sensor (Figure 1, Sheet 2, Item 18) onto coolant surge tank.

15. Remove tag and connect ECM to EMCP harness connector ENG-P16 to low coolant sensor (Figure 1, Sheet
2, Item 18).

16. Install turbo outlet pressure sensor (Figure 1, Sheet 2, Item 17) with O-ring.

17. Remove tag and connect engine harness connector ENG-P200 to turbo outlet pressure sensor (Figure 1,
Sheet 2, Item 17).

18. Install intake manifold air temperature sensor (Figure 1, Sheet 2, Item 16) with O-ring onto engine.

19. Remove tag and connect engine harness connector ENG-P103 to intake manifold air temperature sensor
(Figure 1, Sheet 2, Item 16).

20. Install bolt (Figure 1, Sheet 2, Item 14) and clamp (Figure 1, Sheet 2, Item 15).

21. Install coolant temperature sensor (Figure 1, Sheet 2, Item 10) with O-ring onto water outlet manifold
(Figure 1, Sheet 2, Item 13).

22. Remove tag and connect engine harness connector ENG-P100 to coolant temperature sensor (Figure 1,
Sheet 2, Item 10)..

23. Install bolt (Figure 1, Sheet 2, Item 12) and clamp (Figure 1, Sheet 2, Item 11).

24. Refill cooling system to the correct level (WP 0065).

25. Align a ring gear tooth directly in the center of the magnetic speed pickup threaded sensor opening.

0098-7
 TM 9-6115-730-24 0098

INSTALLATION - Continued

26. Screw magnetic speed pickup (Figure 1, Sheet 1, Item 9) into hole until end of sensor contacts gear tooth.

27. Back out magnetic speed pickup (Figure 1, Sheet 1, Item 9) by turning counterclockwise (CCW) 120 degrees
(1/3 turn).

28. Tighten locknut (Figure 1, Sheet 1, Item 8) to 14-22 lb-ft (20-30 Nm).

29. Install fuel pressure sensor (Figure 1, Sheet 1, Item 5), seal (Figure 1, Sheet 1, Item 6), and adapter
(Figure 1, Sheet 1, Item 7).

30. Remove tag and connect engine harness connector ENG-P202 to fuel pressure sensor (Figure 1, Sheet 1,
Item 5).

31. Refill fuel system as required (WP 0057).

32. Install fuel temperature sensor (Figure 1, Sheet 1, Item 4) with O-ring.

33. Remove tag and connect engine harness connector ENG-P105 to fuel temperature sensor (Figure 1, Sheet 1,
Item 4).

34. Install oil pressure sensor (Figure 1, Sheet 1, Item 1), seal (Figure 1, Sheet 1, Item 2), and elbow (Figure 1,
Sheet 1, Item 3).

35. Remove tag and connect engine harness connector ENG-P201 from oil pressure sensor (Figure 1, Sheet 1,
Item 1).

END OF TASK

END OF WORK PACKAGE

0098-8
 TM 9-6115-730-24 0099

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
FAN PULLEY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, One

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic References
(WP 0123, Item 3)
TM 9-6115-730-24P
Materials/Parts
Equipment Condition
Grease (WP 0124, Item 19)
Sealing compound (WP 0124, Item 41) Engine fan removed (WP 0066)
Seal

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

REMOVAL

1. Remove bolt (Figure 1, Item 1), washer (Figure 1, Item 2), plate (Figure 1, Item 3), pin (Figure 1, Item 4), and
bearing (Figure 1, Item 5).

2. Remove hub (Figure 1, Item 6), spacer (Figure 1, Item 7), bearing (Figure 1, Item 8), seal (Figure 1, Item 9),
spacer (Figure 1, Item 10), and pulley (Figure 1, Item 11) from spindle (Figure 1, Item 12).

0099-1
 TM 9-6115-730-24 0099

REMOVAL - Continued

Figure 1. Fan Pulley.

END OF TASK

0099-2
 TM 9-6115-730-24 0099

INSTALLATION

1. Apply light coat of grease to lips of seal (Figure 1, Item 9). Apply approximately 1/4 ounce (5 grams) of grease
to each bearing (Figure 1, Item 8) and (Figure 1, Item 5). Apply approximately 1 ounce (30 grams) of grease
to cavity of hub (Figure 1, Item 6).

2. Apply sealing compound to threads of bolt (Figure 1, Item 1).

3. Install pulley (Figure 1, Item 11) on spindle (Figure 1, Item 12) and install spacer (Figure 1, Item 10), seal
(Figure 1, Item 9), bearing (Figure 1, Item 8), spacer (Figure 1, Item 7), and hub (Figure 1, Item 6).

4. Install pin (Figure 1, Item 4) in plate (Figure 1, Item 3) and install bearing (Figure 1, Item 5), plate (Figure 1,
Item 3), washer (Figure 1, Item 2), and bolt (Figure 1, Item 1).

5. Using two bolts from fan installation (WP 0066), align holes in hub (Figure 1, Item 6) with holes in pulley
(Figure 1, Item 11). Torque bolt (Figure 1, Item 1) to 74-95 lb-ft (100-130 Nm). Remove two fan bolts.

6. Install engine fan (WP 0066).

END OF TASK

END OF WORK PACKAGE

0099-3/4 blank
 TM 9-6115-730-24 0100

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
VALVE COVER AND BASE MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, Two

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic References
(WP 0123, Item 3)
TM 9-6115-730-24P
Materials/Parts
Equipment condition
Breakthrough cleaning solvent
(WP 0124, Item 45) Remove manifold in tube (WP 0067) and elbow
Gasket (WP 0116)
Silicone sealant (WP 0124, Item 38) Remove atmospheric pressure sensor
Wiping rags (WP 0124, Item 35) (WP 0098)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the engine.

0100-1
 TM 9-6115-730-24 0100

REMOVAL

NOTE
Tag and disconnect wiring as required.

1. Remove the bolt (Figure 1, Sheet 1, Item 1) and washer (Figure 1, Sheet 1, Item 2) that holds the clamp
(Figure 1, Sheet 1, Item 3) for the harness assembly to the valve cover base (Figure 1, Sheet 1, Item 4).

2. Disconnect harness assembly connector ENG-P300 (Figure 1, Sheet 1, Item 5) and clip. Loosen clamp
(Figure 1, Sheet 1, Item 6) and disconnect the hose (Figure 1, Sheet 1, Item 7) from the side of the valve
cover base.

3. Move the clamp and harness assembly out of the way.

4. Remove four bolts (Figure 1, Sheet 2, Item 8) and washers (Figure 1, Sheet 2, Item 9), and pull breather
(Figure 1, Sheet 2, Item 10) and gasket (Figure 1, Sheet 2, Item 11) away from valve cover base (Figure 1,
Sheet 2, Item 4 ref).

5. Remove 18 bolts (Figure 1, Sheet 2, Item 12), washers (Figure 1, Sheet 2, Item 13), and three valve covers
(Figure 1, Sheet 2, Item 14) from valve cover base (Figure 1, Sheet 2, Item 4 ref).

6. Remove eight bolts (Figure 1, Sheet 2, Item 15), washers (Figure 1, Sheet 2, Item 16), isolators (Figure 1,
Sheet 2, Item 17), sleeves (Figure 1, Sheet 2, Item 18), valve cover base (Figure 1, Sheet 1, Item 4), and
gasket (Figure 1, Sheet 1, Item 19).

END OF TASK

CLEANING

1. Remove remaining gasket material from cylinder head and mating surface of valve cover base (Figure 1,
Sheet 1, Item 4).

WARNING
Cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye
protection are required when working in contact with cleaning solvent. Avoid repeated or
prolonged contact. Work in ventilated area only. Failure to comply can cause injury or death to
personnel.

2. Clean all parts thoroughly with cleaning solvent before installing.

END OF TASK

INSTALLATION

1. Apply bead of sealing compound to both sides of new gasket (Figure 1, Sheet 2, Item 19).

2. Install gasket (Figure 1, Sheet 2, Item 19), valve cover base (Figure 1, Sheet 2, Item 4 ref), eight sleeves
(Figure 1, Sheet 2, Item 18), isolators (Figure 1, Sheet 2, Item 17), washers (Figure 1, Sheet 2, Item 16), and
bolts (Figure 1, Sheet 2, Item 15).

0100-2
 TM 9-6115-730-24 0100

INSTALLATION - Continued

Figure 1. Valve Cover and Base (Sheet 1 of 3).

0100-3
 TM 9-6115-730-24 0100

INSTALLATION - Continued

Figure 1. Valve Cover and Base (Sheet 2 of 3).

0100-4
 TM 9-6115-730-24 0100

INSTALLATION - Continued

Figure 1. Valve Cover and Base (Sheet 3 of 3).

3. Using the illustrated sequence (Figure 1, Sheet 3), torque bolts (Figure 1, Sheet 2, Item 15) to 7-11 lb-ft (9-15
Nm).

4. Install three valve covers (Figure 1, Sheet 2, Item 14), 18 washers (Figure 1, Sheet 2, Item 13), and bolts
(Figure 1, Sheet 2, Item 12). Using the illustrated sequence, torque bolts (Figure 1, Sheet 2, Item 12) to 7-11
lb-ft (9-15 Nm), then re-tighten, using the same sequence, to 7-11 lb-ft (9-15 Nm).

5. Install gasket (Figure 1, Sheet 2, Item 11), breather (Figure 1, Sheet 2, Item 10), four washers (Figure 1,
Sheet 2, Item 9), and bolts (Figure 1, Sheet 2, Item 8).

6. Install atmospheric pressure sensor (WP 0098).

7. Install hose (Figure 1, Sheet 1, Item 7) to the side of the valve cover base and tighten clamp (Figure 1, Sheet
1, Item 6).

8. Install clamp (Figure 1, Sheet 1, Item 3) and harness assembly (Figure 1, Sheet 1, Item 5).

9. Install the bolt (Figure 1, Sheet 1, Item 1) and washer (Figure 1, Sheet 1, Item 2) that holds the clamp (Figure
1, Sheet 1, Item 3) for the harness assembly to the valve cover base (Figure 1, Sheet 1, Item 4)

END OF TASK

END OF WORK PACKAGE

0100-5/6 blank
 TM 9-6115-730-24 0101

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
FUEL FILTER BASE AND MANIFOLD MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Shop Equipment, Automotive Maintenance, TM 9-6115-730-24P

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic Equipment Condition
(WP 0123, Item 3)
Fuel priming pump removed
Materials/Parts (WP 0078)
Fuel filter removed (WP 0080)
Cap and plug set (WP 0124, Item 6) Fuel pressure sensor disconnected
O-Ring (WP 0098)

Personnel Required

One

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the fuel system.

0101-1
 TM 9-6115-730-24 0101

REMOVAL

1. Disconnect hose (Figure 1, Item 1), hose (Figure 1, Item 2), and remove elbow (Figure 1, Item 3) and O-ring
(Figure 1, Item 4).

2. Remove two bolts (Figure 1, Item 5), washers (Figure 1, Item 6), fuel filter base (Figure 1, Item 7), and
preformed packing (Figure 1, Item 8).

3. Remove five bolts (Figure 1, Item 9), washers (Figure 1, Item 10), fuel manifold (Figure 1, Item 11), and six
O-rings (Figure 1, Item 12).

4. If necessary, remove plug (Figure 1, Item 13) and O-ring (Figure 1, Item 14), fitting (Figure 1, Item 15) and
O-ring (Figure 1, Item 16), or fitting (Figure 1, Item 17), O-ring (Figure 1, Item 18), and cover (Figure 1,
Item 19) from fuel filter base (Figure 1, Item 7).

5. If necessary, remove two plugs (Figure 1, Item 20) and O-rings (Figure 1, Item 21) or two plugs (Figure 1,
Item 22) and O-rings (Figure 1, Item 23) from fuel manifold (Figure 1, Item 11).

END OF TASK

INSTALLATION

1. If necessary, install plug (Figure 1, Item 13) and O-ring (Figure 1, Item 14), fitting (Figure 1, Item 15) and
O-ring (Figure 1, Item 16), or fitting (Figure 1, Item 17), O-ring (Figure 1, Item 18), and cover (Figure 1, Item
19) to fuel filter base (Figure 1, Item 7).

2. If necessary, install two plugs (Figure 1, Item 20) and O-rings (Figure 1, Item 21) or two plugs (Figure 1,
Item 22) and O-rings (Figure 1, Item 23) from fuel manifold (Figure 1, Item 11).

3. Install six O-rings (Figure 1, Item 12), fuel manifold (Figure 1, Item 11), five washers (Figure 1, Item 10), and
bolts (Figure 1, Item 9).

4. Install fuel filter base (Figure 1, Item 7), preformed packing (Figure 1, Item 8), two washers (Figure 1, Item 6),
and bolts (Figure 1, Item 5).

5. Install elbow (Figure 1, Item 3) and O-ring (Figure 1, Item 4). Connect hose (Figure 1, Item 2). Connect hose
(Figure 1, Item 1).

6. Connect fuel pressure sensor (WP 0098).

7. Install fuel filter (WP 0080).

8. Install fuel priming pump (WP 0078).

0101-2
 TM 9-6115-730-24 0101

INSTALLATION - Continued

Figure 1. Fuel Filter Base and Manifold.

END OF TASK

END OF WORK PACKAGE

0101-3/4 blank
 TM 9-6115-730-24 0102

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
FUEL TRANSFER PUMP MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, automotive Maintenance, One

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic References
(WP 0123, Item 3)
TM 9-6115-730-24P
Materials/Parts

Cap and plug set (WP 0124, Item 6)

Seal
Wiping rags (WP 0124, Item 35)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the engine.

REMOVAL

1. At lower left front of engine, below water separator, disconnect hose (Figure 1, Item 1) and remove elbow
(Figure 1, Item 2) from fuel transfer pump (Figure 1, Item 3).

2. Disconnect tube (Figure 1, Item 4) and remove elbow (Figure 1, Item 5).

0102-1
 TM 9-6115-730-24 0102

REMOVAL - Continued

3. Remove two bolts (Figure 1, Item 6), washers (Figure 1, Item 7), fuel transfer pump (Figure 1, Item 3), and
seal (Figure 1, Item 8).

Figure 1. Fuel Transfer Pump.

END OF TASK

0102-2
 TM 9-6115-730-24 0102

INSTALLATION

1. Install seal (Figure 1, Item 8), fuel transfer pump (Figure 1, Item 3), two washers (Figure 1, Item 7), and bolts
(Figure 1, Item 6). Torque bolts (Figure 1, Item 4) to 34-48 lb-ft (45-65 Nm).

2. Connect elbow (Figure 1, Item 5), tube (Figure 1, Item 4), elbow (Figure 1, Item 2), and hose (Figure 1,
Item 1).

END OF TASK

END OF WORK PACKAGE

0102-3/4 blank
 TM 9-6115-730-24 0103

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
TURBOCHARGER MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, One

common no. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic References
(WP 0123, Item 3)
TM 9-6115-730-24P
Materials/Parts
Equipment Condition
Antiseize compound (WP 0124, Item 2)
Cap and plug set (WP 0124, Item 6) Manifold out tube disconnected from
Engine oil (WP 0124, Items 23-30) turbocharger (WP 0067)
Gasket Exhaust elbow disconnected from
Gasket turbocharger (WP 0069)
Gasket Air vent hose disconnected from
Seal turbocharger (WP 0072)
Wiping rags (WP 0124, Item 35) Heat shield baffle removed (WP 0069)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the engine.

0103-1
 TM 9-6115-730-24 0103

REMOVAL

1. Place a suitable container under the turbocharger (Figure 1, Item 1) to catch the oil that will flow from the oil
tubes (Figure 1, Item 2) and (Figure 1, Item 3). Use wiping rags to wipe up any oil spills.

2. Remove nut (Figure 1, Item 4), two washers (Figure 1, Item 5), bolt (Figure 1, Item 6), and two clips (Figure 1,
Item 7).

3. Remove two bolts (Figure 1, Item 8), washers (Figure 1, Item 9), and bosses (Figure 1, Item 10). Disconnect
tube (Figure 1, Item 3) from turbocharger (Figure 1, Item 1) and remove gasket (Figure 1, Item 11).

4. Remove tube (Figure 1, Item 3), connector (Figure 1, Item 12), and seal (Figure 1, Item 13) from cylinder
block.

5. Remove two bolts (Figure 1, Item 14), washers (Figure 1, Item 15), and spacers (Figure 1, Item 16). Dis-
connect tube (Figure 1, Item 2) and remove gasket (Figure 1, Item 17) from turbocharger (Figure 1, Item 1).

6. Remove tube (Figure 1, Item 2), seal (Figure 1, Item 18), two bolts (Figure 1, Item 19), adapter (Figure 1, Item
20), and seal (Figure 1, Item 21) from cylinder block.

7. Remove four nuts (Figure 1, Item 22), turbocharger (Figure 1, Item 1), and gasket (Figure 1, Item 23).

END OF TASK

INSTALLATION

1. Apply antiseize compound to threads of four studs (Figure 1, Item 24). Pour a small amount of engine oil into
turbocharger oil inlet port (top of turbocharger) for lubrication during engine startup.

2. Install gasket (Figure 1, Item 23) and turbocharger (Figure 1, Item 1) with four nuts (Figure 1, Item 22).
Torque nuts (Figure 1, Item 22) to 48-55 lb-ft (65-75 Nm).

3. Install seal (Figure 1, Item 21), adapter (Figure 1, Item 20), and two bolts (Figure 1, Item 19) on cylinder
block. Apply light coat of engine oil to seal (Figure 1, Item 18) and install seal in adapter (Figure 1, Item 20).
Position tube (Figure 1, Item 2) into adapter (Figure 1, Item 20).

4. Install gasket (Figure 1, Item 17) on turbocharger (Figure 1, Item 1) and install tube (Figure 1, Item 2), two
spacers (Figure 1, Item 16), washers (Figure 1, Item 15), and bolts (Figure 1, Item 14).

5. Install seal (Figure 1, Item 13) and connector (Figure 1, Item 12) on cylinder block, and install tube (Figure 1,
Item 3).

6. Install gasket (Figure 1, Item 11) and connect tube (Figure 1, Item 3) to turbocharger (Figure 1, Item 1) with
two bosses (Figure 1, Item 10), washers (Figure 1, Item 9), and bolts (Figure 1, Item 8).

7. Install two clips (Figure 1, Item 7) with bolt (Figure 1, Item 6), two washers (Figure 1, Item 5), and nut
(Figure 1, Item 4).

0103-2
 TM 9-6115-730-24 0103

INSTALLATION - Continued

Figure 1. Turbocharger.

0103-3
 TM 9-6115-730-24 0103

INSTALLATION - Continued

8. Connect air vent hose to turbocharger (WP 0072).

9. Connect exhaust elbow to turbocharger (WP 0069).

10. Connect MAN OUT tube to turbocharger (WP 0067).

11. Install heat shield baffle (WP 0069).

END OF TASK

END OF WORK PACKAGE

0103-4
 TM 9-6115-730-24 0104

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
CRANKSHAFT VIBRATION DAMPER AND PULLEY MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, One

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic References
(WP 0123, Item 3)
TM 9-6115-730-24P
Materials/Parts
Equipment Condition
Wiping rags (WP 0124, Item 35)
Belt tension released and belt removed
(WP 0077)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the engine.

0104-1
 TM 9-6115-730-24 0104

REMOVAL

1. Remove six bolts (Figure 1, Item 2) and pulley (Figure 1, Item 3).

2. Remove eight bolts (Figure 1, Item 4), washers (Figure 1, Item 5), spacer (Figure 1, Item 6), damper
(Figure 1, Item 7), and adapter (Figure 1, Item 8) from crankshaft.

END OF TASK

INSTALLATION

1. Install adapter (Figure 1, Item 8), damper (Figure 1, Item 7), spacer (Figure 1, Item 6), eight washers
(Figure 1, Item 5), and bolts (Figure 1, Item 4). Torque bolts (Figure 1, Item 4) to 34-48 lb-ft (45-65 Nm).

2. Install pulley (Figure 1, Item 3) and six bolts (Figure 1, Item 2). Torque bolts (Figure 1, Item 2) to 145-305 lb-ft
(200-280 Nm).

3. Install belt (Figure 1, Item 1) and set belt tension (WP 0077).

0104-2
 TM 9-6115-730-24 0104

INSTALLATION - Continued

Figure 1. Crankshaft Vibration Damper and Pulley.

END OF TASK

END OF WORK PACKAGE

0104-3/4 blank
 TM 9-6115-730-24 0105

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
CRANKSHAFT FRONT SEAL MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, One

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic References
(WP 0123, Item 3)
TM 9-6115-730-24P
Materials/Parts
Equipment Condition
Wiping rags (WP 0124, Item 35)
Crankshaft vibration damper and pulley
removed (WP 0104)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the engine.

0105-1
 TM 9-6115-730-24 0105

REMOVAL

1. Remove five nuts (Figure 1, Item 1) and washers (Figure 1, Item 2).

2. Remove crankshaft front seal retainer (Figure 1, Item 3) and seal (Figure 1, Item 4).

END OF TASK

INSTALLATION

NOTE
Crankshaft front seal must be installed dry.

1. Place seal (Figure 1, Item 4) on crankshaft. Push crankshaft front seal retainer (Figure 1, Item 3) into place.
This will dislodge the shipping sleeve.

2. Install five washers (Figure 1, Item 2) and nuts (Figure 1, Item 1).

3. Install crankshaft vibration damper and pulley (WP 0104).

0105-2
 TM 9-6115-730-24 0105

INSTALLATION - Continued

Figure 1. Crankshaft Front Seal.

END OF TASK

END OF WORK PACKAGE

0105-3/4 blank
 TM 9-6115-730-24 0106

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
FRONT COVER MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Shop Equipment, Automotive Maintenance, TM 9-6115-730-24P

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic Equipment Condition
(WP 0123, Item 3)
Fan pulley removed (WP 0099)
Materials/Parts Crankshaft vibration damper and pulley
removed (WP 0104)
Gasket Crankshaft front seal removed (WP 0105)
Wiping rags (WP 0124, Item 35)

Personnel Required

Two

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the engine.

0106-1
 TM 9-6115-730-24 0106

REMOVAL

1. Remove 19 bolts (Figure 1, Item 1), washers (Figure 1, Item 2), bolt (Figure 1, Item 3), and washer (Figure 1,
Item 4).

2. Remove two studs (Figure 1, Item 5), washers (Figure 1, Item 6), front cover (Figure 1, Item 7), and gasket
(Figure 1, Item 8).

3. If necessary, remove two bolts (Figure 1, Item 9), washers (Figure 1, Item 10), cover (Figure 1, Item 11), and
gasket (Figure 1, Item 12).

END OF TASK

INSTALLATION

1. If removed, install cover (Figure 1, Item 11), gasket (Figure 1, Item 12), two washers (Figure 1, Item 10), and
bolts (Figure 1, Item 9).

2. Install gasket (Figure 1, Item 8), front cover (Figure 1, Item 7), two washers (Figure 1, Item 6), and studs
(Figure 1, Item 5).

3. Install washer (Figure 1, Item 4), bolt (Figure 1, Item 3), 19 washers (Figure 1, Item 2), and bolts (Figure 1,
Item 1). Torque bolts (Figure 1, Item 3) and (Figure 1, Item 1) to 15-25 lb-ft (21-35 Nm).

4. Install crankshaft front seal (WP 0105).

5. Install crankshaft vibration damper and pulley (WP 0104).

6. Install fan pulley (WP 0099).

0106-2
 TM 9-6115-730-24 0106

INSTALLATION - Continued

Figure 1. Front Cover.

END OF TASK

END OF WORK PACKAGE

0106-3/4 blank
 TM 9-6115-730-24 0107

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
OIL FILTER BASE MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Materials/Parts (cont.)

Shop Equipment, Automotive Maintenance, O-Ring

Common No. 1 (WP 0123, Item 2) Sealing compound (WP 0124, Item 42)
Shop Equipment, Field Maintenance, Basic
(WP 0123, Item 3) Personnel Required

Materials/Parts One

Cap and plug set (WP 0124, Item 6) References

Engine oil (WP 0124, Items 23-30)
O-Ring TM 9-6115-730-24P
O-Ring
O-Ring Equipment Condition
O-Ring
O-Ring (2) Oil filter removed (WP 0079)
O-Ring (2)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

0107-1
 TM 9-6115-730-24 0107

WARNING
Oil filter base and housing springs are under tension and can act as projectiles when being
removed. Use eye protection when removing springs. Failure to comply can cause injury to
personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the engine.

REMOVAL

NOTE
Cut tiedown straps as required.

For use during installation, note which two bottom bolts securing oil filter base to engine block are
marked.

1. Remove six bolts (Figure 1, Item 1), washers (Figure 1, Item 2), four bolts (Figure 1, Item 3), washers (Figure
1, Item 4), and oil filter base (Figure 1, Item 5).

2. Remove O-ring (Figure 1, Item 6) and two O-rings (Figure 1, Item 7) from rear of oil filter base (Figure 1,
Item 5). Remove two O-rings (Figure 1, Item 8) from top of oil filter base (Figure 1, Item 5).

END OF TASK

DISASSEMBLY

1. At rear of oil filter base (Figure 1, Item 5), remove bolt (Figure 1, Item 9), spring seat (Figure 1, Item 10),
retainer spring (Figure 1, Item 11),retainer (Figure 1, Item 12), and spacer (Figure 1, Item 13).

2. Remove two bolts (Figure 1, Item 14), washers (Figure 1, Item 15), cover (Figure 1, Item 16), O-ring (Figure
1, Item 17), spring (Figure 1, Item 18), and relief valve plunger (Figure 1, Item 19).

3. Remove stud (Figure 1, Item 20), bolt (Figure 1, Item 21), two washers (Figure 1, Item 22), cover (Figure 1,
Item 23), O-ring (Figure 1, Item 24), spring (Figure 1, Item 25), and bypass valve (Figure 1, Item 26).

4. Remove stud (Figure 1, Item 27), bolt (Figure 1, Item 28), two washers (Figure 1, Item 29), cover (Figure 1,
Item 30), O-ring (Figure 1, Item 31), spring (Figure 1, Item 32), and relief valve plunger (Figure 1, Item 33).

5. Remove stud (Figure 1, Item 34) and stud (Figure 1, Item 35).

6. Remove plug (Figure 1, Item 36) and O-ring (Figure 1, Item 37).

0107-2
 TM 9-6115-730-24 0107

DISASSEMBLY - Continued

Figure 1. Oil Filter Base.

END OF TASK

0107-3
 TM 9-6115-730-24 0107

ASSEMBLY

1. Install O-ring (Figure 1, Item 37) and plug (Figure 1, Item 36).

2. Install stud (Figure 1, Item 35) and torque to 37-51 lb-ft (50-70 Nm).

3. Install stud (Figure 1, Item 34) and torque to 45-55 lb-ft (61-75 Nm).

4. Install relief valve plunger (Figure 1, Item 33), spring (Figure 1, Item 32), O-ring (Figure 1, Item 31), cover
(Figure 1, Item 30), two washers (Figure 1, Item 29), bolt (Figure 1, Item 28), and stud (Figure 1, Item 27).

5. Install bypass valve (Figure 1, Item 26), spring (Figure 1, Item 25), O-ring (Figure 1, Item 24), cover (Figure 1,
Item 23), two washers (Figure 1, Item 22), bolt (Figure 1, Item 21), and stud (Figure 1, Item 20).

6. Install relief valve plunger (Figure 1, Item 19), spring (Figure 1, Item 18), O-ring (Figure 1, Item 17), cover
(Figure 1, Item 16), two washers (Figure 1, Item 15), and bolts (Figure 1, Item 14).

7. Install spacer (Figure 1, Item 13), retainer (Figure 1, Item 12), retainer spring (Figure 1, Item 11), spring seat
(Figure 1, Item 10), and bolt (Figure 1, Item 9).

END OF TASK

INSTALLATION

1. Apply light coat of engine oil to two O-rings (Figure 1, Item 8), two O-rings (Figure 1, Item 7), and O-ring
(Figure 1, Item 6).

2. Install two O-rings (Figure 1, Item 8) on top of oil filter base (Figure 1, Item 5).

3. Install two O-rings (Figure 1, Item 7) and O-ring (Figure 1, Item 6).

4. Apply thread locking compound to threads of six bolts (Figure 1, Item 1) and four bolts (Figure 1, Item 3).

NOTE
Note which two bottom bolts securing oil filter base to engine block are marked and install in
correct locations.

5. Position oil filter base (Figure 1, Item 5) and install six washers (Figure 1, Item 2) and bolts (Figure 1, Item 1).

6. Install four washers (Figure 1, Item 4) and bolts (Figure 1, Item 3).

7. Install oil filter (WP 0079).

END OF TASK

END OF WORK PACKAGE

0107-4
 TM 9-6115-730-24 0108

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
OIL COOLER MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, One

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic References
(WP 0123, Item 3)
TM 9-6115-730-24P
Materials/Parts
Equipment Condition
Cap and plug set (WP 0124, Item 6)
O-Ring Turbocharger oil lines removed from in front
O-Ring of oil cooler (WP 0103)
O-Ring (2)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the engine.

0108-1
 TM 9-6115-730-24 0108

REMOVAL

1. Remove two bolts (Figure 1, Item 1), one stud (Figure 1, Item 2), and three washers (Figure 1, Item 3).

2. Remove elbow (Figure 1, Item 4), coupling (Figure 1, Item 5), two O-rings (Figure 1, Item 6), and O-ring
(Figure 1, Item 7).

3. Remove three bolts (Figure 1, Item 8) and washers (Figure 1, Item 9).

4. Remove three bolts (Figure 1, Item 10), washers (Figure 1, Item 11), oil cooler (Figure 1, Item 12), and three
O-rings (Figure 1, Item 13).

5. Loosen two hose clamps (Figure 1, Item 14) and remove bonnet (Figure 1, Item 15), hose (Figure 1, Item 16)
from elbow (Figure 1, Item 17).

6. If necessary, remove two screws (Figure 1, Item 18), washers (Figure 1, Item 19), elbow (Figure 1, Item 17),
and gasket (Figure 1, Item 20).

7. If necessary, remove three plugs (Figure 1, Item 21) from elbow (Figure 1, Item 17).

8. If necessary, remove plug (Figure 1, Item 22) from bonnet (Figure 1, Item 15).

9. If necessary, remove plug (Figure 1, Item 23) and O-ring (Figure 1, Item 24) from elbow (Figure 1, Item 17).

END OF TASK

CLEANING

1. Clean cooler core with brush.

2. Clean tube bundles with rod of suitable diameter.

3. Inspect oil cooler for cracks or leaks.

END OF TASK

INSTALLATION

1. If necessary, install plug (Figure 1, Item 23) and O-ring (Figure 1, Item 24) to elbow (Figure 1, Item 17).

2. If necessary, install plug (Figure 1, Item 22) to bonnet (Figure 1, Item 15).

3. If necessary, install three plugs (Figure 1, Item 21) to elbow (Figure 1, Item 17).

0108-2
 TM 9-6115-730-24 0108

INSTALLATION - Continued

Figure 1. Oil Cooler.

0108-3
 TM 9-6115-730-24 0108

INSTALLATION - Continued

4. If necessary, install two screws (Figure 1, Item 18), washers (Figure 1, Item 19), elbow (Figure 1, Item 17),
and gasket (Figure 1, Item 20).

5. Install hose (Figure 1, Item 16) and bonnet (Figure 1, Item 15) on elbow (Figure 1, Item 17). Do not tighten
hose clamps (Figure 1, Item 14).

6. Install three O-rings (Figure 1, Item 13), oil cooler (Figure 1, Item 12), three washers (Figure 1, Item 11), and
bolts (Figure 1, Item 10).

7. Install three washers (Figure 1, Item 9) and bolts (Figure 1, Item 8).

8. Install O-ring (Figure 1, Item 7), two O-rings (Figure 1, Item 6), coupling (Figure 1, Item 5), and elbow
(Figure 1, Item 4).

9. Install three washers (Figure 1, Item 3), one stud (Figure 1, Item 2), and two bolts (Figure 1, Item 1).

10. Tighten two hose clamps (Figure 1, Item 14).

11. Install turbocharger oil lines (WP 0103).

END OF TASK

END OF WORK PACKAGE

0108-4
 TM 9-6115-730-24 0109

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
OIL PUMP MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, One

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic References
(WP 0123, Item 3)
TM 9-6115-730-24P
Materials/Parts

Cap and plug set (WP 0124, Item 6)

Engine oil (WP 0124, Items 23-30)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the engine.

REMOVAL

1. Remove two bolts (Figure 1, Item 1) and washers (Figure 1, Item 2) holding tube (Figure 1, Item 3) to elbow
(Figure 1, Item 4).

2. Remove two bolts (Figure 1, Item 5) and washers (Figure 1, Item 6) holding oil pump (Figure 1, Item 7) to
engine block.

0109-1
 TM 9-6115-730-24 0109

REMOVAL - Continued

Figure 1. Oil Pump.

0109-2
 TM 9-6115-730-24 0109

REMOVAL - Continued

3. Remove two bolts (Figure 1, Item 8) and washers (Figure 1, Item 9) holding oil pump (Figure 1, Item 7) to
front housing.

4. Remove oil pump (Figure 1, Item 7), O-ring (Figure 1, Item 10), and O-ring (Figure 1, Item 11).

END OF TASK

DISASSEMBLY

1. Remove elbow (Figure 1, Item 4) and two O-rings (Figure 1, Item 12) from oil pump (Figure 1, Item 7).

2. Remove four bolts (Figure 1, Item 13), washers (Figure 1, Item 14), and cover (Figure 1, Item 15) from pump
housing (Figure 1, Item 16).

3. Remove O-ring (Figure 1, Item 17), idler gear (Figure 1, Item 18), and gear (Figure 1, Item 19) from cover
(Figure 1, Item 15).

4. Remove drive shaft (Figure 1, Item 20) from pump housing (Figure 1, Item 16).

END OF TASK

INSPECTION OF INSTALLED ITEMS

1. Inspect two shaft bores in pump body for diameter of 0.710-0.711 in. (18.04-18.06 mm).

2. Inspect two shaft bores in pump body for depth of 1.973-1.974 in. (50.11-50.15 mm).

3. Inspect shaft of idler gear (Figure 1, Item 18) and drive shaft (Figure 1, Item 20) for diameter of 0.7084-0.7088
in. (17.995-18.005 mm).

END OF TASK

ASSEMBLY

1. Heat drive shaft (Figure 1, Item 20), idler gear (Figure 1, Item 18), and gear (Figure 1, Item 19) to a maximum
of 600 degrees F (316 degrees C).

WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after oil
pump gears or shaft have been heated. Wear additional protective clothing as required. Failure to
comply can cause injury to personnel.

NOTE
Lubricate all internal parts, including O-rings, with engine oil before installation.

2. Install drive shaft (Figure 1, Item 20) in pump housing (Figure 1, Item 16).

3. Install gear (Figure 1, Item 19) on end of drive shaft (Figure 1, Item 20). Make sure front face of gear is
1.138-1.177 in. (28.90-29.90 mm) from step face on pump housing (dimension A).

0109-3
 TM 9-6115-730-24 0109

ASSEMBLY - Continued

4. Install idler gear (Figure 1, Item 18) in pump housing.

5. Install O-ring (Figure 1, Item 17) and cover (Figure 1, Item 15) on pump housing (Figure 1, Item 16) and
secure with four washers (Figure 1, Item 14) and bolts (Figure 1, Item 13).

6. Check that oil pump gear (Figure 1, Item 19) rotates freely by hand.

END OF TASK

INSTALLATION

1. Install two O-rings (Figure 1, Item 12) and elbow (Figure 1, Item 4) on oil pump (Figure 1, Item 7).

2. Install O-ring (Figure 1, Item 11), O-ring (Figure 1, Item 10), oil pump (Figure 1, Item 7) and two washers
(Figure 1, Item 9) and bolts (Figure 1, Item 8).

3. Install two washers (Figure 1, Item 6) and bolts (Figure 1, Item 5).

4. Install two washers (Figure 1, Item 2) and bolts (Figure 1, Item 1).

END OF TASK

END OF WORK PACKAGE

0109-4
 TM 9-6115-730-24 0110

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
WATER PUMP MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Shop Equipment, Automotive Maintenance, TM 9-65115-730-24P

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic Equipment Condition
(WP 0123, Item 3)
Alternator removed (WP 0074)
Personnel Required Belt tensioner removed (WP 0077)
Oil cooler removed (WP 0108)
One Lower right fan guard removed (WP 0066)
Water pump coolant hoses removed
(WP 0067)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the engine.

REMOVAL

1. Remove two bolts (Figure 1, Item 1) and washers (Figure 1, Item 2) from tube (Figure 1, Item 3).

2. Remove bolt (Figure 1, Item 4) and washer (Figure 1, Item 5).

3. Remove two bolts (Figure 1, Item 6) and washers (Figure 1, Item 7).

0110-1
 TM 9-6115-730-24 0110

REMOVAL - Continued

4. Remove two bolts (Figure 1, Item 8) and washers (Figure 1, Item 9) from front cover.

5. Remove water pump (Figure 1, Item 10) and tube (Figure 1, Item 3).

6. Remove tube (Figure 1, Item 3) and flange gasket.

Figure 1. Water Pump.

END OF TASK

0110-2
 TM 9-6115-730-24 0110

INSTALLATION

1. Install tube (Figure 1, Item 3) in water pump (Figure 1, Item 10), position water pump, and install two washers
(Figure 1, Item 9) and bolts (Figure 1, Item 8). Torque bolts (Figure 1, Item 8) to 16-26 lb-ft (21-35 Nm).

2. Install flange gasket between tube (Figure 1, Item 3) and water temperature regulator housing. Install two
washers (Figure 1, Item 2) and bolts (Figure 1, Item 1). Torque bolts (Figure 1, Item 1) to 16-26 lb-ft
(21-35 Nm).

3. Install two washers (Figure 1, Item 7) and bolts (Figure 1, Item 6).

4. Install washer (Figure 1, Item 5) and bolt (Figure 1, Item 4).

5. Install lower radiator hose (WP 0067).

6. Install hose (WP 0067).

7. Install lower right fan guard (WP 0066).

8. Install oil cooler (WP 0108).

9. Install belt tensioner (WP 0077).

10. Install alternator (WP 0074).

END OF TASK

END OF WORK PACKAGE

0110-3/4 blank
 TM 9-6115-730-24 0111

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
FLYWHEEL MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, Two

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic References
(WP 0123, Item 3)
TM 9-6115-730-24P
Materials/Parts

Thread locking compound

(WP 0124, Item 42)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

WARNING
Flywheel weighs more than 125 pounds (57 kg) and requires a two-person lift. Lifting flywheel can
cause back strain. Ensure proper lifting techniques are used when lifting flywheel. Failure to
comply can cause injury to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the engine.

0111-1
 TM 9-6115-730-24 0111

REMOVAL

1. Attach suitable lifting device to flywheel (Figure 1, Item 1).

2. Remove eight bolts (Figure 1, Item 2), washers (Figure 1, Item 3), and slide flywheel (Figure 1, Item 1) off
guide pins.

3. If necessary, remove ring gear (Figure 1, Item 4) with a hammer and punch.

END OF TASK

INSTALLATION

WARNING
Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after flywheel
ring gear has been heated. Wear additional protective clothing as required. Failure to comply can
cause injury to personnel.

1. If removed, heat ring gear to a maximum of 600 degrees F (315 degrees C). Install ring gear (Figure 1,
Item 4) on flywheel (Figure 1, Item 1) with part number toward crankshaft, using a soft hammer.

2. Place flywheel (Figure 1, Item 1) in original position on crankshaft and align arrows on crankshaft and
flywheel.

3. Apply thread locking compound to threads of eight bolts (Figure 1, Item 2). Install eight washers (Figure 1,
Item 3) and bolts (Figure 1, Item 2). Torque bolts (Figure 1, Item 2) evenly to 133-251 lb-ft (260-340 Nm).

0111-2
 TM 9-6115-730-24 0111

INSTALLATION - Continued

Figure 1. Flywheel.

END OF TASK

END OF WORK PACKAGE

0111-3/4 blank
 TM 9-6115-730-24 0112

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
CRANKSHAFT REAR SEAL MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, One

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic References
(WP 0123, Item 3)
TM 9-6115-730-24P
Materials/Parts
Equipment Condition
Cap and plug set (WP 0124, Item 6)
Thread locking compound Flywheel removed (WP 0111)
(WP 0124, Item 42)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the engine.

REMOVAL

1. Remove three locking bolts (Figure 1, Item 1), washers (Figure 1, Item 2), six bolts (Figure 1, Item 3), and
washers (Figure 1, Item 4).

2. Use a screwdriver to remove crankshaft rear seal (Figure 1, Item 5).

3. Remove O-ring (Figure 1, Item 6).

0112-1
 TM 9-6115-730-24 0112

REMOVAL - Continued

Figure 1. Crankshaft Rear Seal.

END OF TASK

0112-2
 TM 9-6115-730-24 0112

INSTALLATION

1. Clean surface of crankshaft. Lubricate O-ring (Figure 1, Item 6) with engine oil and position on back of
crankshaft rear seal.

NOTE
Leave shipping sleeve on crankshaft rear seal in place. Seal must be installed dry.

2. Position crankshaft rear seal (Figure 1, Item 5) on crankshaft and push into place. This will dislodge the
shipping sleeve.

3. Install six washers (Figure 1, Item 4) and bolts (Figure 1, Item 3).

4. Apply thread locking compound to threads of three locking bolts (Figure 1, Item 1). Install three washers
(Figure 1, Item 2) and locking bolts (Figure 1, Item 1) at bottom of crankshaft rear seal (Figure 1, Item 5).
Torque locking bolts (Figure 1, Item 1) to 79-133 lb-in. (9-15 Nm).

5. Install flywheel (WP 0111).

END OF TASK

END OF WORK PACKAGE

0112-3/4 blank
 TM 9-6115-730-24 0113

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
FLYWHEEL HOUSING MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Shop Equipment, Automotive Maintenance, TM 9-6115-730-24P

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic Equipment Condition
(WP 0123, Item 3)
Starter removed (WP 0076)
Materials/Parts Magnetic speed pickup removed (WP 0098)
Flywheel removed (WP 0111)
Cap and plug set (WP 0124, Item 6) Crankshaft rear seal removed (WP 0112)
Sealant compound (WP 0124, Item 37)

Personnel Required

Two

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

WARNING
Flywheel housing weighs more than 50 pounds (23 kg) and requires a two-person lift. Lifting
flywheel housing can cause back strain. Ensure proper lifting techniques are used when lifting
flywheel housing. Failure to comply can cause injury to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the engine.

0113-1
 TM 9-6115-730-24 0113

REMOVAL

1. Attach suitable lifting device to flywheel housing (Figure 1, Item 1).

2. Remove 12 bolts (Figure 1, Item 2), washers (Figure 1, Item 3), flywheel housing (Figure 1, Item 1), and seal
(Figure 1, Item 4).

3. Remove two bolts (Figure 1, Item 5), washers (Figure 1, Item 6), cover (Figure 1, Item 7), and seal (Figure 1,
Item 8).

4. Remove two plugs (Figure 1, Item 9) and seals (Figure 1, Item 10).

5. Remove plug (Figure 1, Item 11), seal (Figure 1, Item 12), plug (Figure 1, Item 13) and seal (Figure 1,
Item 14).

END OF TASK

INSTALLATION

1. Install seal (Figure 1, Item 14), plug (Figure 1, Item 13), seal (Figure 1, Item 12), and plug (Figure 1, Item 11).

2. Install two seals (Figure 1, Item 10) and plugs (Figure 1, Item 9).

3. Install seal (Figure 1, Item 8), cover (Figure 1, Item 7), two washers (Figure 1, Item 6), and bolts (Figure 1,
Item 5).

4. Install seal (Figure 1, Item 4), flywheel housing (Figure 1, Item 1), 12 washers (Figure 1, Item 3) and bolts
(Figure 1, Item 2).

5. Install crankshaft rear seal (WP 0112).

6. Install flywheel (WP 0111).

7. Install magnetic speed pickup (WP 0098).

8. Install starter (WP 0076).

0113-2
 TM 9-6115-730-24 0113

INSTALLATION - Continued

Figure 1. Flywheel Housing.

END OF TASK

END OF WORK PACKAGE

0113-3/4 blank
 TM 9-6115-730-24 0114

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
CRANKSHAFT REAR SEAL CARRIER MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Shop Equipment, Automotive Maintenance, TM 9-6115-730-24P

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic Equipment Condition
(WP 0123, Item 3)
Flywheel removed (WP 0111)
Materials/Parts Flywheel housing removed (WP 0113)

Cap and plug set (WP 0124, Item 6)

Personnel Required

One

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the engine.

0114-1
 TM 9-6115-730-24 0114

REMOVAL

1. Remove four bolts (Figure 1, Item 1), washers (Figure 1, Item 2), and crankshaft rear seal carrier (Figure 1,
Item 3).

2. Remove gasket (Figure 1, Item 4) from cylinder block.

END OF TASK

INSTALLATION

1. Install gasket over two dowel pins (Figure 1, Item 5).

2. Install crankshaft rear seal carrier (Figure 1, Item 3), four washers (Figure 1, Item 2), and bolts (Figure 1,
Item 1).

3. Install flywheel housing (WP 0113).

4. Install flywheel (WP 0111).

0114-2
 TM 9-6115-730-24 0114

INSTALLATION - Continued

Figure 1. Crankshaft Rear Seal Carrier.

END OF TASK

END OF WORK PACKAGE

0114-3/4 blank
 TM 9-6115-730-24 0115

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
EXHAUST MANIFOLD MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, One

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic References
(WP 0123, Item 3)
TM 9-6115-730-24P
Materials/Parts
Equipment Condition
Antiseize compound (WP 0124, Item 1)
Cap and plug set (WP 0124, Item 6) Turbocharger removed (WP 0103)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the engine.

0115-1
 TM 9-6115-730-24 0115

REMOVAL

1. Remove 12 locknuts (Figure 1, Item 1), washers (Figure 1, Item 2), spacers (Figure 1, Item 3), three exhaust
manifolds (Figure 1, Item 4), (Figure 1, Item 5), and (Figure 1, Item 6), and six gaskets (Figure 1, Item 7).

2. Separate three exhaust manifolds (Figure 1, Item 4), (Figure 1, Item 5), and (Figure 1, Item 6).

3. Remove 12 studs (Figure 1, Item 8) from cylinder block.

4. If necessary, remove four studs (Figure 1, Item 9) from exhaust manifold (Figure 1, Item 5).

END OF TASK

INSTALLATION

1. If removed, apply antiseize compound to threads of four studs (Figure 1, Item 9) and install in exhaust
manifold (Figure 1, Item 5). Torque studs (Figure 1, Item 9) to 22-30 lb-ft (30-40 Nm).

2. Apply antiseize compound to threads of 12 studs (Figure 1, Item 8) and install in cylinder block. Torque studs
(Figure 1, Item 8) to 22-30 lb-ft (30-40 Nm).

3. Assemble three exhaust manifolds (Figure 1, Item 6), (Figure 1, Item 5), and (Figure 1, Item 4).

4. Install six gaskets (Figure 1, Item 7), three exhaust manifolds (Figure 1, Item 6), (Figure 1, Item 5), and
(Figure 1, Item 4), 12 spacers (Figure 1, Item 3), and washers (Figure 1, Item 2).

5. Apply antiseize compound to threads of 12 locknuts (Figure 1, Item 1) and install on 12 studs (Figure 1,
Item 8). Torque 12 locknuts (Figure 1, Item 1) to 34-48 lb-ft (45-65 Nm).

6. Install turbocharger (WP 0103).

0115-2
 TM 9-6115-730-24 0115

INSTALLATION - Continued

Figure 1. Exhaust Manifold.

END OF TASK

END OF WORK PACKAGE

0115-3/4 blank
 TM 9-6115-730-24 0116

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
INLET MANIFOLD MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Shop Equipment, Automotive Maintenance, TM 9-6115-730-24P

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic Equipment Condition
(WP 0123, Item 3)
Turbo outlet pressure sensor and intake
Materials/Parts manifold air temperature sensor removed
(WP 0098)
Seal

Personnel Required

One

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the engine.

0116-1
 TM 9-6115-730-24 0116

REMOVAL

1. Remove six bolts (Figure 1, Item 1), washers (Figure 1, Item 2), bolts (Figure 1, Item 3), washers (Figure 1,
Item 4), inlet manifold (Figure 1, Item 5) and three gaskets (Figure 1, Item 6).

2. If necessary, remove plug (Figure 1, Item 7), plug (Figure 1, Item 8), seal (Figure 1, Item 9), and plug
(Figure 1, Item 10).

3. If necessary, remove four screws (Figure 1, Item 11), washers (Figure 1, Item 12), elbow (Figure 1, Item 13),
and gasket (Figure 1, Item 14).

4. If necessary, remove plug (Figure 1, Item 15).

END OF TASK

INSTALLATION

1. If necessary, install plug (Figure 1, Item 15).

2. If necessary, install elbow (Figure 1, Item 13) and gasket (Figure 1, Item 14) with four screws (Figure 1,
Item 11) and washers (Figure 1, Item 12).

3. If necessary, install plug (Figure 1, Item 10), seal (Figure 1, Item 9), plug (Figure 1, Item 8), and plug
(Figure 1, Item 7).

4. Install three gaskets (Figure 1, Item 6), inlet manifold (Figure 1, Item 5), six washers (Figure 1, Item 4), bolts
(Figure 1, Item 3), washers (Figure 1, Item 2), and bolts (Figure 1, Item 1). Torque bolts (Figure 1, Item 3) and
(Figure 1, Item 1) to 34-48 lb-ft (45-65 Nm).

5. Install intake manifold air temperature sensor and turbo outlet pressure sensor (WP 0098).

0116-2
 TM 9-6115-730-24 0116

INSTALLATION - Continued

Figure 1. Inlet Manifold.

END OF TASK

END OF WORK PACKAGE

0116-3/4 blank
 TM 9-6115-730-24 0117

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
OIL PAN MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, One

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic References
(WP 0123, Item 3)
TM 9-6115-730-24P
Materials/Parts
Equipment Condition
Cap and plug set (WP 0124, Item 6)
Engine oil (WP 0124, Items 23-30) Engine oil drained (WP 0079)
Gasket
Seal

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the engine.

0117-1
 TM 9-6115-730-24 0117

REMOVAL

1. Remove 14 bolts (Figure 1, Item 1), washers (Figure 1, Item 2), isolators (Figure 1, Item 3), and sleeves
(Figure 1, Item 4), and remove oil pan (Figure 1, Item 5) and gasket (Figure 1, Item 6).

2. Remove drain valve (Figure 1, Item 7), pipe reducer (Figure 1, Item 8), bushing (Figure 1, Item 9), recessed
washer (Figure 1, Item 10), and seal (Figure 1, Item 11), plug (Figure 1, Item 12), magnetic plug (Figure 1,
Item 13), and seal (Figure 1, Item 14).

3. If necessary, scrape gasket material (Figure 1, Item 6) off engine block and oil pan.

4. Inspect magnetic plug (Figure 1, Item 13) for metal particles and wipe clean. Notify supervisor if metal
particles are found on magnetic plug.

END OF TASK

INSTALLATION

1. Install seal (Figure 1, Item 14), magnetic plug (Figure 1, Item 13), plug (Figure 1, Item 12), seal (Figure 1,
Item 11), recessed washer (Figure 1, Item 10), bushing (Figure 1, Item 9), pipe reducer (Figure 1, Item 8), and
drain valve (Figure 1, Item 7).

2. Install gasket (Figure 1, Item 6), oil pan (Figure 1, Item 5), 14 sleeves (Figure 1, Item 4), isolators (Figure 1,
Item 3), washers (Figure 1, Item 2), and bolts (Figure 1, Item 1).

3. Refill lubrication system (WP 0079).

0117-2
 TM 9-6115-730-24 0117

INSTALLATION - Continued

Figure 1. Oil Pan.

END OF TASK

END OF WORK PACKAGE

0117-3/4 blank
 TM 9-6115-730-24 0118

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
UNIT INJECTOR MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, One

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic References
(WP 0123, Item 3)
TM 9-6115-730-24P
Materials/Parts
Equipment Condition
Cap and plug set (WP 0124, Item 6)
Engine oil (WP 0124, Items 23-30) Valve cover and base removed (WP 0100)
Rocker shaft and pushrods removed
(WP 0119)
Manifold in tube removed (WP 0067)

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the engine.

0118-1
 TM 9-6115-730-24 0118

REMOVAL

NOTE
Mark valve bridges for correct assembly.

1. Disconnect unit injector harness connector from unit injector (Figure 1, Item 1).

2. Remove bolt (Figure 1, Item 2), spacer (Figure 1, Item 3), and clamp (Figure 1, Item 4).

3. Carefully pry clamp and unit injector (Figure 1, Item 1) out of cylinder head.

4. Repeat steps 3 thru 5 for remaining unit injectors.

END OF TASK

CLEANING

1. Clean injector seating (A) with tapered brush.

2. Clean injector bore (B) with small bore brush.

END OF TASK

INSTALLATION

NOTE
If fuel injector is replaced, the new injector electronic injector code must be programmed into the
engine personality module software using the calibration menu. If the new code is not entered,
the previous unit injector’s characteristics will be assumed.

If it is not possible to immediately reprogram the new injector code, the engine will not be
severely harmed, but the new code should be entered as soon as possible to optimize engine
performance.

1. If new injector is being installed, record the new injector code (Figure 1, C), located on the solenoid.

2. Lightly lubricate three seals (Figure 1, D) and the bore (Figure 1, B) with engine oil.

3. Position unit injector (Figure 1, Item 1) on cylinder head. Push down on injector spring to seat unit injector
(Figure 1, Item 1).

4. Install clamp (Figure 1, Item 4), spacer (Figure 1, Item 3) and bolt (Figure 1, Item 2) and tighten bolt. This will
completely seat the unit injector (Figure 1, Item 1). Torque bolt (Figure 1, Item 2) to 17-27 lb-ft (23-37 Nm).

5. Connect unit injector harness connector.

6. Repeat steps 1 thru 5 for remaining unit injectors.

7. Install rocker shaft and pushrods (WP 0119).

0118-2
 TM 9-6115-730-24 0118

INSTALLATION - Continued

8. Install valve cover and base (WP 0100).

9. Load new injector code/codes (Figure 1, C) into ECM (WP 0013, SYMPTOM 12).

Figure 1. Unit Injector.

END OF TASK

END OF WORK PACKAGE

0118-3/4 blank
 TM 9-6115-730-24 0119

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
ROCKER SHAFT AND PUSHROD MAINTENANCE

INITIAL SETUP:

Tools and Special Tools Personnel Required

Shop Equipment, Automotive Maintenance, Two

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic References
(WP 0123, Item 3)
TM 9-6115-730-24P
Materials/Parts
Equipment Condition
Cap and plug set (WP 0124, Item 6)
Engine oil (WP 0124, Items 23-30) Valve cover and base removed (WP 0100)
O-Ring
Seal

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the heater system.

0119-1
 TM 9-6115-730-24 0119

REMOVAL

NOTE
Place identification mark on each rocker arm to assure installation in the proper location.

1. Remove two bolts (Figure 1, Item 1) and rocker arm assembly (Figure 1, Item 2).

2. Remove injector pushrod (Figure 1, Item 3) and two valve pushrods (Figure 1, Item 4). Keep each pushrod
(Figure 1, Item 3) and (Figure 1, Item 4) with its rocker arm assembly (Figure 1, Item 2).

3. Remove two valve bridges (Figure 1, Item 5).

4. Repeat steps 2 thru 4 for remaining five rocker arm assemblies.

END OF TASK

DISASSEMBLY

1. Remove nut (Figure 1, Item 6) and adjustment screw (Figure 1, Item 7) from exhaust valve rocker arm (Figure
1, Item 8).

2. Remove nut (Figure 1, Item 9), adjustment screw (Figure 1, Item 10), button (Figure 1, Item 11), and O-ring
(Figure 1, Item 12) from unit injector rocker arm (Figure 1, Item 13).

3. Remove nut (Figure 1, Item 14) and adjustment screw (Figure 1, Item 15) from inlet valve rocker arm (Figure
1, Item 16).

4. Remove shaft (Figure 1, Item 17), from support (Figure 1, Item 18), and remove spring pin (Figure 1, Item 19),
exhaust valve rocker arm (Figure 1, Item 8), unit injector rocker arm (Figure 1, Item 13), and inlet valve rocker
arm (Figure 1, Item 16).

5. If necessary, remove plug (Figure 1, Item 20) from shaft (Figure 1, Item 17), and remove dowel (Figure 1,
Item 21) from support (Figure 1, Item 18).

6. If necessary, remove bearing (Figure 1, Item 22) from unit injector rocker arm (Figure 1, Item 13).

7. Repeat steps 1 thru 6 for remaining five rocker arm assemblies.

0119-2
 TM 9-6115-730-24 0119

DISASSEMBLY - Continued

Figure 1. Rocker Shaft and Pushrod Removal and Installation.

END OF TASK

0119-3
 TM 9-6115-730-24 0119

INSPECTION OF INSTALLED ITEMS

1. Inspect rocker arm shaft (Figure 2, Item 17) for minimum diameter (Dimension A) of 1.3382 in. (33.99 mm).

2. Inspect all parts for signs of excessive wear or cracking.

3. Inspect bore in unit injector rocker arm bearing (Figure 2, Item 22) for inside diameter (Dimension B) of 1.340-
1.341 in. (34.035-34.065 mm).

4. Inspect bore in unit injector rocker arm (Figure 2, Item 13) for inside diameter (Dimension C) of 1.456-1.457
in. (36.98-37.02 mm).

Figure 2. Rocker Shaft Inspection.

END OF TASK

0119-4
 TM 9-6115-730-24 0119

ASSEMBLY

1. If removed, install bearing (Figure 1, Item 22) in unit injector rocker arm (Figure 1, Item 13) so that oil hole
openings in bearing are centered over oil passages in rocker arm, and so that bearing does not extend
beyond either face of rocker arm.

2. If removed, install dowel (Figure 1, Item 21) in support (Figure 1, Item 18) so that it extends 0.178-0.216 in.
(4.5-5.5 mm) (Figure 2, Dimension D) from bottom of support.

3. If removed install plug (Figure 1, Item 20) in shaft (Figure 1, Item 17) to a depth of 0.39-0.59 in. (1.0-1.5 mm)
(Figure 2, Dimension E).

4. Install inlet valve rocker arm (Figure 1, Item 16), unit injector rocker arm (Figure 1, Item 13), exhaust valve
rocker arm (Figure 1, Item 8), spring pin (Figure 1, Item 19), and shaft (Figure 1, Item 17) in support (Figure 1,
Item 18). Install spring pin (Figure 1, Item 19) so that it extends 1.54-1.61 in. (39-41 mm) (Figure 2,
Dimension F) from the opposite side of the shaft (Figure 1, Item 17).

5. Install adjustment screw (Figure 1, Item 15) and nut (Figure 1, Item 14) on inlet valve rocker arm (Figure 1,
Item 16).

6. Install O-ring (Figure 1, Item 12), button (Figure 1, Item 11), adjustment screw (Figure 1, Item 10), and nut
(Figure 1, Item 9) on unit injector rocker arm (Figure 1, Item 13).

7. Install adjustment screw (Figure 1, Item 7) and nut (Figure 1, Item 6) on exhaust valve rocker arm (Figure 1,
Item 8).

8. Repeat steps 1 thru 7 for five remaining rocker arm assemblies.

END OF TASK

INSTALLATION

1. Lubricate top pad of two valve bridges (Figure 1, Item 5) with engine oil and install.

2. Install two valve pushrods (Figure 1, Item 4), injector pushrod (Figure 1, Item 3), rocker arm assembly (Figure
1, Item 2), and two bolts (Figure 1, Item 1).

3. Repeat steps 1 and 2 for remaining five rocker arm assemblies.

4. Perform valve lash check.

END OF TASK

0119-5
 TM 9-6115-730-24 0119

VALVE LASH CHECK

WARNING
Do not use the engine starter to turn the flywheel. Failure to comply can cause injury to
personnel.

CAUTION
All clearance measurements must be made with the engine stopped and the valves fully closed.
Otherwise, incorrect adjustments will be made resulting in engine damage.

NOTE
Valve lash adjustment is not necessary if measurement is in the acceptable range.

Engine must be turned with the eight large bolts on flywheel.

1. Remove crankshaft vibration damper and pulley (WP 0104).

2. Remove two bolts (Figure 3, Item 23), washers (Figure 3, Item 24), cover (Figure 3, Item 25), and seal
(Figure 3, Item 26) from flywheel housing.

3. Install one bolt (Figure 3, Item 23) in hole 5-6 inches (12.7-15.2 cm) above where cover (Figure 3, Item 25)
was removed. This becomes the timing bolt (Figure 3, Item 23).

4. Using eight large bolts on flywheel, turn flywheel in direction of normal engine rotation, which is
counterclockwise (CCW) when viewed from flywheel end, until timing bolt (Figure 3, Item 23) engages
with threaded hole in flywheel.

Figure 3. Valve Lash Check.

0119-6
 TM 9-6115-730-24 0119

VALVE LASH CHECK - Continued

NOTE
If flywheel is turned beyond point that timing bolt (Figure 3, Item 23) engages in the threaded
hole, the flywheel must be turned opposite normal engine rotation approximately 30 degrees.
Then turn the flywheel in the direction of normal rotation (CCW) until timing bolt (Figure 3,
Item 23) engages with threaded hole. This removes play from gears.

Inlet valves and exhaust valves for the No. 1 cylinder are fully closed if No. 1 piston is on the
compression stroke and the rocker arms can be moved by hand. If the rocker arms cannot be
moved by hand and the valves are slightly open, the No. 1 piston is on the exhaust stroke.

When the actual stroke position is identified and the other stroke is needed, it is necessary to
remove the timing bolt (Figure 3, Item 23) from the flywheel, turn the flywheel counterclockwise
(CCW) 360 degrees, and reinstall the timing bolt (Figure 3, Item 23).

Valve lash is measured between the rocker arm and the valve bridge.

5. Refer to Table 1 for crankshaft positions for valve lash settings. Check inlet valves 1, 2, and 4, and exhaust
valves 1, 3, and 5, against criteria in Table 2.

Table 1. Crankshaft Positions for Valve Lash Setting.

Rotation (viewed from flywheel end) Counterclockwise

Check and adjust with piston no. 1 on this stroke Top center compression stroke
Inlet Valves 1-2-4
Exhaust Valves 1-3-5
Unit Injectors 3, 5, 6
Check and adjust with no. 6 piston on this stroke Top center compression stroke
Inlet Valves 3-5-6
Exhaust Valves 2-4-6
Unit Injectors 1, 2, 4
Firing order 1-5-3-6-2-4

Table 2. Check for Valve Lash.

VALVES ACCEPTABLE RANGE

Inlet 0.012-0.018 in. (0.30-0.46 mm)

Exhaust 0.022-0.028 in. (0.56-0.72 mm)

0119-7
 TM 9-6115-730-24 0119

VALVE LASH CHECK - Continued

6. Remove timing bolt (Figure 3, Item 23) and turn flywheel 360 degrees in the direction of engine rotation. This
will put No. 6 piston at top center on the compression stroke. Install timing bolt (Figure 3, Item 23) in hole.

7. Check inlet valves 3, 5, and 6, and exhaust valves 2, 4, and 6, against criteria in Table 2.

8. If valve lash for all valves is within acceptable range Table 2, proceed with steps 10 thru 12.

9. Perform valve lash adjustment on any valve with readings outside the acceptable range.

10. Remove timing bolt (Figure 3, Item 23) from flywheel. Install seal (Figure 3, Item 26), cover (Figure 3,
Item 25), two washers (Figure 3, Item 24), and bolts (Figure 3, Item 23) on back of flywheel housing.

11. Install crankshaft vibration damper and pulley (WP 0104).

12. Install valve cover and base (WP 0100).

END OF TASK

VALVE LASH ADJUSTMENT

1. Loosen nut (Figure 1, Item 14) and loosen adjustment screw (Figure 1, Item 15) on inlet valve rocker arm
(Figure 1, Item 16) for cylinders 1, 2, and 4. Loosen nut (Figure 1, Item 6) and loosen adjustment screw
(Figure 1, Item 7) on exhaust valve rocker arm (Figure 1, Item 8) for cylinders 1, 3, and 5.

2. Refer to Table 3 and insert feeler gage of correct dimension between rocker arm (Figure 1, Item 16) or
(Figure 1, Item 8) and valve bridge (Figure 1, Item 5).

Table 3. Valve Lash Settings.

VALVES ACCEPTABLE RANGE

Inlet 0.015 in. (0.38 mm)

Exhaust 0.025 in. (0.64 mm)

3. Turn adjustment screw (Figure 1, Item 15) or (Figure 1, Item 7) clockwise (CW) until rocker arm (Figure 1,
Item 16) or (Figure 1, Item 8) is set to specification in Table 3.

4. Tighten nut (Figure 1, Item 14) or (Figure 1, Item 6) to 17-27 lb-ft (23-37 Nm) and check adjustment again.

5. Loosen nut (Figure 1, Item 9) and loosen adjustment screw (Figure 1, Item 10) on unit injectors for cylinders
3, 5, and 6.

6. Turn adjustment screw (Figure 1, Item 10) clockwise (CW) until contact is made with unit injector. Turn
adjustment screw (Figure 1, Item 10) CW an additional 180 degrees (1/2 turn). Tighten nut (Figure 1, Item 9)
to 34-47 lb-ft (45-65 Nm).

0119-8
 TM 9-6115-730-24 0119

VALVE LASH ADJUSTMENT - Continued

7. Remove timing bolt (Figure 1, Item 23) and turn flywheel 360 degrees in the direction of engine rotation. This
will put No. 6 piston at top center on the compression stroke. Install timing bolt (Figure 1, Item 23) in hole.

8. Loosen nut (Figure 1, Item 14) and loosen adjustment screw (Figure 1, Item 15) on inlet valve rocker arm
(Figure 1, Item 16) for cylinders 3, 5, and 6. Loosen nut (Figure 1, Item 6) and loosen adjustment screw
(Figure 1, Item 7) on exhaust valve rocker arm (Figure 1, Item 8) for cylinders 2, 4, and 6.

9. Refer to Table 3 and insert feeler gage of correct dimension between rocker arm (Figure 1, Item 16) or
(Figure 1, Item 8) and valve bridge (Figure 1, Item 5).

10. Turn adjustment screw (Figure 1, Item 15) or (Figure 1, Item 7) clockwise (CW) until rocker arm (Figure 1,
Item 16) or (Figure 1, Item 8) is set to specification in Table 3.

11. Tighten nut (Figure 1, Item 14) or (Figure 1, Item 6) to 13-23 lb-ft (18-32 Nm) and check adjustment again.

12. Loosen nut (Figure 1, Item 9) and loosen adjustment screw (Figure 1, Item 10) on unit injectors for cylinders
1, 2, and 4.

13. Turn adjustment screw (Figure 1, Item 10) clockwise (CW) until contact is made with unit injector. Turn
adjustment screw (Figure 1, Item 10) CW an additional 180 degrees (1/2 turn). Tighten nut (Figure 1, Item 9)
to 34-47 lb-ft (45-65 Nm).

14. Remove timing bolt (Figure 3, Item 23) from flywheel. Install seal (Figure 3, Item 26), cover (Figure 3,
Item 25), two washers (Figure 3, Item 24), and bolts (Figure 3, Item 23) on back of flywheel housing.

15. Install crankshaft vibration damper and pulley (WP 0104).

16. Install valve cover and base (WP 0100).

END OF TASK

END OF WORK PACKAGE

0119-9/10 blank
 TM 9-6115-730-24 0120

DIRECT SUPPORT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
CYLINDER HEAD MAINTENANCE

INITIAL SETUP:

Tools and Special Tools References

Shop Equipment, Automotive Maintenance, TM 9-6115-730-24P

Common No. 1 (WP 0123, Item 2)
Shop Equipment, Field Maintenance, Basic Equipment Condition
(WP 0123, Item 3)
Thermostat housing removed (WP 0081)
Materials/Parts Valve cover and base removed (WP 0100)
Fuel filter base removed (WP 0101)
Antiseize compound (WP 0124, Item 1) Exhaust manifold removed (WP 0115)
Cap and plug set (WP 0124, Item 6) Inlet manifold removed (WP 0116)
Cleaning solvent (WP 0124, Item 8) Rocker shaft and pushrods removed
Engine oil (WP 0124, Items 23-30) (WP 0119)
Gasket

Personnel Required

Two

WARNINGS
Metal jewelry will conduct electricity. All jewelry can become entangled in generator set
components. Remove all jewelry when working on generator set. Failure to comply can cause
injury or death to personnel by electrocution.

DO NOT wear loose clothing when performing checks, services and maintenance. Failure to
comply can cause injury or death to personnel.

High voltage is produced when this generator set is in operation. Make sure unit is completely shut
down and free of any power source before attempting any repair or maintenance on the unit.
Failure to comply can cause injury or death to personnel.

High voltage is produced when the generator set is in operation. Never attempt to start or
maintain the generator set unless it is properly grounded. Failure to comply can cause injury or
death to personnel.

CAUTION
All fittings and openings must be capped or plugged immediately after opening to prevent
contamination of the engine.

0120-1
 TM 9-6115-730-24 0120

REMOVAL

1. Remove 26 bolts (Figure 1, Item 1) and washers (Figure 1, Item 2).

2. Remove seven bolts (Figure 1, Item 3).

WARNING
Cylinder head weighs more than 300 pounds (135 kg) and requires an assistant and a suitable
lifting device. Ensure proper lifting techniques are used when lifting cylinder head. Failure to
comply can cause injury to personnel.

CAUTION
Cylinder head must be removed level and straight up, or damage will result.

3. With lifting device attached to front lifting bracket (Figure 1, Item 4) and rear lifting bracket (Figure 1, Item 5),
carefully lift cylinder head (Figure 1, Item 6) straight up away from engine block.

4. Remove three bolts (Figure 1, Item 7), washers (Figure 1, Item 8), front lifting bracket (Figure 1, Item 4), and
plate (Figure 1, Item 9).

5. Remove three bolts (Figure 1, Item 10), washers (Figure 1, Item 11), rear lifting bracket (Figure 1, Item 5),
and plate (Figure 1, Item 12).

6. Remove gasket (Figure 1, Item 13).

END OF TASK

CLEANING

WARNING
Cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin and eye
protection are required when working in contact with cleaning solvent. Avoid repeated or
prolonged contact. Work in ventilated area only. Failure to comply can cause injury or death to
personnel.

1. Clean all parts with cleaning solvent.

CAUTION
Be careful not to gouge or scrape contact surface of cylinder head or engine block. Imperfections
in contact surface may cause leakage of cylinder head gasket and equipment damage.

Contact surfaces of cylinder head and engine block must be thoroughly clean before installation
or cylinder head gasket may leak and cause equipment damage.

2. Carefully remove all remnants of head gasket from bottom of head gasket and from top of engine block.

3. Measure contact surface of cylinder head for flatness using a feeler gage and straight edge. Maximum
deviation should not exceed 0.002 in (0.05 mm) in a six inch area, or 0.006 in (0.15 mm) overall.

0120-2
 TM 9-6115-730-24 0120

CLEANING - Continued

Figure 1. Cylinder Head.

END OF TASK

0120-3
 TM 9-6115-730-24 0120

INSTALLATION

1. Install rear lifting bracket (Figure 1, Item 5) on cylinder head (Figure 1, Item 6) with plate (Figure 1, Item 12),
four washers (Figure 1, Item 11) and bolts (Figure 1, Item 10).

2. Install front lifting bracket (Figure 1, Item 4) on cylinder head (Figure 1, Item 6) with plate (Figure 1, Item 9),
four washers (Figure 1, Item 8) and bolts (Figure 1, Item 7).

3. Place gasket (Figure 1, Item 12) on engine block.

WARNING
Cylinder head weighs more than 300 pounds (135 kg) and requires an assistant and a suitable
lifting device. Ensure proper lifting techniques are used when lifting cylinder head. Failure to
comply can cause injury to personnel.

CAUTION
Cylinder head must be removed level and straight up, or damage will result.

4. With lifting device attached to front lifting bracket (Figure 1, Item 4) and rear lifting bracket (Figure 1, Item 5),
carefully position cylinder head (Figure 1, Item 6) straight over engine block and carefully lower cylinder head
onto engine block.

5. Apply engine oil to threads of seven bolts (Figure 1, Item 3).

6. Apply antiseize compound to threads of 26 bolts (Figure 1, Item 1) and both sides of 26 washers (Figure 1,
Item 2).

7. Install seven bolts (Figure 1, Item 3). Install 26 washers (Figure 1, Item 2) and bolts (Figure 1, Item 1).

8. Using bolt tightening sequence shown, tighten bolts numbered 1 thru 26 by sequence to 107-129 lb-ft
(145-175 Nm).

9. Re-tighten bolts numbered 1 thru 26 by sequence to 107-129 lb-ft (145-175 Nm).

10. Tighten bolts numbered 1 thru 26 by sequence an additional 90 degrees (1-1/2 hex flats).

11. Loosen bolts numbered 1 thru 26 to a torque of 0 lb-ft (0 Nm).

12. Repeat steps 8 thru 10.

13. Torque bolts numbered 27 thru 33 by sequence to 16-25 lb-ft (21-35 Nm).

14. Install rocker shaft and pushrods (WP 0119).

15. Install inlet manifold (WP 0116).

0120-4
 TM 9-6115-730-24 0120

INSTALLATION - Continued

16. Install exhaust manifold (WP 0115).

17. Install fuel filter base (WP 0101).

18. Install valve cover and base (WP 0100).

19. Install thermostat housing (WP 0081).

END OF TASK

END OF WORK PACKAGE

0120-5/6 blank
 TM 9-6115-730-24

CHAPTER 6

GENERAL SUPPORT
Moved to Sustainment (NMWR)
 TM 9-6115-730-24

CHAPTER 7

SUPPORTING INFORMATION
 TM 9-6115-730-24

CHAPTER 7

SUPPORTING INFORMATION

WORK PACKAGE INDEX

Title WP Sequence No.

REFERENCES ....................................................................................................................................... 0121

MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION ........................................................... 0122
MAINTENANCE ALLOCATION CHART (MAC)....................................................................................... 0123
EXPENDABLE AND DURABLE ITEMS LIST .......................................................................................... 0124
LAMINATES.............................................................................................................................................. 0125

Change 1
 TM 9-6115-730-24 0121

FIELD AND SUSTAINMENT MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
REFERENCES

SCOPE

This work package lists all field manuals, forms, technical manuals, technical bulletins, and miscellaneous
publications for use with the kW Tactical Quiet Generator.

FIELD MANUALS

FM 3-3 Chemical and Biological Contamination Avoidance

FM 3-3-1 Nuclear Contamination Avoidance
FM 3-11.4 NBC Protection
FM 3-11.5 NBC Decontamination
FM 3-97.6 Mountain Operations
FM 4-25.11 First Aid
FM 5-20 Camouflage
FM 9-207 Operation and Maintenance of Ordnance Materiel in Cold Weather (0q to –65q)
FM 10-67-1 Concepts and Equipment of Petroleum Operations
FM 10-564 Air Drop of Supplies and Equipment
FM 21-6 Techniques of Military Instruction
FM 21-30 Military Symbols
FM 21-40 Chemical, Biological, Radiological, and Nuclear Defense
FM 21-305 Manual for Wheeled Vehicle Driver
FM 31-70 Basic Cold Weather Manual
FM 31-71 Northern Operations

FORMS

AFTO Form 22 Technical Order Publication Improvement Report

AFR 66-1 Maintenance Reporting
DA Form 2028 Recommended Changes to Publications and Blank Forms
DA Form 2028-2 Recommended Changes to Equipment Technical Publications
NAVMC 10772 Recommended Changes to Publications and Blank Forms
DA Form 2062 Hand Receipt
DA Form 2404 Equipment Inspection and Maintenance Worksheet
DA Form 2407 Maintenance Request
DA Form 2408 Equipment Log Assembly (Records)
DA Form 2408-9 Equipment Control Record
DA Form 2408-20 Oil Analysis Log
DA Form 5988-E Equipment Inspection and Maintenance Worksheet
DD Form 314 Preventive Maintenance Schedule and Record
DD Form 518 Accident Identification Card
DD Form 1397 Processing and Deprocessing Record for Shipment, Storage, and Issue of Vehicles and
Spare Engines
DD Form 2326 Preservation and Packing Data
NAVMC10524 Consolidated Engineer Equipment Operations Log and Service Record

0121-1
 TM 9-6115-730-24 0121

FORMS - Continued

NAVMC10560 Worksheet for Quarterly Preventive Maintenance and Technical Inspection for Engineer
Equipment
NAVMC 10772 Tracking Program
SF Form 91 Motor Vehicle Accident Report
SF Form 361 Transportation Discrepancy Report
SF Form 364 Report of Discrepancy (ROD)
SF Form 368 Product Quality Deficiency Report

MISCELLANEOUS PUBLICATIONS
AR 190-13 Army Physical Security Program
AR 190-16 Physical Security
AR 385-11 Safety Ionizing Protection
AR 700-138 Army Logistics Readiness and Sustainability
AR 735-11-2 Reporting of Supply Discrepancies
AR 750-1 Army Materiel Maintenance Policy and Retail Maintenance Operations
AR 750-244-2 Procedures for Destruction of Electronics Materiel to Prevent Enemy Use
CTA 8-100 Army Medical Department Expendable/Durable Items
CTA 50-970 Expendable Items (Except Medical Class V, Repair Parts, and Heraldic Items)
TC 38-3 Guide for Basic Military Preservation and Packing
TC 9-237 Operator’s Circular, Welding Theory and Application

PAMPHLETS
DA PAM 25-30 Consolidated Index of Publications and Blank Forms
DA PAM 750-8 Functional Users Manual for the Army Maintenance Management System (TAMMS)
TECHNICAL BULLETINS
TB 43-0209 Color, Marking, and Camouflage Painting of Military Vehicles, Construction
Equipment, and Materials Handling Equipment
TB 43-0213 Corrosion Prevention and Control
TB ORD 1032 Description, Use, Bonding Techniques, and Properties of Adhesives
MILITARY STANDARDS AND SPECIFICATIONS
MIL-DTL-53072C Chemical Agent Resistant Coating (CARC) System Application Procedures and Quality
Control Inspection
MIL-PRF-2104 Lubricating Oil, Internal Combustion Engine, Combat/Tactical Service
MIL-L-21260 Lubricating Oil, Internal Combustion Engine, Preservative and Break-In
MIL-L-46167 Lubricating Oil, Internal Combustion Engine, Arctic
MIL-PRF-5624 Turbine Fuels, Aviation, Grades JP-4, JP-5, and JP-5/JP-8 ST
A-A-52557 Fuel Oil, Diesel
MIL-STD-913 Requirements for the Certification of Sling Loaded Military Equipment for External
Transportation by Department of Defense Helicopters
DEPARTMENT OF DEFENSE (DOD) STANDARDS
DOD 4100-1-R Department of Defense Materiel Management Regulations
DOD 4100-39-M FLIS Program Manual

0121-2
 TM 9-6115-730-24 0121

DETAIL SPECIFICATION
MIL-DTL 83133E Turbine Fuels, Aviation, Kerosene Types NATO F-34 (JP-8), NATO F-35, and JP8+10

TECHNICAL MANUALS
TO 00-350-54 Unsatisfactory Equipment Reporting
TM 3-220 Chemical, Biological, and Radiological (CBR) Decontamination
TM 9-214 Inspection, Care, and Maintenance of Antifriction Bearings
TM 9-238 Deepwater Fording of Ordnance Material
TM 9-247 Materials Used for Cleaning, Preserving, Abrading, and Cementing Ordnance Material
and Related Material Including Chemicals
TM 43-0139 Painting Instructions for Army Materiel
TM 4700-15 Operation and Maintenance of Ground Equipment
TM 55-1500-323-24 Installation Practices for Aircraft Electrical and Electronic Wiring
TM 740-90-1/TO 35-1-4 Administrative Storage of Equipment
TM 750-244-2 Procedures for Destruction of Electronics Materiel to Prevent Enemy Use
TM 9-6115-730-10 Operator Manual Tactical Quiet Generator Set, Skid Mounted, 200 kW, 50/60 Hz MEP-
809A and Tactical Quiet Generator Set, Trailer Mounted, 200 kW, 50/60 Hz, PU-809A
TM 9-6115-730-24P Repair Parts and Special Tools Lists for Tactical Quiet Generator Set, Skid Mounted,
200 kW, 50/60 Hz MEP-809A and Tactical Quiet Generator Set, Trailer Mounted,
200 kW, 50/60 Hz, PU-809A
TM 9-2330-376-14&P Operator’s, Organizational, DS, and GS Maintenance Manual Including Repair Parts and
Special Tools Lists for Trailer, 5-Ton, 4-Wheel, GEMSS, XM979; Trailer, Flatbed: 5-Ton,
4-Wheel, XM1061/M1061A1; and Trailer, General Purpose, Flatbed: 7-1/2-Ton, XM1073

END OF WORK PACKAGE

0121-3/4 blank
 TM 9-6115-730-24 0122

FIELD AND SUSTAINMENT MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz
6115-01-296-1462 MEP-809A/6115-01-471-7085 PU-809A
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION

INTRODUCTION

The Army Maintenance System MAC

This introduction provides a general explanation of all maintenance and repair functions authorized at various
maintenance levels under the two-level Army Maintenance System concept.

The MAC (immediately following the introduction) designates overall authority and responsibility 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 shall be consistent with the capacities and capabilities of the
designated maintenance levels, which are shown on the MAC in column (4) as:

Field Level – includes three subcolumns, C (operator/crew), O (unit) maintenance, and F (direct support)

Sustainment Level – includes two subcolumns, H (general support) and D (depot).

The tools and test equipment requirements (immediately following the MAC) list the tools and test equipment
(both special tools and common tool sets) required for each maintenance function as referenced from the MAC.

The remarks (immediately following the tools and test equipment requirements) contain supplemental instructions
and explanatory notes for a particular maintenance function.

Maintenance Functions

Maintenance functions are limited to and defined as follows:

1. Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or electrical
characteristics with established standards through examination (e.g., by sight, sound or feel). This includes
scheduled inspection and gagings and evaluation of cannon tubes.
2. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or electrical characteristics
of an item and comparing those characteristics with prescribed standards on a scheduled basis, i.e., load
testing of lift devices and hydrostatic testing of pressure hoses.
3. Service. Operations required periodically to keep an item in proper operating condition; e.g., to mark (restore
obliterated identification), to clean (includes decontaminate, when required), to preserve, to drain, to touchup
paint, or to replenish fuel, lubricants, chemical fluids, or gases. This includes scheduled exercising and
purging of recoil mechanisms.
4. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper position, or by setting the
operating characteristics to specified parameters.
5. Align. To adjust specified variable elements of an item to bring about optimum or desired performance.

0122-1
 TM 9-6115-730-24 0122

Maintenance Functions - Continued

6. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments of test,

measuring, and diagnostic equipment used in precision measurement. Consists of comparisons 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.
7. 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, seating, or fixing into position a spare, repair part, or module
(component or assembly) in a manner to allow the proper functioning of an equipment or system.
8. Replace. To remove an unserviceable item and install a serviceable counterpart in its place. "Replace" is
authorized by the MAC and assigned maintenance level is shown as the third position code of the Source,
Maintenance and Recoverability (SMR) code.
9. Repair. The application of maintenance services, including fault location/troubleshooting, removal/installation,
disassembly/assembly procedures, painting, and maintenance actions to identify troubles and restore
serviceability to an item by correcting specific damage, fault, malfunction, or failure in a part, subassembly,
module (component or assembly), end item, or system.

NOTE
The following definitions are applicable to the "repair" maintenance function:
Services. Inspect, test, service, adjust, align, calibrate, and/or replace.
Fault location/troubleshooting. The process of investigating and detecting the cause of equipment
malfunctioning; the act of isolating a fault within a system or Unit Under Test (UUT).
Disassembly/assembly. The step-by-step breakdown (taking apart) of a spare/functional group
coded item to the level of its lowest component, that is assigned an SMR code for the level of
maintenance under consideration (i.e., identified as maintenance significant).
Actions. Welding, grinding, riveting, straightening, facing, machining, and/or resurfacing.
10. Overhaul. That maintenance effort (service/action) prescribed to restore an item to a completely
serviceable/operational condition as required by maintenance standards in appropriate technical publications
(i.e., DMWR/NMWR). Overhaul is normally the highest degree of maintenance performed by the Army.
Overhaul does not normally return an item to like new condition.
11. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment to a like
new condition in accordance with original manufacturing standards. Rebuild is the highest degree of materiel
maintenance applied to Army equipment. The rebuild operation includes the act of returning to zero those age
measurements (e.g., hours/miles) considered in classifying Army equipment/components.
Explanation of Columns in the MAC

Column (1) Group Number. Column (1) lists functional group code (FGC) numbers, the purpose of which is to
identify maintenance significant components, assemblies, subassemblies, and modules with the Next Higher
Assembly (NHA).

Column (2) Component/Assembly. Column (2) contains the item names of components, assemblies,
subassemblies, and modules for which maintenance is authorized.

Column (3) Maintenance Function. Column (3) lists the functions to be performed on the item listed in column (2).
(For a detailed explanation of these functions refer to "Maintenance Functions" outlined above.)

0122-2
 TM 9-6115-730-24 0122

Explanation of Columns in the MAC - Continued

Column (4) Maintenance Level. Column (4) specifies each level of maintenance authorized to perform each
function listed in column (3), by indicating work time required (expressed as man hours in whole hours or
decimals) in the appropriate sub column. This work time 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 figures are to be shown
for each level. The work time figure represents the average time required to restore an item (assembly,
subassembly, component, module, end item, or system) to a serviceable condition under typical field operating
conditions. This time includes preparation time (including any necessary disassembly/assembly time),
troubleshooting/fault location time, and quality assurance time in addition to the time required to perform the
specific tasks identified for the maintenance functions authorized in the MAC. The symbol designations for the
various maintenance levels under the two level maintenance concept are as follows:

Field:
C - Operator or Crew maintenance
O - Unit maintenance
F - Direct Support maintenance

Sustainment:
L - Specialized Repair Activity (SRA)
H - General Support maintenance
D - Depot maintenance

NOTE
The "L" maintenance level is not included in column (4) of the MAC. Functions to this level of
maintenance are identified by a work time figure in the "H" column of column (4), and an
associated reference code is used in the REMARKS column (6). This code is keyed to the
remarks and the SRA complete repair application is explained there.
Column (5) Tools and Equipment Reference Code. Column (5) specifies, by code, those common tool sets (not
individual tools), Common Test, Measurement and Diagnostic Equipment (TMDE), and special tools, special
TMDE and special support equipment required to perform the designated function. Codes are keyed to the entries
in the tools and test equipment table.

Column (6) Remarks Code. When applicable, this column contains a letter code, in alphabetical order, which is
keyed to the remarks table entries.

Explanation of Columns in the Tools and Test Equipment Requirements

Column (1) Tool or Test Equipment Reference Code. The tool or test equipment reference code correlates with a
code used in column (5) of the MAC.

Column (2) Maintenance Level. The lowest level of maintenance authorized to use the tool or test equipment
under the two-level MAC.

Column (3) Nomenclature. Name or identification of the tool or test equipment.

Column (4) National Stock Number (NSN). The NSN of the tool or test equipment.

Column (5) Tool Number. The manufacturer's part number, model number, or type number.

0122-3
 TM 9-6115-730-24 0122

Explanation of Columns in the Remarks

Column (1) Remarks Code. The code recorded in column (6) of the MAC.

Column (2) Remarks. This column lists information pertinent to the maintenance function being performed as
indicated in the MAC.

END OF WORK PACKAGE

0122-4
 TM 9-6115-730-24 0123

FIELD AND SUSTAINMENT MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz
6115-01-296-1462 MEP-809A/6115-01-471-7085 PU-809A
MAINTENANCE ALLOCATION CHART (MAC)

Table 1. MAC.

(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT
DIRECT GENERAL
UNIT SUPPORT SUPPORT DEPOT
REF CODE
TOOLS AND
GROUP COMPONENT MAINTENANCE C O F H D EQUIPMENT REMARKS
00 200 kW Generator Set None N/A N/A

01 200 kW Generator Set Inspect 0.5 0.5

Assembly

01 200 kW Generator Inspect 0.5 0.5 1.0

Set Assembly
Test 1.0 3
Quarterly Service 8.0 1,2
Semi-Annual Service 10.0
Annual Service 16.0
Repair 2.0 8.0 3
Adjust 1.0
0101 Housing Installation Inspect 0.1 0.2

Door Assemblies Repair 1.0

Ceiling Assemblies Repair 3.0
Access Covers Repair 1.0
Housing Assemblies Repair 1.0
Panel Assemblies Repair 1.0
Complete Assembly Repair 7.0 1 A
0102 Control Box Assembly Inspect 0.1 0.2 B
Diode Test 0.1
Replace 0.5
Load Sharing Module R
A4 Repair 1.0
Digital Voltage R
Regulator A3 Repair 1.0
Bus Transformer Box R
A6 Test 0.2
Replace 0.8
AC Transformer Box
A5 Test 0.2
Replace 0.8
Resistor Assembly A7 Repair 1.0
Switches Replace 0.3
Test 0.2
Relay Repair 0.5
Harness Assembly Repair 5.0
Complete Assembly Repair 11.2 1 B

0123-1
 TM 9-6115-730-24 0123

Table 1. MAC - Continued.

(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT
DIRECT GENERAL
UNIT SUPPORT SUPPORT DEPOT
REF CODE
TOOLS AND
GROUP COMPONENT MAINTENANCE C O F H D EQUIPMENT REMARKS
010201 Control Box Door 3.0 1
Panel Assembly Replace
Generator Set Control 1.0 1 R
A1 Repair
Alarm Module A2 Repair 1.0
Switches/Gauges Test 0.2
Replace 0.2
0103 Electrical Component 0.5
Installation Inspect
Repair 2.0 1,2
Battery Disconnect
Switch Repair 0.5
Batteries Repair 1.0
Dead Crank Switch Repair 0.5
NATO Slave Repair
Receptacle 1.5
Main Load Contactor Repair
K1 1.0
Engine to EMCP Repair
Harness Assembly 3.0
Engine Harness Repair
Assembly 16.0
010301 Reconnection Inspect 0.1 0.2 C
Terminal Board
Replace 1.0 1 R
Assembly Repair 1.0 1 C
Terminal Stud Replace 0.5 R
Complete Assembly Repair 1.5 1 C
010302 Load Terminal Board Inspect 0.1 0.1
Assembly
EMI Filter Assembly Repair 1.0
L1, L2, and L3
EMI Filter Assembly N Repair 1.0 D
to Ground
Varistor Wire Replace 0.2 R
Terminal Stud Replace 0.5 R
Output Load Terminal Repair 3.5 R
Board TB2
010303 Cable Assemblies Inspect 1.5 E
Battery Cable Repair 0.5
Assemblies
Complete Assembly Repair 3.0
Power Cable Repair 16.0 1,2 E, R
Assemblies
Fuel System
E
0104 Installation Inspect 0.1 0.8
Fuel Level Switch Repair 1.0
Assembly
Fuel Hose Assemblies Replace 1.5
Fuel Pickup Tube Repair
Assembly 1.0
Fuel Level Sender Repair 1.0
Auxiliary Fuel Pump Repair 1.0
Solenoid Valve Repair 1.0
Hose Assemblies Replace 0.5
Fuel Tank Replace 25.0

0123-2
 TM 9-6115-730-24 0123

Table 1. MAC - Continued.

(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT
DIRECT GENERAL
UNIT SUPPORT SUPPORT DEPOT
REF CODE
TOOLS AND
GROUP COMPONENT MAINTENANCE C O F H D EQUIPMENT REMARKS
0105 Cooling System Inspect 0.2 0.2
Installation Service 0.2 1.0 1
Surge Tank Repair 0.5
Coolant Recovery Repair 0.5
Tank
Radiator Repair 8.0
Engine Fan Repair 2.0
Radiator Shrouds Repair 2.0
Coolant Hoses Repair 1.5
0106 Exhaust System Inspect 0.1 0.5
Muffler Inlet Tubes Replace 0.5
Exhaust Muffler Replace 1.0
Muffler Outlet Tubes Replace 0.5
Complete Assembly 2.0
Air Cleaner
0107 Installation Inspect 0.1 0.1
Service 0.3 1
Repair 0.5
Complete Assembly Replace 1.5
Crankcase Ventilation Replace 0.5
Filter
0108 Engine/Generator Inspect 0.1 0.1
Base Assembly Repair 1.0 2.0 3
010801 Generator Inspect 0.1 0.5
Main Stator Repair 22.0
Test 1.0
Exciter Stator Repair 23.0
Test 0.5
Main Rotor Repair 23.0 R
Test 1.0
Complete Assembly Replace 23.0 2,4
010802 Engine Inspect 0.2 0.5 R
Engine Replace 24.0
Pulley Replace 2.0 G
Water Line Repair 1.5
Water Regulator Repair 3.5
Water Regulator
Housing Repair 10.0
Water Pump Replace 2.0
Starter Repair 2.0 R
Alternator Repair 1.5
Engine Supports Repair 12.0
01080201 Engine Electrical
System
Consisting of
Inspect 0.2
Electronic Control
3.0
Wiring Group Repair
Injector Unit Wiring Repair 6.0 H
Sensor Replace 1.5
Engine Control
3.0 R
Module Repair

0123-3
 TM 9-6115-730-24 0123

Table 1. MAC - Continued.

(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT
DIRECT GENERAL
UNIT SUPPORT SUPPORT DEPOT
REF CODE
TOOLS AND
GROUP COMPONENT MAINTENANCE C O F H D EQUIPMENT REMARKS
01080202 Engine Intake and
0.5
Exhaust System Inspect 0.5 R
Turbocharger Repair 2.5
Exhaust Manifold Repair 3.0 I
Intake Manifold Repair 5.0

01080203 Engine Oil System Inspect 0.1 0.2

Oil Pan Replace 25.0
Oil Pump Repair 3.0 J
Oil Filter Replace 0.5
Oil Cooler Repair 1.5
Oil Filler Replace 0.5
01080204 Engine Fuel System
Inspect 0.2
Injection Fuel Repair 3.0 K
Primary Fuel Pump Repair 0.5
Fuel Transfer Repair 3.0
Fuel Filter and Line Repair 1.5
01080205 Engine Cylinder Head
0.2
Assembly Inspect
Valve cover Replace 2.5
Valve Mounting Repair 3.5
Cylinder Head Replace 8.5 L
01080206 Engine Flywheel and
Housing Assembly Inspect 0.2
Flywheel Replace 25.0
Flywheel Housing Replace 25.0 M

01080207 Engine Crankshaft

Pulley Inspect 0.2
Repair 1.0 3
Crankshaft Pulley Repair
Crankshaft Damper Repair N
Crankshaft Seals Repair
Crankshaft Repair
01080208 Engine Timing Gear
Cover Inspect 0.2
Repair 1.0 3
Front Housing Repair
Front Gear Repair O

01080209 Engine Block

Assembly Inspect 0.2
Repair 1.0 3,4
Camshaft Repair
Piston Group Repair P
Block Group Repair

0123-4
 TM 9-6115-730-24 0123

Table 1. MAC - Continued.

(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT
DIRECT GENERAL
UNIT SUPPORT SUPPORT DEPOT
REF CODE
TOOLS AND
GROUP COMPONENT MAINTENANCE C O F H D EQUIPMENT REMARKS

Winterization Kit
03 Installation Inspect 0.2 0.2
Replace 0.5 1
Repair 3.1 Q
Repair 1.0 1
04 Trailer Installation Repair 1.0 1

Table 2. Tools and Test Equipment Requirements.

TOOL OR TEST
EQUIPMENT MAINTENANCE NATIONAL STOCK TOOL
REF CODE LEVEL NOMENCLATURE NUMBER NUMBER
1 O Tool Kit, General Mechanic’s, 5180-00-177-7033 SC 5180-95-N26
Automotive (GMTK) (01 September
2001)

2 OFH Shop Equipment, Automotive

SC 4910-95-A74
Maintenance and Repair;
4910-00-754-0654 (01 September
Organizational Maintenance,
2001)
Common No. 1, Less Power
3 FH
Shop Equipment, Automotive SC 4910-95-A31
Maintenance and Repair: Field 4910-00-754-0705 (01 September
Maintenance, Basic, Less Power 2001)
4 FH Lifting Strap, 2000 lb. capacity XXX EE2801

0123-5
 TM 9-6115-730-24 0123

Table 3. Remarks.

REMARKS
CODE REMARKS
A Housing Installation repair function includes replacement of Right Battery Access Door
Assembly, Left Battery Door Assembly, Control Box Door Assembly, Left Front Door
Assembly (Latch), Left Rear Door Assembly, Left Rear Door Assembly (Latch), Load Board
Door Assembly, Right Front Door Assembly (Latch), Right Rear Door Assembly, Right Rear
Door Assembly (Latch), Engine Generator Compartment Ceiling Assembly, Access Cover
Assembly, Generator Access Cover Assembly, Front Section Housing Assembly, Rear
Section Housing Assembly, Front Roof Section Housing Assembly, Rear Roof Section
Housing Assembly, Left Center Panel Assembly, Right Center Panel Assembly, Right Rear
Panel Assembly, and Left Rear Panel Assembly.
B Control Box Assembly repair function includes replacement of Resistor Assembly A7 and
Control Box Harness Assembly.
C Reconnection Terminal Board Assembly inspection and repair functions include inspection
and replacement of Reconnection Terminal Board.
D Load Terminal Board Assembly repair function includes replacement of EMI Filter Assembly
L1, L2, and L3, EMI Filter Assembly N to Ground, Varistor Wire L1, Varistor Wire L2, Varistor
Wire L3, and Varistor Wire N.
E Cables Assemblies inspect, service, and repair functions include inspection, servicing, and
replacement of Battery Cable Assembly 12A, Battery Cable Assembly 24D, Battery Cable
Assembly 1 C, Battery Cable Assembly 2A, Battery Cable Assembly 1A, Battery Cable
Assembly 24A, Battery Cable Assembly 2C, Power Cable Assembly 110K, Power Cable
Assembly 121A, Power Cable Assembly 122A, Power Cable Assembly 123A, Power Cable
Assembly 103A, Power Cable Assembly 102A, and Power Cable Assembly 101 A.
F Fuel System Installation inspect and repair functions include inspection and replacement of
Fuel Level Switch Assembly, Hose Assembly, Hose Assembly, Hose Assembly, Hose
Assembly, Hose Assembly, Fuel Pickup Tube Assembly, and Hose Assembly.
G Engine repair function includes repair and adjustment of Alternator Mounting Group, Pulley
Group, Fan Drive Group, Fan Drive Mounting Group, Water Line Group, Water Regulator
Group, Water Regulator Housing Group, Water Pump Group, Air Compressor Cover Group,
Starter Group, and Engine Support Group
H Engine Electrical System repair function includes repair of Electronic Control Wiring Group,
Injector Unit Wiring Group, and Electronic Control Mounting Group
I Engine Intake and Exhaust System repair function includes inspection and repair of
Turbocharger Group, Exhaust Manifold Group, and Intake Manifold Group
J Engine Oil System repair function includes inspection and repair of Oil Pan Group, Oil Pump
Group, Oil Filter Group, Oil Cooler Group, Oil Filler Group, Oil Gage Group, and Oil Sampling
Group
K Engine Fuel System repair function includes inspection and repair of Priming Fuel Pump
Group, Injection Fuel Group, Primary Fuel Group, Fuel Transfer Group, and Fuel Injection
Group

0123-6
 TM 9-6115-730-24 0123

Table 3. Remarks - Continued.

REMARKS
CODE REMARKS
L Engine Cylinder Head Assembly repair function includes inspection and repair of Valve
Mounting Group and Cylinder Head Group
M Engine Flywheel and Housing Assembly repair function includes inspection and repair of
Flywheel Group and Flywheel Housing Group
N Engine Crankshaft Pulley repair function includes inspection and repair of Crankshaft Pulley
Group, Crankshaft Damper Group, Crankshaft Seal Group, and Crankshaft Group
O Engine Timing Gear Cover repair function includes inspection and repair of Front Housing
Group and Front Gear Group
P Engine Block Assembly repair function includes inspection and repair of Camshaft Group,
Piston Group, and Block Group
Q Winterization Kit Installation repair function includes replacement of Winterization Wiring
Harness, Winterization Wiring Harness, Winterization Resistor Assembly, Winterization Diode
Assembly, and Winterization Thermostat Assembly.

END OF WORK PACKAGE

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FIELD AND SUSTAINMENT MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-807A/PU-807A
EXPENDABLE AND DURABLE ITEMS LIST

INTRODUCTION

This work package lists expendable and durable items that you will need to operate and maintain the 200 kW
Tactical Quiet Generator. This list is for information only and is not authority to requisition the listed items. These
items are authorized to you by CTA 50-970, Expendable/Durable Items (Except Medical, Class V Repair Parts, and
Heraldic Items), CTA 50-909, Field and Garrison Furnishings and Equipment, or CTA 8-100, Army Medical
Department Expendable/Durable Items.

EXPENDABLE/DURABLE ITEMS LIST COLUMN DESCRIPTIONS (TABLE 1)

Column (1) - ITEM NUMBER. This number is assigned to the entry in the list and is referenced in the narrative
instructions to identify the item (e.g., Use adhesive (WP 0133, Item 4)).

Column (2) - LEVEL. This column identifies the lowest level of maintenance that requires the listed item (C =
Operator/Crew, O = Unit, F = Direct Support, H = General Support, D = Depot).

Column (3) - NATIONAL STOCK NUMBER (NSN). This is the NSN assigned to the item which you can use to
requisition it.

Column (4) - ITEM NAME, DESCRIPTION, PART NUMBER/(CAGEC). This column provides the other information
you need to identify the item. The last line below the description is the part number and the Commercial and
Government Entity Code (CAGEC) (in parentheses).

Column (5) - U/I. Unit of Issue (U/I) code shows the physical measurement or count of an item, such as gallon,
dozen, gross, etc.

Table 1. Expendable and Durable Items List.

(1) (2) (3) (4) (5)

ITEM NATIONAL STOCK ITEM NAME, DESCRIPTION,

NUMBER LEVEL NUMBER (NSN) PART NUMBER/(CAGEC) U/I
1 F 8030-00-597-5367 Antiseize Compound CN
2-1/2 lb can
MIL-A-907 (81349)
2 F 8030-01-451-1403 Antiseize Compound TU
5P3931 (11083)
3 F 8030-00-117-8510 Adhesive BT
10 cc bottle
RTV 3145 Clear (71984)
4 F 6810-00-286-5435 Alcohol, Technical CN
1 gallon can
TT-I-735 (81348)

0124-1
 TM 9-6115-730-24 0124

Table 1. Expendable and Durable Items List - Continued.

(1) (2) (3) (4) (5)

ITEM NATIONAL STOCK ITEM NAME, DESCRIPTION,

NUMBER LEVEL NUMBER (NSN) PART NUMBER/(CAGEC) U/I
5 C 6850-00-664-1403 Antifreeze, Ethylene Glycol GL
1 gallon
A-A-52624 (58536)
6 O 5340-00-450-5718 Cap and Plug Set KT
Protective
10935405 (19207)
7 H 6850-00-543-7801 Carbon Removing Compound, Type II CN
5 gallon can
MIL-C-19853 (81349)
8 F 6850-00-281-1985 Cleaning Solvent CN
1 gallon can
PS-661 (02978)
9 O 5350-00-221-0872 Cloth, Abrasive PG
Crocus
A-A-1206 (58536)
10 F Damping Sheet SH
Adhesive Back
0116-1957-01 (93742)
11 F Damping Sheet SH
Adhesive Back
0116-1957-02 (93742)
12 F Damping Sheet SH
Adhesive Back
0116-1957-03 (93742)
13 F Damping Sheet SH
Adhesive Back
U-127U-PSA (69202)
14 F Damping Sheet SH
Adhesive Back
U-381 U-PSA (69202)
15 F Damping Sheet SH
Adhesive Back
V-05 (69202)
16 C 9140-00-286-5286 Fuel, Diesel, DF-1 GL
bulk
A-A-52557 (58536)

0124-2
 TM 9-6115-730-24 0124

Table 1. Expendable and Durable Items List - Continued.

(1) (2) (3) (4) (5)

ITEM NATIONAL STOCK ITEM NAME, DESCRIPTION,

NUMBER LEVEL NUMBER (NSN) PART NUMBER/(CAGEC) U/I
17 C 9140-00-286-5294 Fuel, Diesel, DF-2 GL
bulk
A-A-52557 (58536)
18 H 9150-01-035-5391 Gear Lubricating Oil CN
5 gallon can
MIL-PRF-2105 (81349)
19 O 9150-01-197-7689 Grease, Automotive and Artillery CN
6.5 lb can
MIL-PRF-10924 (81349)
20 H 9150-00-223-4004 Grease, Molybdenum Disulfide CN
6-1/2 lb can
MIL-G-21164 (81349)
21 C 6850-01-287-8067 Inhibitor, Corrosion, Liquid Cooling System GL
1 gallon
MIL-A-53009 (81349)
22 O 5970-00-815-1300 Insulation Sleeving FT
Electrical
MIL-I-23053/5 (81349)
23 C 9150-01-402-2372 Lubricating Oil, Engine, Arctic, OEA CN
5 gallon can
MIL-PRF-46167 (81349)
24 C 9150-01-189-6727 Lubricating Oil, Engine, OE/HDO-10 QT
1 quart
MIL-PRF-2104 (81349)
25 C 9150-01-186-6668 Lubricating Oil, Engine, OE/HDO-10 CN
5 gallon
MIL-PRF-2104 (81349)
26 C 9150-00-186-6681 Lubricating Oil, Engine, OE/HDO-30 QT
1 quart
MIL-PRF-2104 (81349)
27 C 9150-00-188-9858 Lubricating Oil, Engine, OE/HDO-30 CN
5 gallon
MIL-PRF-2104 (81349)
28 C 9150-01-152-4117 Lubricating Oil, Engine, OE/HDO-15/40 QT
1 quart
MIL-PRF-2104 (81349)

0124-3
 TM 9-6115-730-24 0124

Table 1. Expendable and Durable Items List - Continued.

(1) (2) (3) (4) (5)

ITEM NATIONAL STOCK ITEM NAME, DESCRIPTION,

NUMBER LEVEL NUMBER (NSN) PART NUMBER/(CAGEC) U/I
29 C 9150-01-152-4119 Lubricating Oil, Engine, OE/HDO-15/40 CN
5 gallon
MIL-PRF-2104 (81349)
30 C 9150-00-405-2987 Lubricating Oil, Engine, OE/HDO-40 GL
1 gallon
MIL-PRF-2104 (81349)
31 O 9150-00-111-0209 Lubricating Oil, Engine, Preservation, Grade 30W CN
5 gallon
MIL-PRF-21260 (81349)
32 O 9150-00-111-3199 Lubricating Oil, Engine, Preservation, Grade 10W CN
5 gallon
MIL-PRF-21260 (81349)
33 O 9150-00-231-6689 Lubricating Oil, General Purpose CN
1 quart can
MIL-PRF-32033 (81349)
34 O 9150-00-250-0926 Petroleum Jelly CN
1 lb can
VV-P-236 (81348)
35 O 7920-00-205-3571 Rag, Wiping, Cotton and Cotton Synthetic BX
Grade B
DDD-R-0030 (81348)
36 O 8040-01-108-6660 Repair Kit KT
Adhesive
900M-195 (73168)
37 F 8030-00-981-7005 Sealant
Locktite AA15-1 (05972)
38 F 8030-00-656-1426 Sealant, Silicone CN
1 pint can
MIL-S-45180 (81349)
39 F 5330-01-485-8999 Sealer
High Temperature
2P-2333 (11083)
40 F 8040-01-173-9815 Sealing Compound TU
12 oz. tube
RTV-108 (01139)
41 H 8030-01-025-1692 Sealing Compound BT
250 cc bottle
Locktite 242 (05972)

0124-4
 TM 9-6115-730-24 0124

Table 1. Expendable and Durable Items List - Continued.

(1) (2) (3) (4) (5)

ITEM NATIONAL STOCK ITEM NAME, DESCRIPTION,

NUMBER LEVEL NUMBER (NSN) PART NUMBER/(CAGEC) U/I
42 F 8030-00-148-9833 Sealing Compound, Thread Locking, Type II, BT
Grade N
10 cc bottle
MIL-S-46163 (81349)
43 O 8030-01-063-7510 Sealing Compound, Thread Locking, Type I BT
Grade L
50 cc bottle
MIL-S-46163 (80244)
44 F 3439-00-974-1873 Solder, Tin Alloy, SN60WRMAP2 LB
1 lb spool
QQ-571 E (81348)
45 O 6850-01-378-0679 Solvent, Cleaning Compound CN
5 gallon can
BREAKTHROUGH (OK209)
46 O 5975-01-128-0390 Strap, Tiedown HD
Electrical
PLT-27 (06383)
47 O 5975-01-364-7334 Strap, Tiedown HD
Electrical
PLT.7M-C (06383)
48 O 5975-01-376-6480 Strap, Tiedown HD
Electrical
PLT1.51 (06383)
49 O 9905-00-537-8954 Tag, Marker BD
50 each bundle
MIL-T-12755 (81349)
50 O 7510-00-073-1337 Tape, Pressure Sensitive Adhesive, 3/4 in. W RL
60 yd Roll
PPP-T-60 (81348)
51 C 9130-00-273-2379 Turbine Fuel, Aviation GL
bulk, JP5
MIL-PRF-5624 (81349)
52 C 9130-01-031-5816 Turbine Fuel, Aviation GL
bulk, JP8
MIL-T-83133 (81349)
53 O 9505-00-684-4841 Wire, nonelectrical, 0.031 in. dia RL
1 lb roll
ASTM A641 (81346)

END OF WORK PACKAGE

0124-5/6 blank
 TM 9-6115-730-24 0125

_____________________________________________________________________________
FIELD AND SUSTAINMENT LEVEL MAINTENANCE
TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
LAMINATES
______________________________________________________________________________________

INITIAL SETUP:

Tools and Special Tools Personnel Required

None None

References

None
Materials/Parts

None

INTRODUCTION

Laminates are fielded with each 200kW Generator Set. These laminates are often lost or
damaged and the user must try to locate a replacement. This work package lists all of the
laminates used on the 200kW Tactical Quiet Generator. It is designed so that lost or damaged
laminates may be pulled from the Technical Manual, reproduced and then laminated for use. The
needed page is then placed back into the manual for future use.

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PART N0. 9907-175 REV. A

SERIAL NO. 12285365

161 - 0797 CAGE 31361

LOAD
SHARING
MODULE
UL LISTED 61N6 UL

IND. CONT. EQ.

LOAD SHARING MODULE
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A1 F1
A1 F2
A1 F3
A1 F4
A1 F5
A1 F6
A1 F7

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UNIT (FIELD) LEVEL MAINTENANCE

TACTICAL QUIET GENERATOR 200 kW, 50/60 Hz MEP-809A/PU-809A
REPROGRAMMING

INITIAL SETUP:

Tools and Special Tools References

None WP 0083

Materials/Parts Equipment Condition

None TQG is not operating and powered down

Personnel Required
One

REPROGRAMMING DVR PARAMETERS FOR VOLTAGE AND FREQUENCY CHANGE

The following procedure is used if the voltage and frequency settings for the generator set must be changed
because of mission requirements. When that occurs, the reconnection board must be repositioned and the DVR
must be reprogrammed for specified frequency and voltage. Note that the GSC OP-5 parameters must be
reprogrammed, also.

1. Set Battery Disconnect Switch to ON.

2. Set DEAD CRANK SWITCH to NORMAL.
3. On EMCP, set ENGINE CONTROL Switch (ECS) to COOL DOWN/STOP.
4. Select reprogramming data from Table 1 below according to the desired output voltage and desired
frequency. Mission requirements will define requirements. Note: All 6 of the DVR PARAMETERS must be
changed or verified.

Table 1. 200 kW TQG DVR Voltage and Frequency Programming Parameters and Setpoints.

DESIRED OUTPUT DVR PARAMETER NUMBER

VOLTS HERTZ :01 :02 :03 :04 :05 :06

120/208 60 217 1.0 0 694 4.34 58.8

120/208 50 205 1.0 0 578 3.61 49.8

240/416 60 434 2.0 0 347 4.34 58.8

240/416 50 410 2.0 0 289 3.61 49.8

0125-21 Change 1
 TM 9-6115-730-24 0125

5. Press the up arrow key .DVR display should read :01 (the colon with the number indicates that the
number is a parameter number).

6. Press and hold up arrow key until display shows parameter number :90. Parameter number: 90 is a
password that can be used to protect the settings.

7. Press Function key on DVR once to display data for parameter :90.

8. Press and hold up arrow key or down arrow key to set the data for parameter number :90 to 0200.

9. Press Function key on DVR once to display parameter :90.

10. Press and hold up arrow key or down arrow key to change to parameter number :01

11. Press Function key on DVR once to display data for parameter .

12. Press and hold up arrow key or down arrow key to set the data for parameter per Table 1.

13. Press Function key on DVR once to switch back to the parameter number.

14. Press up arrow key once to change to next parameter number per Table 1.

15. Keep repeating from step 9, entering parameter data from Table 1, until all 6 parameter data is entered or
verified to be correct.

16. Press Function key on DVR once to display data for parameter :90.

17. Press and hold up arrow key or down arrow key to set the data for parameter number :90 to any number but

to OFF/RESET and back to COOL DOWN/STOP or from COOL DOWN/STOP to MANUAL START.

18. Press Function key on DVR once to switch back to parameter number. Press and hold up arrow key
or down arrow key to set the parameter number back to 01.
19. Proceed to REPROGRAMMING GSC SETPOINTS FOR VOLTAGE AND FREQUENCY CHANGE and reprogram the
OP5 parameters for P028 thru P031 (steps 1 thru 25).

20. If the generator set is not to be used, set ENGINE CONTROL Switch (ECS) to OFF/RESET, set
DEAD CRANK SWITCH to OFF, and set Battery Disconnect Switch to OFF.

END OF TASK

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 TM 9-6115-730-24 0125

REPROGRAMMING GSC PARAMETERS FOR VOLTAGE AND FREQUENCY CHANGE

1. Set Battery Disconnect Switch to ON.

2. Set DEAD CRANK SWITCH to NORMAL.
3. On EMCP, set ENGINE CONTROL Switch (ECS) to COOL DOWN/STOP.
4. Select programming data from GSC from Table 3 for desired output voltage and desired frequency.

Table 3. 200 kW TQG GSC Programming Setpoints.

DESIRED OUTPUT OP5-0 OP5-1

VOLTS HERTZ P028 P029 P030 P031 P114 P117 P120 P123

120/208 60 208 694 200 60 63 66 57 54

50 208 576 166 50 53 55 48 45

60 416 347 200 60 63 66 57 54

50 416 288 166 50 53 55 48 45

NOTE

In SERVICE MODE, the buttons on the GSC keypad perform new functions as follows:

POWER METER is Scroll Right

AC METER is Scroll Up
ENGINE METER is Scroll Down
LAMP TEST is Select
ALARM CODES is Enter

5. Press SERVICE MODE key on GSC. SERV will be displayed on upper display. OP1 will be displayed on lower
display.

6. Press AC METER key five times. OP3 will be displayed.

7. Press the LAMP TEST key. P E ----- will be displayed. The left-most underline will be flashing. If an error
is made any time during the password entry, P E FAIL will be displayed. Password entry can be restarted by
pressing LAMP TEST key.
8. Press POWER METER key. P E 1---- will be displayed. The left-most underline will be flashing.
9. Press ENGINE METER key. P E 1 3--- will be displayed. The left-most underline will be flashing.

10. Press AC METER key. P E 1 3 2-- will be displayed. The left-most underline will be flashing.

11. Press AC ENGINE key. P E 1 3 2 3- will be displayed. The underline will be flashing.

12. Press POWER METER key. P E 1 3 2 3 1 will be displayed.

13. Press ALARM CODES key. P E PASS will be displayed.

14. Press EXIT key. OP4 will be displayed.

15. Press AC METER key. OP5 will be displayed.

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NOTE

For input values the OP set and parameter values will toggle between the upper
and lower displays as each OP set is entered.

16. Press AC METER key or ENGINE METER key until OP5-0 is displayed.

17. Press LAMP TEST key. P001 will be displayed followed by the value of the set point.
18. Press ENGINE METER key until P028 is displayed (P028 is first setpoint in table).

19. Press LAMP TEST key. The value of the setpoint will begin to flash.

20. Press AC MRETER key or ENGINE METER key to change the value, as required, to what is shown in Table 3
corresponding to the desired voltage and frequency.

21. Press ALARM CODES key. The value of the setpoint will stop flashing.

22. Repeat steps 18 through 21 until all setpoint values are checked or changed for OP5-0.

23. Repeat steps 16 through 22 for OP5-1. The first set point displayed will be P101. The first setpoint to be
changed/verified is P114, per Table 3.

24. At the completion of the programming, press EXIT key until SERV is no longer displayed on upper display.

25. If the generator set is not to be used, set ENGINE CONTROL Switch (ECS) to OFF/RESET, set
DEAD CRANK SWITCH to OFF, and set Battery Disconnect Switch to OFF.

END OF TASK

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GLOSSARY

TERM DEFINITION
Bus The common power conducting wires or bars to which all power
sources within the power system are connected through their
individual circuit breakers.
Dead Bus A bus from which all the available power sources are disconnected.
De-energize To remove voltage from a circuit or device in order to deactivate it.
Droop Paralleling mode that allows slight fluctuations in frequency so that
lagging generator set can match frequency of companion generator.
EMI Electromagnetic interference is any electromagnetic disturbance that
interrupts, obstructs or other wise degrades or limits the effective
performance of electronics and electrical equipment as a result of
spurious emissions and responses.
Energize To apply voltage to a circuit or device in order to activate it.
Excitation voltage DC voltage applied from the voltage regulator to the generator exciter
field windings.
Generator overload condition Load greater than the load for which the system or mechanism was
intended. For TQGs, overload is defined as the condition when
current in all three phases exceeds 100% of rated current or when
current in a single phase exceeds 130% of rated current.
Ground fault circuit interrupter (GFCI) A device intended for the protection of personnel that functions to de-
energize a circuit or portion thereof within an established period of
time when a current to ground exceeds some predetermined value
that is less than that required to operate the overcurrent protection
device of the supply circuit. The TQG convenience receptacle is
protected by a GFCI.
Incoming generator The generator that is being connected to the bus.
Isochronous Paralleling mode that requires precise matching of frequency for
companion generators.
kV Kilovolt. One kilovolt equals 1000 volts.
KVAR Kilovolt amperes reactive. Measure of reactive power.
KVARhr Kilovolt amperes reactive hours. Measure of reactive power over time.
kW Kilowatt. One kilowatt equals 1000 watts. Measure of real power.
Load bus Common power conducting wires or bars to which all generator set
loads are connected through their individual circuit breakers.
Overcurrent condition Any current in excess of the rated current of equipment. The condition
may result from overload, short circuit, or ground fault.
Paralleling The procedure for synchronizing and connecting two or more
generator sets to a common load bus.

GLOSSARY-1
 TM 9-6115-730-24

GLOSSARY - Continued

TERM DEFINITION
Reverse power Power flows from one generator set into another generator set when
operating in parallel. For the TQGs, reverse shutdown power occurs
when reverse power exceeds 17% of rated value.
TQG control circuit Primarily consists of 24 Vdc circuitry, meters and controls for
generator set starting, stopping, monitory, and fault annunciation.
Wet stacking Buildup of unburned diesel fuel and carbon residues in the engine and
exhaust system of diesel engines. Wet stacking can cause an oily,
tar-like residue to exit from the exhaust pipe.

GLOSSARY-2
 TM 9-6115-730-24

INDEX

Subject WP Sequence No.

A
Access Covers Maintenance .................................................................................................................. WP 0029
Air Cleaner Filter Maintenance ............................................................................................................... WP 0071
Air Cleaner System Maintenance ........................................................................................................... WP 0072
AL Fault Code Troubleshooting Procedures ........................................................................................... WP 0008
Alternator Belt Maintenance .................................................................................................................... WP 0075
Alternator Maintenance .......................................................................................................................... WP 0074
Auxiliary Fuel Pump Assembly Maintenance .......................................................................................... WP 0059

B
Batteries Maintenance ............................................................................................................................ WP 0050
Battery Cable Assemblies Maintenance ................................................................................................. WP 0047
Battery Disconnect Switch Maintenance ................................................................................................ WP 0051

C
Control Box Assembly Maintenance........................................................................................................ WP 0042
Control Box Door Assembly Maintenance............................................................................................... WP 0020
Control Box Harness Assembly Maintenance ........................................................................................ WP 0044
Control Box Panel Assembly Maintenance ............................................................................................ WP 0041
Coolant Hose Assemblies Maintenance.................................................................................................. WP 0067
Coolant Recovery System Maintenance ................................................................................................ WP 0064
Crankcase Ventilation Filter Maintenance .............................................................................................. WP 0070
Crankshaft Front Seal Maintenance ....................................................................................................... WP 0105
Crankshaft Rear Seal Carrier Maintenance ............................................................................................ WP 0114
Crankshaft Rear Seal Maintenance ........................................................................................................ WP 0112
Crankshaft Vibration Damper and Pulley Maintenance .......................................................................... WP 0104
Current Transformers Maintenance......................................................................................................... WP 0052
Cylinder Head Maintenance .................................................................................................................... WP 0120

D
Door Support Assembly Maintenance .................................................................................................... WP 0040
DVR Fault Code Troubleshooting Procedures ........................................................................................ WP 0010

E
Electrical Installation Maintenance ......................................................................................................... WP 0055
Electronic Technician (ET) Troubleshooting Procedures ........................................................................ WP 0013
Electronic Technician (ET) Troubleshooting Software Installation ......................................................... WP 0012
Engine Control Module Maintenance ..................................................................................................... WP 0082
Engine Electrical System Repair ............................................................................................................ WP 0098
Engine Generator Compartment Ceiling Assembly Maintenance .......................................................... WP 0032
Engine Replacement ............................................................................................................................... WP 0096
Engine/Generator Base Assembly Repair .............................................................................................. WP 0097

INDEX-1 Change 1
 TM 9-6115-730-24

INDEX - Continued

Subject WP Sequence No.

E (cont.)
Equipment Description and Data ............................................................................................................ WP 0002
Ether Injection Assembly Maintenance ................................................................................................... WP 0073
Exhaust Manifold Maintenance ............................................................................................................... WP 0115
Exhaust System Maintenance ................................................................................................................ WP 0069
Expendable and Durable Items List......................................................................................................... WP 0124

F
Failures Without a Fault Code Troubleshooting Procedures .................................................................. WP 0011
Fan and Fan Guards Maintenance.......................................................................................................... WP 0066
Fan Pulley Maintenance ......................................................................................................................... WP 0099
Flywheel Housing Maintenance............................................................................................................... WP 0113
Flywheel Maintenance ............................................................................................................................. WP 0111
Front Cover Maintenance ....................................................................................................................... WP 0106
Front Roof Section Housing Assembly Maintenance ............................................................................. WP 0030
Front Section Housing Assembly Maintenance ...................................................................................... WP 0034
Fuel Cooler Maintenance ....................................................................................................................... WP 0060
Fuel Filter Base and Manifold Maintenance ........................................................................................... WP 0101
Fuel Filter Maintenance ........................................................................................................................... WP 0080
Fuel Hoses Maintenance ........................................................................................................................ WP 0057
Fuel Level Sender Maintenance ............................................................................................................. WP 0062
Fuel Level Switch Assembly Maintenance ............................................................................................. WP 0056
Fuel Pickup Tube Assembly Maintenance ............................................................................................. WP 0058
Fuel Priming Pump Maintenance ........................................................................................................... WP 0078
Fuel Tank Maintenance .......................................................................................................................... WP 0063
Fuel Transfer Pump Maintenance .......................................................................................................... WP 0102

G, H
General Information ................................................................................................................................. WP 0001
General Maintenance Instructions........................................................................................................... WP 0017
Generator Access Cover Assembly Maintenance .................................................................................. WP 0033
Generator Repair .................................................................................................................................... WP 0094
Generator Replacement .......................................................................................................................... WP 0095
GSC Alarm Indicators and Fault Code Troubleshooting Procedures...................................................... WP 0006
GSC Fault Code Troubleshooting Procedures........................................................................................ WP 0009

I, J, K
Illustrated List of Manufactured Items...................................................................................................... WP 0086
Inlet Manifold Maintenance...................................................................................................................... WP 0116
Installation of Generator Set on Trailer.................................................................................................... WP 0084
Introduction .............................................................................................................................................. WP 0004

Change 1 INDEX-2
 TM 9-6115-730-24

INDEX - Continued

Subject WP Sequence No.

L
Laminates ....................... ........................................................................................................................ WP 0125
Left Battery Access Door Assembly Maintenance .................................................................................. WP 0019
Left Center Panel Assembly Maintenance .............................................................................................. WP 0036
Left Front Door Assembly (Latch) Maintenance...................................................................................... WP 0021
Left Rear Door Assembly (Latch) Maintenance ..................................................................................... WP 0023
Left Rear Door Assembly Maintenance................................................................................................... WP 0022
Left Rear Panel Assembly Maintenance ................................................................................................ WP 0039
Load Board Door Assembly Maintenance .............................................................................................. WP 0024
Load Terminal Board Assembly Maintenance ........................................................................................ WP 0046

M, N
Main Load Contactor Maintenance ......................................................................................................... WP 0049
Maintenance Allocation Chart (MAC) Introduction .................................................................................. WP 0122
Maintenance Allocation Chart (MAC) ...................................................................................................... WP 0123

O
Oil Cooler Maintenance .......................................................................................................................... WP 0108
Oil Filter Base Maintenance ................................................................................................................... WP 0107
Oil Filter Maintenance and Oil Change.................................................................................................... WP 0079
Oil Pan Maintenance ............................................................................................................................... WP 0117
Oil Pump Maintenance ........................................................................................................................... WP 0109

P, Q
PMCS Introduction................................................................................................................................... WP 0015
PMCS, Including Lubrication Instructions................................................................................................ WP 0016
Potential Transformer Maintenance ....................................................................................................... WP 0053
Power Cable Assemblies Maintenance .................................................................................................. WP 0048
Preparation for Storage or Shipment ...................................................................................................... WP 0085

R
Radiator Assembly Maintenance ............................................................................................................ WP 0068
Rear Roof Section Housing Assembly Maintenance .............................................................................. WP 0031
Rear Section Housing Assembly Maintenance ...................................................................................... WP 0035
Reconnection Terminal Board Assembly Maintenance .......................................................................... WP 0045
References .............................................................................................................................................. WP 0121
Reprogramming ...................................................................................................................................... WP 0083
Resistor Assembly A7 Maintenance ....................................................................................................... WP 0043
Right Battery Access Door Assembly Maintenance ................................................................................ WP 0018
Right Center Panel Assembly Maintenance ........................................................................................... WP 0037
Right Front Door Assembly (Latch) Maintenance .................................................................................. WP 0025
Right Front Door Assembly Maintenance and Storage Box Assembly Maintenance ............................. WP 0026
Right Rear Door Assembly (Latch) Maintenance .................................................................................... WP 0028

INDEX-3 Change 1
 TM 9-6115-730-24

INDEX - Continued

Subject WP Sequence No.

R (cont.)
Right Rear Door Assembly Maintenance ................................................................................................ WP 0027
Right Rear Panel Assembly Maintenance ............................................................................................... WP 0038
Rocker Shaft and Pushrod Maintenance................................................................................................. WP 0119

S
Service Upon Receipt .............................................................................................................................. WP 0014
Slave Receptacle Maintenance .............................................................................................................. WP 0054
SP Fault Code Troubleshooting Procedures........................................................................................... WP 0007
Starter Maintenance ............................................................................................................................... WP 0076
Surge Tank Maintenance ........................................................................................................................ WP 0065

T
Tensioner Maintenance ........................................................................................................................... WP 0077
Theory of Operation ................................................................................................................................ WP 0003
Thermostat Maintenance......................................................................................................................... WP 0081
Torque Limits ........................................................................................................................................... WP 0087
Troubleshooting Index ............................................................................................................................ WP 0005
Turbocharger Maintenance .................................................................................................................... WP 0103

U
Unit Injector Maintenance........................................................................................................................ WP 0118

V
Valve Cover and Base Maintenance ...................................................................................................... WP 0100

W
Water Pump Maintenance ...................................................................................................................... WP 0110
Water Separator Filter and Bracket Maintenance .................................................................................. WP 0061
Winterization Heater Assembly Maintenance ......................................................................................... WP 0090
Winterization Heater Control Box Assembly Maintenance ..................................................................... WP 0089
Winterization Heater Hoses Maintenance .............................................................................................. WP 0091
Winterization Thermostat, Resistors, and Diode Maintenance .............................................................. WP 0092
Winterization Wiring Harnesses Maintenance ........................................................................................ WP 0093
Wire Lists ................................................................................................................................................. WP 0088

Change 1 INDEX-4
 Use Part II (reverse) for Repair Parts and Spe- DATE
RECOMMENDED CHANGES TO PUBLICATIONS AND cial Tool Lists (RPSTL) and Supply Catalogs/
Supply Manuals (SC/SM)
BLANK FORMS
For use of this form, see AR 25--30; the proponent agency is ODISC4. 8/30/02
TO: (Forward to proponent of publication or form)(Include ZIP Code) FROM: (Activity and location)(Include ZIP Code)
Commander, U.S. Army C-E LCMC Jane Q. Doe, SFC
ATTN: AMSEL-LC-LEO-E-ED-P 1234 Any Street
FORT MONMOUTH, NJ 07703-5000 Nowhere Town, AL 34565
PART 1 -- ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE Organizational, Direct Support, And General
Support Maintenance Manual for Machine Gun, .50
TM 11-4940-355-12 16 Sep 2002 Caliber M3P and M3P Machine Gun Electrical Test Set
Used On Avenger Air Defense Weapon System
ITEM PAGE PARA-- LINE FIGURE TABLE
RECOMMENDED CHANGES AND REASON
NO. NO. GRAPH NO. * NO. NO.

1 WP0005 2 Test or Corrective Action column should identify a different WP number.

PG 3

* Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/ SIGNATURE
AUTOVON, PLUS EXTEN-
SION
Jane Q. Doe, SFC 788--1234
DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPA V3.01
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
Commander, U.S. Army C-E LCMC Jane Q. Doe, SFC
ATTN: AMSEL-LC-LEO-E-ED-P 1234 Any Street
8/30/02
FORT MONMOUTH, NJ 07703-5000 Nowhere Town, AL 34565
PART II -- REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE

TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
RECOMMENDED ACTION
NO. NO. NO. NUMBER NO. NO. NO. ITEMS
SUPPORTED

PART III -- REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE

PLUS EXTENSION

Jane Q. Doe, SFC 788--1234

USAPA V3.01
 RECOMMENDED CHANGES TO PUBLICATIONS AND DATE
BLANK FORMS Use Part II (reverse) for Repair Parts and
For use of this form, see AR 310-1; the proponent agency is the US Special Tool Lists (RPSTL) and Supply
Army Adjutant General Center. Catalogs/Supply Manuals (SC/SM).

TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code)

PART I - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE

ITEM PAGE PARA- LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON
NO. NO. GRAPH NO.* NO. NO. (Exact wording of recommended change must be given)

* Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION

FORM REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

DA 1 FEB 74 2028
TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code) DATE

PART II- REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION/FORM NUMBER DATE TITLE

TOTAL NO. RECOMMENDED ACTION

PAGE COLM LINE FEDERAL STOCK REFERENCE FIGURE ITEM OF MAJOR
NO. NO. NO. NUMBER NO. NO. NO. ITEMS
SUPPROTED

PART III - REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE

PLUS EXTENSION

U.S. GOVERNMENT PRINTING OFFICE 1981 341-646/8606

 RECOMMENDED CHANGES TO PUBLICATIONS AND DATE
BLANK FORMS Use Part II (reverse) for Repair Parts and
For use of this form, see AR 310-1; the proponent agency is the US Special Tool Lists (RPSTL) and Supply
Army Adjutant General Center. Catalogs/Supply Manuals (SC/SM).

TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code)

PART I - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE

ITEM PAGE PARA- LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON
NO. NO. GRAPH NO.* NO. NO. (Exact wording of recommended change must be given)

* Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION

FORM REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

DA 1 FEB 74 2028
TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code) DATE

PART II- REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION/FORM NUMBER DATE TITLE

TOTAL NO. RECOMMENDED ACTION

PAGE COLM LINE FEDERAL STOCK REFERENCE FIGURE ITEM OF MAJOR
NO. NO. NO. NUMBER NO. NO. NO. ITEMS
SUPPROTED

PART III - REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE

PLUS EXTENSION

U.S. GOVERNMENT PRINTING OFFICE 1981 341-646/8606

 RECOMMENDED CHANGES TO PUBLICATIONS AND DATE
BLANK FORMS Use Part II (reverse) for Repair Parts and
For use of this form, see AR 310-1; the proponent agency is the US Special Tool Lists (RPSTL) and Supply
Army Adjutant General Center. Catalogs/Supply Manuals (SC/SM).

TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code)

PART I - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE

ITEM PAGE PARA- LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON
NO. NO. GRAPH NO.* NO. NO. (Exact wording of recommended change must be given)

* Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION

FORM REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

DA 1 FEB 74 2028
TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code) DATE

PART II- REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION/FORM NUMBER DATE TITLE

TOTAL NO. RECOMMENDED ACTION

PAGE COLM LINE FEDERAL STOCK REFERENCE FIGURE ITEM OF MAJOR
NO. NO. NO. NUMBER NO. NO. NO. ITEMS
SUPPROTED

PART III - REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE

PLUS EXTENSION

U.S. GOVERNMENT PRINTING OFFICE 1981 341-646/8606

By Order of the Secretary of the Army:

PETER J. SCHOOMAKER
General, United States Army
Official: Chief of Staff

JOYCE E. MORROW
Administrative Assistant to the
Secretary of the Army
0627801

DISTRIBUTION:

To be distributed in accordance with the initial distribution number (IDN) 256917

requirements for TM 9-6115-730-24.
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